Toro 03634, 03635, reelmaster 5210 series, reelmaster 5410 series, reelmaster 5010-h series Operator's Manual

FormNo.3392-633RevA

8and11-BladeDPACuttingUnit
with5inReel

Reelmaster

®

5010-H/5210/5410Series

TractionUnit

ModelNo.03634—SerialNo.315000001andUp
ModelNo.03635—SerialNo.315000001andUp

Registeratwww.T oro.com.
OriginalInstructions(EN)

*3392-633*A

WARNING

CALIFORNIA

Proposition65Warning

Thisproductcontainsachemicalorchemicals

knowntotheStateofCaliforniatocausecancer,

birthdefects,orreproductiveharm.

ThisproductcomplieswithallrelevantEuropeandirectives.
Fordetails,pleaseseetheDeclarationofIncorporation(DOI)
atthebackofthispublication.

ModelNo.

SerialNo.

Thismanualidentiespotentialhazardsandhassafety
messagesidentiedbythesafetyalertsymbol(Figure2),
whichsignalsahazardthatmaycauseseriousinjuryordeath
ifyoudonotfollowtherecommendedprecautions.

Thisreel-bladelawnmowerismountedtoaride-onmachine
andisintendedtobeusedbyprofessional,hiredoperatorsin
commercialapplications.Itisprimarilydesignedforcutting
grassonwell-maintainedlawnsinparks,golfcourses,sports
elds,andoncommercialgrounds.Itisnotdesignedfor
cuttingbrush,mowinggrassandothergrowthalongside
highways,orforagriculturaluses.

Introduction

Readthisinformationcarefullytolearnhowtooperateand
maintainyourproductproperlyandtoavoidinjuryand
productdamage.Youareresponsibleforoperatingthe
productproperlyandsafely.

YoumaycontactTorodirectlyatwww .Toro.comforproduct
safetyandoperationtrainingmaterials,accessoryinformation,
helpndingadealer,ortoregisteryourproduct.

Wheneveryouneedservice,genuineT oroparts,oradditional
information,contactanAuthorizedServiceDealerorToro
CustomerServiceandhavethemodelandserialnumbersof
yourproductready.Figure1identiesthelocationofthe
modelandserialnumbersontheproduct.Writethenumbers
inthespaceprovided.

Figure2

1.Safetyalertsymbol

Thismanualuses2wordstohighlightinformation.
Importantcallsattentiontospecialmechanicalinformation
andNoteemphasizesgeneralinformationworthyofspecial
attention.

Contents

Safety...........................................................................3

SafetyandInstructionalDecals.................................3

Setup............................................................................4

1InspectingtheCuttingUnit....................................4

2CuttingUnitKickstand..........................................4

3AdjustingtheRearShield.......................................4

4InstallingtheLooseParts.......................................5

ProductOverview..........................................................7

Specications.........................................................7

CuttingUnitAccessoriesandKits(seeparts

catalogforpartnumbers)......................................7

Operation.....................................................................8

MakingAdjustments................................................8

Height-of-CutChartTerms.....................................10

Height-of-CutChart...............................................11

ServicingtheBedknife............................................15

Maintenance.................................................................16

Lubrication............................................................16

ServicingtheBedbar...............................................16

ServicingtheRoller.................................................18

1.Locationofthemodelandserialnumbers

©2015—TheToro®Company
8111LyndaleAvenueSouth
Bloomington,MN55420

Figure1

Contactusatwww.Toro.com.

2

PrintedintheUSA

AllRightsReserved

Safety

ThismachinehasbeendesignedinaccordancewithENISO
5395:2013.

Hazardcontrolandaccidentpreventionaredependent
upontheawareness,concern,andpropertraining
ofthepersonnelinvolvedintheoperation,transport,
maintenance,andstorageofthemachine.Improper
useormaintenanceofthemachinecanresultininjury
ordeath.Toreducethepotentialforinjuryordeath,
complywiththefollowingsafetyinstructions.

•Read,understand,andfollowallinstructionsinthe

tractionunitoperatorsmanualbeforeoperatingthe
cuttingunit.

•Read,understand,andfollowallinstructionsinthis

Operator’sManualbeforeoperatingthecuttingunit.

•Neverallowchildrentooperatethetractionunitor

cuttingunits.Donotallowadultstooperatetractionunit
orcuttingunitswithoutproperinstruction.Onlytrained
operatorswhohavereadthismanualshouldoperatethe
cuttingunits.

•Neveroperatethecuttingunitswhenundertheinuence

ofdrugsoralcohol.

•Keepallshieldsandsafetydevicesinplace.Ifashield,

safetydeviceordecalisillegibleordamaged,repairor
replaceitbeforeoperationiscommenced.Alsotighten
anyloosenuts,bolts,andscrewstoensurecuttingunitis
insafeoperatingcondition.

•Alwayswearsubstantialshoes.Donotoperatecutting

unitswhilewearingsandals,tennisshoes,sneakersor

shorts.Also,donotwearloosettingclothingwhich
couldgetcaughtinmovingparts.Alwayswearlongpants
andsubstantialshoes.Wearingsafetyglasses,safetyshoes
andahelmetisadvisableandrequiredbysomelocal
ordinancesandinsuranceregulations.

•Removealldebrisorotherobjectsthatmightbepicked

upandthrownbythecuttingunitreelblades.Keepall
bystandersawayfromtheworkingarea.

•Ifthecuttingbladesstrikeasolidobjectortheunit

vibratesabnormally,stopandshuttheengineoff.Check
cuttingunitfordamagedparts.Repairanydamagebefore
restartingandoperatingthecuttingunit.

•Lowerthecuttingunitstothegroundandremovekey

fromignitionswitchwhenevermachineisleftunattended.

•Besurecuttingunitsareinsafeoperatingconditionby

keepingnuts,boltsandscrewstight.

•Removekeyfromignitionswitchtopreventaccidental

startingoftheenginewhenservicing,adjustingorstoring
themachine.

•Performonlythosemaintenanceinstructionsdescribedin

thismanual.Ifmajorrepairsareeverneededorassistance
isdesired,contactanAuthorizedT oroDistributor.

•Toensureoptimumperformanceandsafety ,always

purchasegenuineTororeplacementpartsandaccessories.

Donotuse"will-t"replacementpartsand
accessoriesmadebyothermanufacturers.Lookfor

theT orologotoassuregenuineness.Usingunapproved
replacementpartsandaccessoriescouldvoidthewarranty
ofTheToroCompany.

SafetyandInstructionalDecals

Safetydecalsandinstructionsareeasilyvisibletotheoperatorandarelocatednearanyareaofpotential
danger.Replaceanydecalthatisdamagedorlost.

93–6688

1.Warning—readthe
Operator’sManualbefore
performingmaintenance.

2.Cuttinghazardofhandor
foot—stoptheengineand
waitforallmovingpartsto
stop.

3

Setup

LooseParts

Usethechartbelowtoverifythatallpartshavebeenshipped.

ProcedureDescription

1

2

3
4

Cuttingunit

Nopartsrequired

Nopartsrequired

Straightgreasetting
O-ring

MediaandAdditionalParts

Description

PartsCatalog
Operator'sManual

Note:Determinetheleftandrightsidesofthemachine
fromthenormaloperatingposition.

1

InspectingtheCuttingUnit

Qty.

Qty.

1Inspectthecuttingunit.

–

–

1
1

1
1

Reviewthematerialandsaveinanappropriateplace:

Usethekickstandwhentippingthe
cuttingunit.

Adjusttherearshield.

Installthelooseparts.

Use

Use

2

CuttingUnitKickstand

NoPartsRequired

Partsneededforthisprocedure:

1

Cuttingunit

Procedure

Afterthecuttingunitisremovedfromthebox,inspectthe
following:

1.Checkeachendofthereelforgrease.

Note:Greaseshouldbevisiblyevidentintheinternal
splinesofthereelshaft.

2.Ensurethatallnutsandboltsaresecurelytightened.

3.Makesurethatthecarrierframesuspensionoperates
freelyanddoesnotbindwhenmovedbackandforth.

Procedure

Wheneverthecuttingunithastobetippedtoexposethe
bedknife/reel,propuptherearofthecuttingunitwiththe
kickstand(suppliedwiththetractionunit)tomakesurethat
thenutsonthebackendofthebedbaradjustingscrewsare
notrestingontheworksurface(Figure3).

Figure3

1.Cuttingunitkickstand

4

3

4

AdjustingtheRearShield

NoPartsRequired

Procedure

Undermostconditions,bestdispersionisattainedwhenthe
rearshieldisclosed(frontdischarge).Whenconditionsare
heavyorwet,rearshieldmaybeopened.

Toopentherearshield(Figure4),loosenthecapscrew
securingtheshieldtotheleftsideplate,rotatetheshieldto
theopenpositionandtightenthecapscrew.

InstallingtheLooseParts

Partsneededforthisprocedure:

1

Straightgreasetting

1

O-ring

Procedure

Thegreasettingsmustbeinstalledonthereelmotorsideof
thecuttingunit.Usethefollowingdiagramtodeterminethe
positionofthereelmotors.

Figure5

1.Removeanddiscardthesetscrewonthereel-motor
side-plate(Figure6).

1.Capscrew

Figure4

2.Rearshield

Figure6

1.Capscrew(2)3.Greasetting

2.Setscrew4.Greasevent

2.Installthestraightgreasetting(Figure6).

3.Iftherearenocapscrewsonthereel-motorside-plate,
installthem(Figure6).

4.InstalltheO-ringonthereelmotor(Figure7).

5

Figure7

1.O-ring

5.Installthereelmotor,andgreasethesideplateuntil
excessgreasepoursoutofthegreasevent(Figure6).

6

ProductOverview

Specications

ModelNumberNetWeight

03634

03635

41kg(90lb)

42kg(93lb)

CuttingUnitAccessoriesandKits(see partscatalogforpartnumbers)

Note:Allaccessoriesandkitsare1percuttingunitunless

otherwisespecied.
BroomerKit:Multiplebrushstripswovenintothehelical

groomerbladesimprovetheeffectivenessofthegroomerkit.
Performanceofthegroomerisenhancedbyenablingafull
width"Brooming"effectofturfwhileopeningupthecanopy
forbettergrassclippingintegration.Thecombinationof
groomerandbroomersystemsoptimizethequalityofcutand
after-cutappearanceformoreconsistentplayingconditions.

CollarKit(6neededperroller):Reducesover-lapmarks
forwarmseasongrasses(Bermuda,Zoysia,Paspalum).This
kitisinstalledontheouter3groovesoftheexistingWiehle
roller,butisnotasaggressiveastheShoulderroller.

Comb/ScraperKit:Axedcombinstalledbehindthefront
rollerwhichhelpsreducegrainandspongyturfbystanding
upthegrassbeforecutting.AscraperforthefrontWiehle
rollerisincludedinthekit.

FullFrontRoller:Producesamorepronouncedstriping
(repeatedcuttinginthesamedirection/path).Effective
height-of-cutisraisedandthequalityofthecutisreduced.

GrassBasketKit:Aseriesofclippingcollectionbaskets
attachedtothefrontofthecuttingunitstocollectgrass
clippings.

GroomerKit:Rotatingbladesassembledbehindthefront
rollerwhichprovidethebestmethodforreducinggrainand
spongyturfbystandingupthegrassbeforecutting.The
groomeralsoknocksoffanydewfordecreasedstickiness
andclumping.Thiskitopensupthecanopyforbettergrass
clippingintegration,andliftsgrassforacleancrispcut.The
overalldesignimprovesthequalityofcutforhealthierturf
grasswhileimprovingtheaftercutappearance.

HighHOCKit:Newfrontrollerbracketsandadditional
spacersfortherearrollerallowsthecuttingunittoachieve
heightsofcutabove5mm(1.00inch).Thenewfrontroller
bracketsalsomovesthefrontrolleroutfarthertoimprove
after-cutappearanceattheseheightsofcut.

LongRearRoller:Helpsreduceover-lapmarksand
mismatchbetweencuttingunitsforwarmseasongrasses
(Bermuda,Zoysia,Paspalum).

RearLiftCylinderKit:Collarsassembledontherearcutting
unitliftarmcylinderstolimittheheightofthecuttingunits.
Thisincreasestheareaforthereargrassbaskets.

RearRollerBrushKit:Ahigh-speed,high-contactbrush
thatkeepstherearrollerfreeofgrassanddebris,which

maintainsaconsistentheightofcutandpreventsclumping.
Thisleadstoabetterafter-cutappearance.

RollerRebuildKit:Includesallthebearings,bearingnuts,
innerseals,andoutersealsrequiredtorebuildaroller.

RollerRebuildT oolKit:Includesallthetoolsand
installationinstructionsrequiredtorebuildarollerwiththe
rollerrebuildkit.

Scrapers(Wiehle,Shoulder,Rearroller,FullFront
Roller):Fixedscrapersforalloptionalrollersareavailable

forreducinggrassbuilduponrollerswhichcanaffect
height-of-cutsettings.

ShoulderRoller:Helpsreduceover-lapmarksforwarm
seasongrasses(Bermuda,Zoysia,Paspalum).

WeightKit:Includescounterweightsthatattachtothe
cuttingunitsandmaintainbalancewhenotheraccessories
arenotinuse.

7

Operation

Note:Determinetheleftandrightsidesofthemachine

fromthenormaloperatingposition.

MakingAdjustments

AdjustingtheBedknifetotheReel

Usethisproceduretosetthebedknifetothereelandtocheck
theconditionofthereelandbedknifeandtheirinteraction.
Aftercompletingthisprocedure,alwaystestthecutting
unitperformanceunderyoureldconditions.Youmay
needtomakefurtheradjustmentstoobtainoptimalcutting
performance.

Important:Donotovertightenthebedknifetothereel
oryouwilldamageit.

•Afterbacklappingthecuttingunitorgrindingthereel,you

mayneedtomowwiththecuttingunitforafewminutes
andthenperformthisproceduretoadjustthebedknifeto
thereelasthereelandbedknifeadjusttoeachother.

•Youmayneedadditionaladjustmentsiftheturfis

extremelydenseoryourcuttingheightisverylow .

Youwillneedthefollowingtoolstocompletethisprocedure:

•Shim(0.002inch)

Figure9

1.Cuttingunitkickstand

4.Rotatethereelsothatabladecrossesthebedknife
approximately25mm(1inch)infromtheendofthe
bedknifeontherighthandsideofthecuttingunit.

Note:Putanidentifyingmarkonthisbladetomake
subsequentadjustmentseasier.

5.Insertthe0.05mm(0.002inch)shimbetweenthe
markedreelbladeandthebedknifeatthepointwhere
thebladecrossesthebedknife.

6.Turntherightbedbaradjusterclockwiseuntilyoufeel
lightpressure(i.e.drag)ontheshim,thenbackoffthe
bedbaradjustertwoclicksandremovetheshim.

•Cuttingperformancepaper

1.Positionthecuttingunitonaat,levelworksurface.

2.Turnthebedbaradjustingscrewscounterclockwiseto
ensurethatthebedbardoesnotcontactthereel(Figure

8).

Figure8

1.Bedbaradjustingscrew

3.Tipthemower,toexposethebedknifeandreel.

Important:Makesurethatthenutsontheback
endofthebedbaradjustingscrewsarenotresting
ontheworksurface(Figure9).

Note:Adjusting1sideofthecuttingunitaffectsthe
otherside,the2clickswillprovideclearanceforwhen
theothersideisadjusted.

Note:Ifstartingwithalargegap,bothsidesshould
initiallybedrawncloserbyalternatelytighteningthe
rightandlefthandsides.

7.Slowlyrotatethereelsothatthesamebladethatyou
checkedontherightsideiscrossingthebedknife
approximately25mm(1inch)infromtheendofthe
bedknifeonthelefthandsideofthecuttingunit.

8.Turntheleftbedbaradjusterclockwiseuntiltheshim
canbeslidthroughthereeltobedknifegapwithlight
drag.

9.Returntotherightsideandadjustasnecessarytoget
lightdragontheshimbetweenthesamebladeand
bedknife.

10.Repeatsteps8and9untiltheshimcanbeslidthrough
bothgapswithslightdrag,butoneclickinonboth
sidespreventstheshimfrompassingthroughonboth
sides.

Note:Thebedknifeisnowparalleltothereel.

Note:Thisprocedureshouldnotbeneededondaily

adjustments,butshouldbedoneaftergrindingor
disassembly.

8