Reelmaster® 5410 and 5510 Traction Unit

Before starting the machine each day, perform the Each Use/Daily procedures listed in .

Important: You must bleed the fuel system before starting the engine if you are starting the engine for the first time, the engine has stopped due to lack of fuel, or you have performed maintenance on the fuel system; refer to Bleeding the Fuel System.

You can adjust the counterbalance on the rear cutting-unit lift arms to compensate for different turf conditions and to maintain a uniform height of cut in the rough conditions or in areas of thatch buildup.

You can adjust each counterbalance spring to 1 of 4 settings. Each increment increases or decreases counterbalance on the cutting unit by 2.3 kg (5 lb). You can position the springs on the back side of the first spring actuator to remove all counter balance (fourth position).

1. Position the machine on a level surface, lower the cutting units, stop the engine, engage the parking brakes, and remove the key from the ignition switch.

2. Insert a tube or similar object onto the long spring end and pivot it around the spring actuator to the desired position (Figure 29).

   Caution

   The springs are under tension and could cause personal injury.

   Use caution when adjusting them.

   

   Figure 29

   1. Spring
   2. Spring actuator

3. Repeat the procedure on the other spring.

1. Position the machine on a level surface, lower the cutting units, stop the engine, engage the parking brakes, and remove the key from the ignition switch.

2. The lift-arm switch is located underneath the hydraulic tank behind the front, right lift arm (Figure 30).

3. Loosen the switch-mounting screws (Figure 30) and move the switch down to increase the lift-arm turnaround height or move the switch up to decrease the lift-arm turnaround height.

   

   Figure 30

   1. Switch
   2. Lift-arm sensing device

4. Tighten the mounting screws.

To achieve a consistent, high quality of cut and a uniform after cut appearance, it is important that you set the reel speed to the proper setting. Adjust the reel speed as follows:

1. In the InfoCenter, under the settings menu, enter the blade count, mow speed and HOC to calculate the proper reel speed.

2. If further adjustments are required, in the settings menu, scroll down 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 need to be increased or decreased to compensate for varying turf conditions.

Figure 31

5 inch (127 mm) Reel Speed Chart

Figure 32

7 inch (177.8 mm) Reel Speed Chart

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 InfoCenter, above the display screen (Figure 33). When the machine is functioning properly and the key switch is moved to the ON/RUN position, the diagnostic light turns on briefly to indicate the light is working properly. When a machine advisory message is displayed, the light illuminates when the message is present. When a fault message is displayed, the light blinks until the fault is resolved.

Figure 33

1. Diagnostic light

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 the seat or if the parking brake is left engaged.

Use the list below to identify and understand the different functions of the solenoids in the hydraulic manifold. Each solenoid must be energized to allow the function to occur.

In an emergency, the machine can be moved by opening 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) because internal transmission damage may occur. The bypass valve must be open whenever the machine is pushed or towed.

1. Rotate the bypass-valve bolt 1-1/2 turns to open and allow oil to bypass internally (Figure 34).

   Note: The bypass valve is located on the left side of the hydrostat. By bypassing the fluid, you can move the machine slowly without damaging the transmission.

   

   Figure 34

   1. Bypass valve

2. Close the bypass valve before starting the engine. However, do not exceed 7 to 11 N-m. (5 to 8 ft-lb) torque to close the valve.

   Important: Running the engine with the bypass valve open causes the transmission to overheat.

Note: Use jack stands to support the machine when required.

• Front—rectangular pad, under the axle tube, inside each front tire (Figure 35).

  

  Figure 35

  1. Front jacking point

• Rear—rectangular axle tube on the rear axle

Lubricate all grease fittings for the bearings and bushings after with No. 2 lithium grease.

The grease fitting locations and quantities are as follows:

• Pump-driveshaft U-joint (3) (Figure 36)

  

  Figure 36

• Cutting-unit lift-arm cylinders (2 each) (Figure 37)

  

  Figure 37

• Lift-arm pivots (1 each) (Figure 37)

• Cutting-unit carrier-frame and pivot (2 each) (Figure 38)

  

  Figure 38

• Lift-arm pivot shaft (1 each) (Figure 39)

  

  Figure 39

• Rear axle tie rod (2) (Figure 40)

  

  Figure 40

• Axle-steering pivot (1) (Figure 41)

  

  Figure 41

• Steering-cylinder ball joints (2) (Figure 42)

  

  Figure 42

• Brake pedal (1) (Figure 43)

  

  Figure 43

The engine is shipped with oil in the crankcase; however, the oil level must be checked before and after the engine is first started.

Crankcase capacity: 5.2 L (5.5 US qt) with the filter

Use high-quality engine oil that meets the following specifications:

• API Classification Level Required: CH-4, CI-4 or higher

• Preferred oil: SAE 15W-40 (above 0 degrees F)

• Alternate oil: SAE 10W-30 or 5W-30 (all temperatures)

Toro Premium Engine oil is available from your distributor in either 15W-40 or 10W-30 viscosity.

1. Park the machine on a level surface, stop the engine, set the parking brake, and remove the key from the ignition switch.

2. Open the hood.

3. Remove the dipstick, wipe it clean, and install it (Figure 44).

   

   Figure 44

   1. Dipstick

4. Remove dipstick and check the oil level on dipstick.

   Note: 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 45) and add oil until the level reaches the Full mark on the dipstick.

   

   Figure 45

   1. Oil-fill cap

   Do not overfill the engine.

   Important: Make sure that you keep the engine-oil level between the upper and lower limits on the oil gauge. Engine failure may occur as a result of overfilling or underfilling the engine oil.

6. Install the oil-fill cap and close the hood.

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 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.

Important: Make sure that the cover is seated correctly and seals with the air-cleaner body.

1. Release the latches securing the air-cleaner cover to the air-cleaner body (Figure 46).

   

   Figure 46

   1. Air-cleaner cover
   2. Air-cleaner-cover latch
   3. Air-cleaner service indicator

2. Remove the cover from the air-cleaner body.

3. Before removing the filter, use low pressure air (40 psi, clean and dry) to help remove large accumulations of debris packed between outside of the filter and the canister.

   Important: Avoid using high-pressure air which could force dirt through the filter into the intake tract.

   Note: This cleaning process prevents debris from migrating into the intake when the filter is removed.

4. Remove and replace the filter (Figure 47).

   Note: Cleaning of the used element is not recommended due to the possibility of damage to the filter media.

   

   Figure 47

   1. Air-cleaner cover
   2. Air-cleaner filter
   3. Air-cleaner indicator

5. Inspect the new filter for shipping damage, checking the sealing end of the filter and the body.

   Important: Do not use a damaged element.

6. Insert the new filter by applying pressure to the outer rim of the element to seat it in the canister.

   Important: Do not apply pressure to the flexible center of the filter.

7. Clean the dirt-ejection port located in the removable cover. Remove the rubber outlet valve from the cover, clean the cavity, and replace the outlet valve.

8. Install the cover orienting the rubber outlet valve in a downward position—between approximately 5 o’clock to 7 o’clock when viewed from the end.

9. Secure the latches.

1. Remove the drain plug (Figure 48) and let the oil flow into a drain pan.

   

   Figure 48

   1. Oil-drain plug

2. When the oil is drained, install the drain plug.

3. Remove the oil filter (Figure 49).

   

   Figure 49

   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. Turn the oil filter clockwise until the rubber gasket contacts the filter adapter, then tighten the filter an additional 1/2 turn.

   Important: Do not over-tighten the filter.

6. Add oil to the crankcase; refer to Checking the Engine-Oil Level.

1. Position the throttle lever forward so that it is approximately 3 mm (1/8 inch) from the front of the control-arm slot.

2. Loosen the throttle-cable connector, on the throttle cable, next to the injection-pump lever (Figure 50).

   

   Figure 50

   1. Throttle-cable pivot
   2. Injection-pump-lever arm
   3. High idle stop
   4. Throttle-cable connector

3. Hold the injection-pump-lever arm against the high idle stop (Figure 50).

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.

Drain and clean the fuel tank if the fuel system becomes contaminated or if the machine is to be stored for an extended period. Use clean fuel to flush out the tank.

Check the fuel lines and connections for deterioration, damage, or loose connections.

1. Place a clean container under the fuel filter.

2. Loosen the drain plug on the bottom of the filter canister.

   

   Figure 51

   1. Water separator filter canister

3. Clean the area where the filter canister mounts.

4. Remove the filter canister and clean the mounting surface.

5. Lubricate the gasket on the filter canister with clean oil.

6. Install the filter canister by hand until the gasket contacts mounting surface, then rotate it an additional 1/2 turn.

7. Tighten the drain plug on the bottom of the filter canister.

The fuel pick-up tube, located inside the fuel tank, is equipped with a screen to help prevent debris from entering the fuel system. Remove the fuel pick-up tube and clean the screen as required.

Bleed the fuel system after you replace the water separator.

1. Loosen the drain plug on the bottom of the fuel-filer canister.

2. Turn the key switch to the On position.

   Note: The electric fuel pump runs to automatically bleed air from the fuel system. The time varies from 10 to 60 seconds.

Keep the terminals and the entire battery case clean because a dirty battery will discharge slowly. To clean the battery, wash the entire case with a solution of baking soda and water. Rinse it with clear water.

There are 8 fuses in the electrical system. The fuse block (Figure 52) is located behind the control arm access panel.

Figure 52

1. Fuse block

Figure 53

Torque the wheel nuts to 94 to 122 N-m (70 to 90 ft-lb).

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 ground.

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.

   Note: On 4-wheel-drive models, the rear tires must also be off the ground.

3. On the right side of the hydrostat, loosen the locknut on the traction-adjustment cam (Figure 54).

   

   Figure 54

   1. Locknut
   2. Traction-adjustment cam

   Warning

   The engine must be running so the final adjustment of the traction adjustment cam can be performed. This could cause personal 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 ground.

7. Test drive the machine to make sure that it does not creep.

1. Rotate the steering wheel so that the rear wheels are straight ahead.

2. Loosen the jam nut on each end of the tie rod (Figure 55).

   Note: The end of the tie rod with the external groove is a left-hand thread.

   

   Figure 55

   1. Jam nut
   2. Tie rod
   3. Wrench slot

3. Using the wrench slot, rotate the tie rod.

4. Measure the distance at the front and rear of the rear wheels at axle height.

   Note: The distance at the front of the rear wheels should be less than 6 mm (1/4 inch) of the distance measured at the rear of the wheels.

5. Repeat procedure as required.

Clean debris off 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.

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. The capacity of the cooling system is 6.6 L (7.0 US qt).

1. Check the level of coolant in the expansion tank (Figure 56).

   The coolant level should be between the marks on the side of the tank.

   

   Figure 56

   1. Expansion tank

2. If the coolant level is low, remove the expansion-tank cap and replenish the system. Do not overfill the tank.

3. Install the expansion-tank cap.

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).

   

   Figure 57

   1. Rear-screen latch
   2. Rear screen

4. Thoroughly clean the screen thoroughly with compressed air.

5. Pivot the latches inward to release the oil cooler (Figure 58).

   

   Figure 58

   1. Oil cooler
   2. Oil-cooler latches

6. Thoroughly clean both sides of the oil cooler and the radiator (Figure 59) with compressed air.

   

   Figure 59

   1. Radiator

7. Pivot the oil cooler back into position and secure the latches.

8. Close the screen and secure the latch.

Adjust the brakes when there is more than 2.5 cm (1 inch) of free travel (Figure 60) of the brake pedal, or when more holding force is required. Free travel is the distance the brake pedal moves before you feel braking resistance.

Figure 60

1. Free travel

Note: Use the wheel-motor backlash to rock the drums back and forth to ensure that the drums are free, prior to and after the adjustment.

1. To reduce free travel of the brake pedals, tighten the brakes by loosening the front nut on the threaded end of the brake cable (Figure 61).

   

   Figure 61

   1. Brake cables
   2. Front nuts

2. Tighten the rear nut to move the cable backward until brake pedals have 6 to 13 mm (1/4 to 1/2 inch) of free travel (Figure 60), 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.

If the parking brake fails to engage and latch, an adjustment to the brake pawl is required.

1. Loosen the 2 screws securing the parking-brake pawl to the frame (Figure 62).

   

   Figure 62

   1. Brake cables
   2. Screws (2)
   3. Parking-brake pawl
   4. Brake detent

2. Press the parking-brake pedal forward until the brake detent completely engages on the brake pawl (Figure 62).

3. Tighten the 2 screws locking the adjustment.

4. Press the brake pedal to release the parking brake.

5. Check the adjustment and adjust it as required.

1. Open the hood.

2. Check the tension of the alternator belt by pressing it (Figure 63) midway between the alternator and the crankshaft pulleys with 10 kg (22 lb) of force.

   

   Figure 63

   1. Brace
   2. Alternator belt
   3. Pivot bolt

   Note: The belt should deflect 11 mm (7/16 inch). If the deflection is incorrect, proceed to step 3. If correct, continue operation.

3. Loosen the bolt securing the brace to the engine (Figure 63), the bolt securing the alternator to the brace and the pivot bolt.

4. Insert a pry bar between the alternator and the engine and pry out on the alternator.

5. When you achieve the proper tension, tighten the alternator, brace, and pivot bolts to secure the adjustment.

The reservoir is filled at the factory with 56.7 L (15 US gallons) of high-quality hydraulic fluid. The best time to check the hydraulic oil is when the fluid is cold. The machine should be in its transport configuration. The recommended replacement fluid is:

Alternative fluids: If the Toro fluid is not available, other conventional, petroleum-based fluids may be used, provided that they meet all of the following material properties and industry specifications. Check with your oil supplier to see whether the oil meets these specifications.

Note: Toro does not assume responsibility for damage caused by improper substitutions, so use only products from reputable manufacturers who stand behind their recommendation.

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 difficult to spot leaks. A red dye additive for the hydraulic system oil is available in 20 ml (2/3 oz) bottles. 1 bottle is sufficient for 15 to 22 L (4 to 6 US gallons) of hydraulic oil. Order Part Number 44-2500 from your Toro Distributor.

This high-quality, synthetic, biodegradable fluid has been tested and found compatible for this Toro model. Other brands of synthetic fluid may have seal compatibility problems and Toro cannot assume responsibility for unauthorized substitutions.

Note: This synthetic fluid is not compatible with the Toro Biodegradable Fluid previously sold. See your Toro Distributor for more information.

1. Position the machine on a level surface, lower the cutting units, and stop the engine.

2. Clean the area around the filler neck and the cap of the hydraulic tank (Figure 64).

   

   Figure 64

   1. Hydraulic-tank cap

3. Remove the cap/dipstick from the filler neck and wipe it with a clean rag.

4. Insert the dipstick into the filler neck; then remove it and check the level of fluid.

   Note: The fluid level should be within operating range on the dipstick.

   Important: Do not overfill the tank.

5. If the level is low, add the appropriate amount of fluid to raise the level to the full mark.

6. Install the cap/dipstick onto the filler neck.

If the fluid becomes contaminated, contact your 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 65).

   

   Figure 65

   1. Hose

3. Disconnect the hose from the bottom of the fitting and let the hydraulic fluid flow into the drain pan.

4. Install the hose when hydraulic fluid stops draining.

5. Fill the reservoir with approximately 56.7 L (15 US gallons) of hydraulic fluid; refer to Checking the Hydraulic-Fluid Level

   Important: Use only the hydraulic fluids specified. Other fluids could cause system damage.

6. Install the reservoir cap.

7. Start the engine and use all of the hydraulic controls to distribute hydraulic fluid throughout the system. Also check for leaks.

8. Stop the engine.

9. Check the level of the hydraulic fluid and add enough to raise level to the Full mark on the dipstick.

   Important: Do not overfill the reservoir.

The hydraulic system is equipped with a service-interval indicator (Figure 66). 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-restriction indicator

Important: Use of any other filters may void the warranty on some components.

1. Position the machine on a level surface, lower the cutting units, stop the engine, engage the parking brake, and remove the key from the ignition switch.

2. Clean the area around the filter mounting area and place a drain pan under filter (Figure 67 and Figure 68).

   

   Figure 67

   1. Hydraulic filter
   

   Figure 68

   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 procedure on the other filter.

8. Start the engine and let it run for about 2 minutes to purge air from the system.

9. Stop the engine and check for leaks.

Check hydraulic lines and hoses for leaks, kinked lines, loose mounting supports, wear, loose fittings, weather deterioration, and chemical deterioration. Make all necessary repairs before operating.

Use the hydraulic system test ports to test the pressure in the hydraulic circuits. Contact your Toro Distributor for assistance.

Use the test ports on the front hydraulic tubes (Figure 69) to assist in troubleshooting the traction circuit.

Figure 69

1. Traction-circuit test port

Use the test ports on the mow manifold block (Figure 70) to assist in troubleshooting the mow circuit.

Figure 70

1. Mow-circuit test ports (2)

Use the test port on the lift manifold block (Figure 71) to assist in troubleshooting the lift circuit.

Figure 71

1. Lift-circuit test port

Check the reel-to-bedknife contact, regardless of whether the quality of cut had previously been acceptable. There must be light contact across the full length of the reel and the bedknife (refer to Adjusting the Reel to Bedknife in the cutting unit Operator's Manual).

Note: When backlapping, the front units all operate together, and the rear units operate together.

1. Position the machine on a level surface, lower the cutting units, stop the engine, engage the parking brake, and move the Enable/Disable switch to the DISABLE position.

2. Unlock and raise the seat to expose the backlap levers (Figure 72).

3. Make initial reel-to-bedknife adjustments appropriate for backlapping on all cutting units which are to be backlapped; refer to the cutting unit Operator's Manual.

4. Start the engine and run at low idle speed.

   Danger

   Changing the engine speed while backlapping may cause the reels to stall.

   • Never change the engine speed while backlapping.

   • Only backlap at idle engine speed.

5. Select either the front, rear, or both backlap levers to determine which units to backlap (Figure 72).

   Danger

   To avoid personal injury, be certain that you are clear of the cutting units before proceeding.

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-handled brush.

   Note: 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 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 and the Enable/Disable switch to the DISABLE position, and stop the engine.

   After completing the adjustments, repeat steps 4 through 8.

   

   Figure 72

   1. Backlap levers

10. Repeat the procedure for all cutting units you want to backlap.

11. When finished, return the backlap levers to the MOW position, lower the seat, and wash all lapping compound off the cutting units.

    Note: Adjust cutting unit reel to bedknife as needed. Adjust the cutting-unit reel speed to the desired mowing setting.

    Important: If the backlap switch is not returned to the OFF position after backlapping, the cutting units do not raise or function properly.

    Note: For a better cutting edge, run a file across the front face of the bedknife after lapping. This removes any burrs or rough edges that may have built up on the cutting edge.