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.

1. Sit on the seat, keep your foot off the traction pedal so that it is in NEUTRAL, engage the parking brake, set the throttle to the FAST position, and ensure that the Enable/Disable switch is in the DISABLE position.

2. Turn the key to the ON/PREHEAT position.

   An automatic timer controls the glow plug preheat for 6 seconds.

3. After preheating the glow plugs, turn the key to the START position.

   Crank the engine for no longer than 15 seconds. Release the key when the engine starts. If additional preheating is required, turn the key to the OFF position and then to the ON/PREHEAT position. Repeat this process as required.

4. Run the engine at low idle speed until it warms up.

1. Move all controls to NEUTRAL, engage the parking brake, move the throttle to the low idle position and allow the engine to reach low idle speed.

   Important: Allow the engine to idle for 5 minutes before shutting it off after a full load operation. Failure to do so may lead to trouble on a turbocharged engine.

2. Turn the key to the OFF position and remove it from the switch.

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. Park the machine on a level surface, lower the cutting units, shut off the engine, engage the parking brake, and remove the key.

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. Park the machine on a level surface, lower the cutting units, shut off the engine, engage the parking brake, and remove the key.

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 shut off 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.

• Front—the hole in the rectangular pad, under the axle tube, inside each front 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

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

• Front—rectangular pad, under the axle tube, inside each front tire (Figure 36).

  

  Figure 36

  1. Front jacking point

• Rear—rectangular axle tube on the rear axle

• Use full-width ramps for loading the machine onto a trailer or truck.

• Tie the machine down securely.

In an emergency, you can move the machine 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) because internal transmission damage may occur. The bypass valve must be open whenever you push or tow the machine.

1. Rotate the bypass-valve bolt 1-1/2 turns to open and allow oil to bypass internally (Figure 37).

   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 37

   1. Bypass-valve bolt

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.

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

The grease fitting locations and quantities are as follows:

• Pump-driveshaft U-joint (3) (Figure 38)

  

  Figure 38

• Cutting-unit lift-arm cylinders (2 each) (Figure 39)

  

  Figure 39

• Lift-arm pivots (1 each) (Figure 39)

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

  

  Figure 45

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. Cover
   2. Latch
   3. Service indicator

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

3. Before removing the filter, use low-pressure air—275 kPa (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. Cover
   2. Filter
   3. 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.

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, lower the cutting units, shut off the engine, engage the parking brake, and remove the key.

2. Open the hood.

3. Remove the dipstick, wipe it clean, and install it (Figure 48).

   

   Figure 48

   1. Dipstick

4. Remove the dipstick and check the oil level on the 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 49) and add oil until the level reaches the Full mark on the dipstick.

   

   Figure 49

   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.

1. Remove the drain plug (Figure 50) and let the oil flow into a drain pan.

   

   Figure 50

   1. Oil-drain plug

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

3. Remove the oil filter (Figure 51).

   

   Figure 51

   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 52).

   

   Figure 52

   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 52).

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 53

   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-pickup tube, located inside the fuel tank, comes with a screen to help prevent debris from entering the fuel system. Remove the fuel-pickup 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 is located behind the control-arm-access panel (Figure 54).

Figure 54

1. Fuse block

Figure 55

Check the tire pressure. The correct air pressure in the front and rear tires is 83 to 103 kPa (12 to 15 psi).

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, lower the cutting units, shut off the engine, and remove the key.

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 56).

   

   Figure 56

   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 stop rotating.

5. Tighten the locknut to secure the adjustment.

6. Shut off 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 to position the rear wheels straight ahead.

2. Loosen the jam nut on each end of the tie rod (Figure 57).

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

   

   Figure 57

   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 this 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 58).

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

   

   Figure 58

   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. Park the machine on a level surface, lower the cutting units, shut off the engine, engage the parking brake, and remove the key.

2. Thoroughly clean all debris out of the engine area.

3. Unlatch the clamp and pivot open the rear screen (Figure 59).

   

   Figure 59

   1. Rear-screen latch
   2. Rear screen

4. Clean the screen thoroughly with compressed air.

5. Pivot the latches inward to release the oil cooler (Figure 60).

   

   Figure 60

   1. Oil cooler
   2. Oil-cooler latches

6. Thoroughly clean both sides of the oil cooler and the radiator (Figure 61) with compressed air.

   

   Figure 61

   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 62) 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 62

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 63).

   

   Figure 63

   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 62), 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 64).

   

   Figure 64

   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 64).

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 65) midway between the alternator and the crankshaft pulleys with 10 kg (22 lb) of force.

   

   Figure 65

   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 65), 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.

Check the 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.

The reservoir is filled at the factory with 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.

1. Park the machine on a level surface, lower the cutting units, shut off the engine, engage the parking brake, and remove the key.

2. Clean the area around the filler neck and the cap of the hydraulic tank (Figure 66).

   

   Figure 66

   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.

The reservoir is filled at the factory with high-quality hydraulic fluid. Check the level of the hydraulic fluid before you first start the engine and daily thereafter; refer to Checking the Hydraulic-Fluid Level.

Recommended hydraulic fluid: Toro PX Extended Life Hydraulic Fluid; available in 19 L (5 US gallon) pails or 208 L (55 US gallon) drums.

Note: A machine using the recommended replacement fluid requires less frequent fluid and filter changes.

Alternative hydraulic fluids: If Toro PX Extended Life Hydraulic Fluid is not available, you may use another conventional, petroleum-based hydraulic fluid having specifications that fall within the listed range for all the following material properties and that it meets industry standards. Do not use synthetic fluid. Consult with your lubricant distributor to identify a satisfactory product.

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

High Viscosity Index/Low Pour Point Anti-wear Hydraulic Fluid, ISO VG 46

Note: Many hydraulic fluids are almost colorless, making it difficult to spot leaks. A red dye additive for the hydraulic fluid is available in 20 ml (0.67 fl oz) bottles. A bottle is sufficient for 15 to 22 L (4 to 6 US gallons) of hydraulic fluid. Order Part No. 44-2500 from your authorized Toro distributor.

Important: Toro Premium Synthetic Biodegradable Hydraulic Fluid is the only synthetic biodegradable fluid approved by Toro. This fluid is compatible with the elastomers used in Toro hydraulic systems and is suitable for a wide-range of temperature conditions. This fluid is compatible with conventional mineral oils, but for maximum biodegradability and performance, the hydraulic system should be thoroughly flushed of conventional fluid. The oil is available in 19 L (5 US gallons) pails or 208 L (55 US gallons) from your authorized Toro distributor.

56.7 L (15 US gallons); refer to Hydraulic Fluid Specifications

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 fluid.

1. Park the machine on a level surface, lower the cutting units, shut off the engine, engage the parking brake, and remove the key.

2. Raise the hood

3. Place a large drain pan under the fitting secured to the bottom of the hydraulic-fluid reservoir (Figure 67).

   

   Figure 67

   1. Hose

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

5. Install the hose when hydraulic fluid stops draining.

6. Fill the reservoir with hydraulic fluid; refer to Hydraulic Fluid Specifications and Hydraulic Fluid Capacity.

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

7. Install the reservoir cap.

8. Start the engine and use all of the hydraulic controls to distribute hydraulic fluid throughout the system.

9. Check for leaks.

10. Shut off the engine.

11. Check the level of the hydraulic fluid and add enough to raise the 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 68). 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 68

1. Hydraulic-filter-restriction indicator

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

1. Park the machine on a level surface, lower the cutting units, engage the parking brake, shut off the engine, and remove the key.

2. Clean the area around the filter mounting area and place a drain pan under filter (Figure 69 and Figure 70).

   

   Figure 69

   1. Hydraulic filter
   

   Figure 70

   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. Shut off the engine and check for leaks.

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 71) to assist in troubleshooting the traction circuit.

Figure 71

1. Traction-circuit test port

Use the test ports on the mow manifold block (Figure 72) to assist in troubleshooting the mow circuit.

Figure 72

1. Mow-circuit test ports (2)

Use the test port on the lift manifold block (Figure 73) to assist in troubleshooting the lift circuit.

Figure 73

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

2. Unlock and raise the seat to expose the backlap levers (Figure 74).

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 74).

   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 shut off the engine.

   After completing the adjustments, repeat steps 4 through 8.

   

   Figure 74

   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.