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04129SL - Toro Media

1. SPARK PLUG 5 Raio 2 Fm 3 ENGINE CONN FRONT AC VIO 2 REG GN IGNITION MODULES SPARK PLUG LOW OIL PRESSURE mm OIL SW ITCH STARTER aBK CARBURETOR HOUR METER IGN SWITCH START Miri OFF RUN START BK 1 T OR d BK VIO 3 IGN SWITCH CONN FRONT 10A A Do NEUTRAL SW RELAY START zm 4 PK w BU ENERGIZED NEUTRAL SW START SNRA RAISE SOLENO Q IN NEUTRAL 2 SVR 12 V SVQ 5 111 1 t BU L 2 FLOAT SVG 14 BU W BU W lt gt gt BN SVQ FAST RAISE SOLENOID 2 0 IGN SW I SV GROUND FOLLOW OFF lt lt gt gt 2 HEAD HIGH TRANSPORT 1 mE s IT OR OR amp 3 HEAD RAISED 1 2 OK LOWER NOT USED 5 PK BK R BK GY 121 Y lt SVL LOWER SOLENOID 2 F AERATE GROUND 1 LATCHING RELAY Y GY
2. LIFT ORF1 CYLINDER POS SS e m CYL 0 gt S N a ER Y SVR i NOT ENERGIZED se NOT ENERGIZED 1 sva ENERGIZED i p o LI BE E cedi i EI VI 5 EE CONTROL CHG G2 ET MANIFOLD 4 WHEEL FORWARD ORE N BOTTOM Y Nr PORT 5 J P port L e N ror A L L L lt Hydraulic System Page4 8 Traction Circuit Forward Shown Working Pressure Low Pressure Charge Return or Suction Flow Rev C ProCore 648 Traction Circuit The traction piston pump P1 is driven by the engine through the pulleys and pump drive belt The traction cir cuit of the hydraulic system acts essentially as a closed loop Taking its suction directly from the return side of the wheel motors of the traction circuit the traction piston pump supplies oil flow to the wheel motors through the supply side of the traction circuit The gear pump P2 is attached to the traction pump and is directly coupled to it The gear pump provides charge oil to replace small amounts of traction pump internal oil leakage Hydraulic charge oil is supplied to the traction circuit from the gear pump through the lift control man ifold manifold por
3. IGN SWITCH RUN PK OFF RUN START NEUTRAL SW TARTE K e re 1 o 8 as SUM S 1 NOT ENERGIZED 1 UE VE SVR RAISE SOLENOID L ote BU 2 SVR 12 V SVQ SVL T ENERGIZED ee ay EET zi Hw Mo E sady Mi w 2 IN SW I FIT SVQ FAST RAISE SOLENOID o GROUND FOLLOW ENERGIZED 2 HEAD HIGH TRANSPORT 1 Lon Moe tu minnie DIL EM OR X Je ad T 2 OK LOWER NOT USED 1 ean BEING LOWERED ge oce eX ELSE 7 M GY He AERATE GROUND 1 5 BK ENERGIZED VER S pedes e s cc ce mes I T T GN 5 AERATOR CONTROL dd SK NEUTRAL SW RELAY LATCH 0 l 12 V SVR MODULE E k o r_a SM PRESSED TO LOWER pay b dec e Y B PORRO 6 IN FORWARD NOT ENERGIZED GY AERATION 4 1 HEAD BEING LOWERED I BN 5 OR W 2 HE
4. ENERGIZED AERATION 3 HEAD LOWERED ENERGIZED BK SVQ FAST RAISE SOLENOID NOT ENERGIZED SVL LOWER SOLENOID ENERGIZED ProCore 648 Aerating Coring Head Fully Lowered Low Spot in Turf Encountered Head High Limit Switch Closed by Turf Guard Movement Power Current Control Current Page 8 7 aBK SPARK PLUG SPARK PLUG HOUR gt BU R VIO IGNITION MODULES ENGINE CONN FRONT AC 4 HEAD LOWERED LOCKOUT RELAY 02 BK LOCKOUT LATCH RELAY OR q e 7 _ E _ prs p J 44 4 4mma 2 1 ENED LIFT RESET ProCore 648 Aerating Coring Head Fully Lowered GN OIL BU 5 START ProCore 648 Aerator w 1 MAG GN N BIL STARTER CARBURETOR SWITCH Aerator Control Module LOW OIL T PRESSURE G F1 Fh 2 W BK 20 A F3 174A IGN SWITCH RUN PK FO RM START Bi NEUTRAL SW per eee _ TART BK ma FE i nein Spo nume A NOT ENERGIZED NEUTRAL SW START RAIS
5. 648 Problem Possible Cause No traction in either direction Parking brake is engaged Oil level in reservoir is low Traction pump by pass valve is open Pump drive belt is loose worn or broken Traction cable broken or damaged Charge pressure is low Hydraulic pump pulley not secure to pump shaft Traction pump or wheel motor s are worn or damaged Wheel motor will not turn Parking brake is engaged rear wheel motors Key on wheel motor shaft is sheared or missing Internal parts in wheel motor are damaged Wheel motor will not hold load in Make up fluid from charge pump is not available neutral Wheel motor s is are worn or damaged Coring head will not lift or lifts slowly System reset switch needs to be pressed Engine speed is too low Reservoir oil level is low Hydraulic Pump pulley drive belt is loose or worn Lift cylinder is binding Coring head is binding Lift control manifold relief valve R1 is stuck open Lift control manifold orifice ORF1 is damaged or plugged Lift control manifold SVQ cartridge valve solenoid is not being energized Gear pump P2 is worn or damaged Coring head raises but will not stay Lift control manifold SVL cartridge stuck open up Lift control manifold SVL cartridge valve leaks ProCore 648 Page 4 15 Hydraulic System This page is intentionally blank Hydraulic System Page 4 16 ProCore 648 Testing The most effective method for isolating p
6. iiM __ _ _____ 648 pair m i LIFT RESET ENERGIZED Transport BK i i EDHRERTOIET IIR t Coring Head Fully Raised CLUTCH RELAY n Power Current 1 obla a 9T er GY Control Current F2 10A 0 03 CLUTCH i ge b ENERGIZED Y fe BN 121 Y 2 AERATION 3 NOT ENERGIZED HEAD RAISED Page 8 10 P2 NEUTRAL SW RELAY P5 LOW OIL PRESSURE REVERSE 89 m SP2 3 LATCHING RELAY P22 NEUTRAL SW P18 HEAD LOW LIMIT HEAD HIGH LIMIT P7 TRANSPORT LIMIT 42 SW PB AERATION 3 SW ci rir AERATION 4 SW i gt p12 SVR svo mite GND FOLLOW SW P23 LIFT RESET SW HR METER SP1 0100 02 DIODE 03 D GROUND A p19 TRANSPORT LIMIT 41 SW DIODE PN ta lt Ne ENGINE CONNECTOR 15 RAISE LOWER SW SPh 01 5 IGN SW 25 LATCH P1 DUC RELAY IGN SW PL NEUTRAL SW RELAY S
7. LOCKOUT RELAY BK ps ssdjal LOCKOUT LATCH RELAY PER Dreano al PK BK 5 zo A 1 7 4 i ee E E 648 LIFT RESET Aerating c Level Ground Surface a PE i GY F2 10 03 J CLUTCH y ENERGIZED AERATION 3 HEAD LOWERED 8 6 aBK SPARK PLUG 2 PLUG HOUR METER ENGINE CONN FRONT V0 y REG 4 GN OIL BU 5 START 1 MAG CARBURETOR GN OIL NE ITCH LOW OIL PRESSURE ProCore 648 Aerator Aerator Control Module BU SVR RAISE SOLENOID NOT ENERGIZED BN LOCKOUT RELAY 6 AME 4 3 1 o TRANSPORT LIMIT 2 1 HEAD LOWERED 02 M Yy p ENERGIZED pa E LIFT RESET F1 2 W BK 20 F3 IGN SWITCH RUN PK OFF RUN START BU o NEUTRAL SW RELAY START BK OR iE 4 5 1 30 PK 1 VIO as PPPA
8. A Remove extension spring from the neutral lever B Loosen two 2 socket head screws item 8 Fig 32 that secure pump lever to pump trunnion shaft C Remove two 2 cap screws with flange nuts items 2 and 4 Fig 32 and washer head screw item 9 Fig 32 that secures control bracket to hydraulic pump D Carefully lift pump control assembly and position away from pump 7 Disconnect all hydraulic hoses and tubes connected to the hydraulic fittings on the hydraulic pump assembly Allow hoses to drain into a suitable container Plug or cap openings of pump and hoses to prevent contamina tion Support hydraulic pump when removing it from the pump support to prevent the pump from fal ling and causing personal injury ProCore 648 Page 4 39 8 Remove both flange head screws and flange nuts securing the hydraulic pump to the pump support Lift pump assembly from the machine NOTE If hydraulic fittings are to be removed from hy draulic pump note correct orientation of fittings before loosening the fittings 9 Remove hydraulic fittings and o rings from the pump as required 10 Discard all removed o rings 9 5 5 gt lt Figure 32 7 Trunnion clamp 8 Socket hd screw 2 used 9 Washer head screw 10 Lock nut 11 Pump shield Hydraulic pump Cap screw 2 used Control bracket Flange nut 2 used Flat washer Pump lever Figure 33 3 Flang
9. B Install hydraulic pump drive pulley with the hub away from engine C Slide clutch onto crankshaft and secure to crank shaft with screw and hardened washer Hold hard ened washer with pliers to prevent crankshaft from turning and torque screw from 50 to 55 ft lb 67 9 to 74 6 N m 4 If removed install belt tensioner components to en gine assembly see Belt Tensioners in this section 5 Reinstall engine to machine A Connect a hoist or chain fall to lift tabs located on each of the cylinder heads One person should operate lift or hoist while another person guides the engine to the ma chine IMPORTANT Make sure not to damage the engine fuel hoses hydraulic lines electrical harness or other parts while installing the engine B Reinstall engine to the machine Make sure fas tener holes of the engine are aligned with the holes in the machine frame C Secure engine to the frame with four 4 cap screws and flange nuts The front two 2 cap screws should be positioned down through engine and frame The rear two 2 cap screws should be up through frame and engine 6 Reconnect electrical connections to engine A Plug engine wire harness connector into machine harness connector Kohler Engine Page 3 14 B Wrap hourmeter wire around spark plug wire and secure with cable tie C Position negative battery cable and wire harness ground wire to the front corner of engine base Fig 10 Place st
10. E Remove hair pin item 8 and clevis pin item 7 that secure spring shackle item 2 to frame Hydraulic System Page 4 50 ProCore 648 5 Start engine and allow coring head to fully raise Turn engine off Secure coring head with service latch Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hy draulic oil See Relieving Hydraulic System Pres sure in the General Information section of this chapter 6 Release hydraulic pressure in lift cylinder A Turn key switch to ON engine not running B Move traction lever to forward direction and de press lower switch on handle to lower coring head onto service latch 7 Disconnect hydraulic hose from hydraulic fitting on lift cylinder Locate and discard o ring from between hose and fitting Allow hose to drain into a suitable con tainer 8 Plug disconnected hose and fitting to prevent con tamination 9 Remove one retaining ring from the upper cylinder pin Pull upper cylinder pin from the lift cylinder and cor ing head frame Locate and retrieve spacer and thrust washer from each side of cylinder pivot Fig 43 10 Remove one retaining ring from the lower cylinder pin on the side of the disconnected extension spring Support lift cylinder and slide lower cylinder pin from the lift cylinder and machine frame 11 Remove lift cylinder from the machine 12 If needed remove hydraulic fitting and o ring from the lift cylinde
11. lt gt a o 875 2 6 HEAD LOW i E 3 T T ON lt lt AERATOR NTR NEUTRAL SW RELAY LATCH 2 H 12 V SVR i MODULE i r Bae pad ace BK T 5 GY 4 vio 65 FARA PK BK a lt 7 a MANUAL RAISE LOW ER 1 olo ENERGIZED NEUTRAL POSITION 1 0 nme Y 85 86 REVERSE IN NEUTRAL OR REVERSE NO NOT ENERGIZED do GY AERATION 4 HEAD RAISED o HEAD LOW LIMIT aN HEAD RAISED 5 T TRANSPORT LIMIT 1 HEAD RAISED oo TRANSPORT LIMIT 2 HEAD RAISED 02 Y Di LOCKOUT RELAY BK 8791 LOCKOUT LATCH RELAY 30 o an i EE i d T p 5 T ap 8 FECA 86 OR quain E po RES 3 6 Ce 86 NOT ENERGIZED 1 Y Y Roe PK LIFT RESET NOT ENERGIZED ProCore 648 BK GN GY Y m em mb F2 03 CLUTCH Y BU BN Di Y A tag chan AERATION 3 NOT ENERGIZED HEAD RAISED Power Current Control Current Indication Current Page 8 4 aBK SPARK PLUG SPARK PLUG 5 Rao IGNITION Lon MODULES i ENGINE CONN FRONT V1 M GN oiL BU 5 START 1 MAG ProCore 648 Aerator CARBURETOR N SW TCR ee m Aerator Control Module PRESSURE
12. 14 15 16 17 18 19 20 21 22 Stroke control cable 24 25 27 Figure 28 Trunnion clamp Socket head screw 2 used Pump lever Cap screw Jam nut Traction lever spacer Lock nut Ball joint Jam nut Traction stud Lock washer Page 4 36 Loctite 242 Ball bearing Cap screw Cap screw Spherical rod end Thrust washer Flange bushing Damper Neutral lever Plug Washer head screw Cable clamp Spacing control cable ProCore 648 Disassembly Fig 28 1 Park machine on a level surface fully raise coring head engage parking brake stop engine and remove key from the ignition switch Secure coring head with service latch 2 Remove pump belt cover from machine see Opera tor s Manual 3 Remove two 2 lock nuts that secure pump shield to pump Fig 29 Remove shield from pump Locate and retrieve two 2 flat washers from tops of studs on pump control assembly The extension spring is under tension and may cause personal injury during removal Use cau tion when removing spring from neutral lever 4 Remove components from pump control assembly as needed using Figures 28 29 and 30 as guides Assembly Fig 28 1 Install removed components to pump control assem bly using Figures 28 29 and 30 as guides A If rod ends were removed from damper apply Loctite 4242 to threads of damper shaft before instal ling rod ends B Dampe
13. 3 Remove pump belt cover from machine see Opera tor s Manual Kohler Engine Page3 12 Rev 4 Remove exhaust system see Exhaust System Re moval in this section 5 Close fuel tank shut off valve 6 Loosen hose clamp and disconnect fuel hose from the fuel filter on the front side of the engine Plug fuel hose to prevent leakage and contamination ProCore 648 7 Disconnect electrical connections from engine NOTE Label all electrical connections for reassembly purposes A Remove harness red wire and positive battery cable from the starter motor solenoid stud Fig 9 B Disconnect negative battery cable and wire har ness ground wire from the front corner of engine base Fig 10 Locate and retrieve starwasher from between engine and wire connectors C Unplug machine harness connector from electric clutch D Remove cable tie that secures hourmeter wire to spark plug wire Position hourmeter wire clear of en gine E Unplug machine wire harness connector from en gine connector Position wiring harness away from the engine 8 Remove primary drive belt coring head see Prima ry Drive Belt in the Service and Repairs section of Chap ter 7 Coring Head 9 Remove hydraulic pump drive belt see Pump Drive Belt in the Service and Repairs section of Chapter 4 Hydraulic System 10 Remove engine from machine A Connect a hoist or chain fall to lift tabs located on each of the cylinde
14. OFF RUN START B NEUTRAL SW 522 RELAY START BK OR v1 e 0 YE 5 o T 1 SEPTEM LE 1 T 1 L vio 4 85 86 oo BU ol ai Fe ed E ama T SVR RAISE SOLENOID ro pru BK CIN NEUTRAD 2A SVR 12 V SVO SVL A pK BU lt 5 2 3 FLOAT sva s e BU W BU W 2 gt BN SVQ FAST RAISE SOLENOID M x xd SVL 1 i GROUND FOLLOW OFF Me 2 HEAD HIGH TRANSPORT 14 ABE HEAD HIGH LIMIT OR AMT p 2 OK LOWER NOT USED PK BK R BK HEAD RAISED GY D Y lt r SVL LOWER SOLENOID RATI GROUND t F LATCHING RELAY Y GY gt gt 2 30 20 GN 2 HEAD Low BE T T AERATOR CONTROL NEUTRAL SW RELAY LATCH 1 1 2 12 V SVR MODULE OO BK lt GY 4 528197 vio 8 6 p PK BK n MANUAL RAISE LOW ER ole Y _ REVERSE acp agire IN NEUTRAL OR REVERSE NO i GY AERATION 4 HEAD RAISED T oo GN HEAD LOW LIMIT HEAD RAI OR 2 4 3 ne Bk M10 TRANSPORT LIMIT 1 HEAD RAISED IGN SWITCH CONN FRONT TRANSPORT LIMIT 2 HEAD RAISED 02 Y Di LOCKOUT RELAY Bk phar Wo 9o Ri i M 5 us BK tect OR Las APPA 3e 1 meee ow SEE US 85 86 zT aep Y Pk ProCore 648 LIFT RESET BK GN 4 CLUTCH RELAY GY GY F2 10 03 CLUTCH Y BU oo BN pi Y AERATION 3 HEAD RAISED 8 3
15. Preface The purpose of this publication is to provide the service technician with information for troubleshooting testing and repair of major systems and components on the ProCore 648 REFER TO THE OPERATOR S MANUALS FOR OP ERATING MAINTENANCE AND ADJUSTMENT INSTRUCTIONS Space is provided in Chapter 2 ofthis book to insert the Operator s Manuals and Parts Cata logs for your machine Replacement Operator s Manu als and Parts Catalogs are available on the internet at www toro com The Toro Company reserves the right to change product specifications or this publication without notice Part No 04129SL Rev C Service Manual ProCore 648 This safety symbol means DANGER WARNING or CAUTION PERSONAL SAFETY INSTRUC TION When you see this symbol carefully read the instructions that follow Failure to obey the instructions may result in personal injury NOTE NOTE will give general information about the correct operation maintenance service testing or re pair of the machine IMPORTANT The IMPORTANT notice will give im portant instructions which must be followed to pre vent damage to systems or components on the machine The Toro Company 2004 2006 2009 This page is intentionally blank ProCore 648 Table Of Contents Chapter 1 Safety Safety 1 5 5 1 2 Jacking 1 4 Safety and Instruction Deca
16. Y ENERGIZED AERATION 3 HEAD LOWERED ENERGIZED High Spot in Turf Encountered Head Low Limit Switch Closed by Turf Guard Movement Power Current Control Current Page 8 8 aBK SPARK PLUG SPARK PLUG 5 Rao IGNITION Lon MODULES i ENGINE CONN FRONT V1 M GN oiL BU 5 START ProCore 648 Aerator 1 MAG CARBURETOR N SW TCR ee m Aerator Control Module PRESSURE 648 IGN SWITCH RUN PK RUN START BU NEUTRAL SW ZURELATCISTARTE BK PENNE PK TES ase ere 1 7 neos L l 1 a 4 oe BU 4 GN NOT ENERGIZED NEUTRAL SW START SVR RAISE SOLENOID NOT IN NEUTRAL 1 ots BU 518 12 V SVQ SVL T ENERGIZED EU lt 7 ra FLOAT SVG 14 Lo lo __ 5 ote OLOR gau BN l ate SVQ FAST RAISE SOLENOID GROUND FOLLOW ON VK ome 5 ENERGIZED OR OR 20 HEAD HIGH TRANSPORT 5 HEAD HIGH LIMIT
17. o IE pe ee e A HIGH LIMIT Us 01 oR 1 1 HEAD RAISED E Y OK LOWER NOT USED it PK BK R BK GY SVL LOWER SOLENOID T m 2 AERATE GROUND 5 NOT ENERGIZED f PONE 8785 6 HEAD LOW 2 159 7 T GN AERATOR CONTROL k NEUTRAL SW RELAY 1 12 V SVR MODULE AE 1 c 6 PK MANUAL RAISE LOW NOT ENERGIZED NEUTRAL POSITION a IN FORWARD NOT ENERGIZED GY AERATION 4 1 HEAD RAISED T 5 5 GN HEAD LOW LIMIT OR 2 HEAD RAISED 4 3 a ee a ce ee ee ee ee ee ee ee ee ee se ee cee ee Nc up Se EN BK vio TRANSPORT LIMIT 1 1 HEAD RAISED IGN SWITCH Lo CONN FRONT grin vm d 71 HEAD RAISED 02 1 pe y LOCKOUT RELAY 2 _87 5 LOCKOUT LATCH RELAY OR Farid Fal d P i 4t
18. 1 00 0 25 6 3 8 in 1 50 0 25 8 1 2 in 1 50 0 25 10 5 8 in 1 50 0 25 12 3 4 in 1 50 0 25 16 1 in 1 50 0 25 Figure 6 ProCore 648 4 5 Hydraulic System Pushing Pulling Machine IMPORTANT If push pull limits are exceeded se vere damage to the piston traction pump may oc cur If it becomes necessary to push pull the machine push pull at a speed below 1 mph 1 6 kph and for a dis tance less than 100 feet 30 5 meters The piston traction pump is equipped with a by pass valve that needs to be rotated counterclockwise loosened one turn for pushing pulling The by pass valve should be torqued from 95 to 120 10 7 to 13 6 before the machine is returned to operation See Operator s Manual for pushing pulling procedures Check Hydraulic Fluid The ProCore 648 hydraulic system is designed to oper ate on anti wear hydraulic fluid The reservoir Fig 8 holds about 1 75 gallons 6 6 liters of hydraulic fluid Check level of hydraulic fluid daily See Operator s Manual for fluid level checking proce dure and hydraulic oil recommendations Relieving Hydraulic System Pressure Before disconnecting or performing any work on the hy draulic system all pressure in the hydraulic system must be relieved With the coring head fully raised turn key switch to OFF and allow engine to stop Secure cor ing head with service latch To relieve hydraulic pressure in traction circuit
19. 3 used Steering arm Cap screw 5 used Slotted hex nut Washer Bearing cone Bearing cup Frame Steering stop Cap screw 2 used Cable guide Cotter pin Chassis 14 15 16 17 18 19 20 Traction control cable 22 23 Compression spring 25 Figure 7 Steering spindle Lock nut 3 used Lock nut 4 used Wheel motor Cap screw 4 used Washer head screw 6 used Lower handle cover Jam nut Spring retainer Override rod Page 6 10 26 27 28 29 30 31 32 33 34 35 36 37 Lock nut Spacer Ball joint Flat washer Cap screw Control handle Neutral proximity switch Reverse proximity switch Relay neutral and latching Low oil pressure light Raise lower switch Handle control cover ProCore 648 Disassembly Fig 7 1 Park machine on a level surface fully raise coring head engage parking brake stop engine and remove key from the ignition switch Secure coring head with service latch 2 Block rear wheels Jack front of machine from ground and support machine with blocking or jack stands see Operator s Manual and Jacking Instructions in Chapter 1 Safety 3 Remove front wheel assembly see Wheel Removal in this section 4 Remove front wheel motor see Wheel Motor Re moval in Service and Repairs section of Chapter 4 Hy draulic System 5 Remove fuel tank from machine see Fuel Tank Re moval in Service and Repairs section of C
20. AD 0092365 2 2 555 6 2 i eS 5 92 9 gs 5 9 5 0 stgo 1 2 3 4 5 ProCore 648 Page 3 10 Kohler Engine Removal Fig 7 The muffler and exhaust pipe may be hot To avoid possible burns allow the engine and ex haust system to cool before working on the ex haust system 1 Park machine on a level surface fully raise coring head engage parking brake stop engine and remove key from the ignition switch Secure coring head with service latch 2 Remove fasteners that secure exhaust heat shield to machine flange head screw and two 2 cap screws with lock washers Remove heat shield from machine 3 Loosen muffler clamps that secure muffler and ex haust elbow 4 Remove two 2 flange nuts that secure muffler to frame Retrieve two 2 carriage screws Remove muf fler and exhaust elbow from machine 5 exhaust manifold removal is required remove four 4 hex nuts from the exhaust manifold studs on engine Separate the exhaust manifold from the engine 6 Remove exhaust gaskets ProCore 648 Page 3 11 Installation Fig 7 NOTE Make sure exhaust manifold and engine seal ing surfaces are free of debris or damage that may pre vent a tight leak free seal 1 If exhaust manifold was removed place exhaust gaskets on the engine exhaust manifold studs Secure exhaust manifold to en
21. AND REPAIR MANUAL at the end of this chapter Clean or replace relief valves as necessary as they are not adjustable If relief valves are in good condition pis ton traction pump should be suspected of wear and in efficiency NOTE Forward and reverse relief valves are identical Relief valves can be switched in piston traction pump to help in identifying a faulty relief valve 16 Disconnect Tee fitting with pressure gauge from pump fitting and hydraulic hose Reconnect hose to pump fitting be _ Figure 21 1 Lower 459 fitting 2 Upper 909 fitting Hydraulic System 2 5 5 gt Gear Pump P2 Flow Test Using Tester With Flow Meter and Pressure Gauge CYL Hydraulic System Figure 22 4 26 Rev C MANIFOLD FRONT WHEEL gt 14 PPOR Working Pressure Low Pressure Charge Return or Suction Flow Direction ProCore 648 Procedure for Gear Pump P2 Flow Test 1 Make sure hydraulic oil is at normal operating tem perature by operating the machine for approximately 10 minutes 2 Park machine on a level surface with the coring head fully raised Make sure engine is off and the parking brake is engaged Secure coring head with service latch 3 Read Precautions For Hydraulic Testing in this sec tion Operate all hydraulic controls to relieve system pressure and avoid injury from pressuri
22. the head low input LED will illuminate slightly later While aerating with the ProCore the turf guards follow surface undulations With the True Core ground fol lowing system on the Aerator Control Module receives an input if the turf guards move enough to close either the head high or head low limit switch The Control Mod ule uses that input to allow a current output to the ap propriate hydraulic solenoid SVR or SVL to raise or lower the coring head slightly Head Low and Head High Switch Test 1 Park machine on a level surface fully raise coring head engage parking brake stop engine and remove key from the ignition switch Secure coring head with service latch 2 Locate switch on depth control housing Disconnect the switch electrical connector 3 Check the continuity of the switch by connecting a multimeter ohms setting across the connector termi nals A The head high switch should be closed continu ity with the coring head raised and the turf guards extended The switch should open no continuity if the turf guards are manually raised B The head low switch should be open no continu ity with the coring head raised and the turf guards extended The switch should close continuity if the turf guards are manually raised 4 Reconnect the switch electrical connector 5 If switch replacement is necessary apply small amount of grease onto the switch ball before installing switch in depth control h
23. 4 Remove cotter pin and flat washer that retain brake cable to brake lever Slide brake cable from brake lever 5 Remove brake cable from parking latch pivot on rear cross tube of frame Fig 6 A Remove hairpin and clevis pin that secure park Figure 6 ing brake cable clevis to parking latch pivot 47 Brake cable 4 Clevis pin 2 Retaining ring 5 Parking latch pivot B Remove retaining ring that secures brake cable 3 Hairpin to rear cross tube of frame 6 Note routing of parking brake cable Remove parking brake cable from machine Installation Fig 3 1 Position new parking brake cable to machine noting original routing 2 Secure brake cable to parking latch pivot on rear cross tube of frame Fig 6 A Position parking brake cable clevis to parking latch pivot and secure with clevis pin and hairpin B Secure brake cable to rear cross tube of frame with retaining ring 3 Position brake cable end to parking brake lever Se cure cable to lever with flat washer and cotter pin 4 Secure parking brake cable to underside of control handle with jam nuts 5 Position lower handle cover to control handle and se cure with six 6 washer head screws 6 Make sure that steering components do not contact cables or wire harness 7 Remove service latch from coring head before ma chine use ProCore 648 Page 6 9 Chassis Steering Assembly CRN CS ON E Grommet Stud
24. 648 The electric clutch is mounted on the engine crankshaft and engages when current is applied to the clutch The clutch also incorporates a magnetic brake to stop clutch rotation when the clutch is de ener gized When the OK to lower latching circuit is closed and the coring head is lowered enough to close the aeration 3 proximity switch the clutch relay will be energized This energized relay provides a current path to energize and engage the clutch See Electric Clutch Circuit in the Cir cuit Operation section of this chapter for additional elec tric clutch information Testing 1 Park machine on a level surface fully raise coring head engage parking brake stop engine and remove key from the ignition switch Secure coring head with service latch 1 Remove pump belt cover from machine see Opera tor s Manual 2 Remove exhaust system shield see Exhaust Sys tem Removal in the Service and Repairs section of Chapter 3 Kohler Engine 3 Locate electric clutch on engine crankshaft Fig 35 Unplug machine wire harness connector from clutch 4 For accurate resistance measuring clutch should be at approximately 68 F 20 C when coil resistance is measured NOTE Prior to taking small resistance readings with a digital multimeter short the meter test leads together The meter will display a small resistance value usually 0 5 ohms or less This resistance is due to the internal resistance of the meter and
25. Coupling 3 shown 5 Coupling plate 2 Iso mount 2 used 6 Cap screw 4 used 3 Coupling 2 shown 7 Locknut 2 used 4 Cap screw 2 used 8 Flat washer 2 used ProCore 648 7 7 Coring Head 5 6 fe Coring Crankshaft Bearing Housings 70 to 80 ft lb 150 to 170 ft lb 95 to 108 N m 203 to 230 N m 150 to 170 ft lb 203 to 230 N m ANTISIEZE LUBRICANT ANTISIEZE LUBRICANT BEARING HOUSING FOR 5 AND 6 STOMPER ARMS SHOWN 150 to 170 ft Ib 203 to 230 N m 70 to 80 ft Ib 95 to 108 Figure 8 1 Cap screw 9 Bearing housing 17 Cap screw 4 used per plate 2 Flat washer 10 Spacer 18 Cap screw 3 Spacer tube 11 Crankarm 19 Coupling 4 Stomper arm 12 Square key 20 Cap screw 4 used per housing 5 Ball bearing 13 Coupling 5 shown 21 Hardened washer 6 Retaining ring 14 Lock nut 22 Spring pin 2 used per housing 7 Crankarm 15 Coupling plate 23 Lock nut 8 Ball bearing 16 Iso mount 24 Coring head frame NOTE The three 3 bearing housings used on the Pro Core 648 are identical Coring crankshaft positions are identified as 1 through 6 The 1 position is on the right pulley side of the coring crankshaft Removal Fig 8 1 Park machine on a level surface fully raise coring head engage parking brake stop engine and remove key from the ignition switch Secure coring head with service latch 2 Remove rear hood see Operator
26. EINEN HEAD LOWERED OK LOWER NOT USED t PK BK R BK GY V ag SVL LOWER SOLENOID 2 AERATE GROUND 155 NOT ENERGIZED LATCHING RELAY Y D y BK 1 Vee 528781 2 6 HEAD LOW z T GN ze NEUTRAL SW RELAY LATCH 2 H 12 V SVR SERRA ONTROL ME He 2 V MODULE 5871 vona py PK BK lt 3 l MANUAL RAISE LOWER Ene NOT ENERGIZED NEUTRAL POSITION ee Y p REVERSE IN NEUTRAL OR REVERSE ENERGIZED CENERE o AERATION 4 ay 1 HEAD LOWERED 2 7 GN HEAD LOW LIMIT 5 OR W 2 HEAD LOWERED 4 3 ue TRANSPORT LIMIT 1 T IGN SWITCH M HEAD LOWERED CONN FRONT o Y TRANSPORT LIMIT 2 HEAD LOWERED 02 J LOCKOUT RELAY EVER LOCKOUT LATCH RELAY OR PY aos t 528780 5 XL 1 i 2 J ENERGIZED Lerma Er pe as LIFT RESET Raise Coring Head M I e e C 24 Traction Lever Moved from Forward S CLUTCH RELAY 25 Power Current GY m PA Con
27. Overheating and engine damage will result 5 Make sure grass screen and blower housing are re installed to the engine if removed 1 Cylinder head 2 Grass screen ProCore 648 Page 3 7 Figure 4 3 Blower housing Kohler Engine Fuel System Anti seize Lubricant Figure 5 1 Fuel tank 5 Fuel shut off valve 9 Clamp 2 Fuel cap 6 Hose clamp 10 Cap screw 4 used 3 Hose clamp 7 Fuel hose 11 Flange bushing 4 used 4 Fuel hose 8 Flat washer 4 used 12 Machine frame Check Fuel Lines and Connections Check fuel lines and connections periodically as recom mended in the Operator s Manual Check fuel lines for deterioration damage or leaking connections Replace Because gasoline is highly flammable use cau hoses clamps and connections as necessary tion when storing or handling it Do not smoke while filling the fuel tank Do not fill fuel tank while engine is running hot or when machine is in an enclosed area Always fill fuel tank outside and wipe up any spilled fuel before starting the engine Store fuel in a clean safety approved mended in the Operator s Manual Also drain and clean container and keep cap in place Use gasoline the fuel tank if the fuel system becomes contaminated for the engine only not for any other purpose or if the machine is to be stored for an extended period Drain and Clean Fuel Tank Drain and clean the fuel tank periodically as reco
28. Power Current Control Current F1 Fh 2 W BK 20 A F3 174A IGN SW ITCH RUN PK OFF RUN START BU NEUTRAL SW FEAT START L BK l s EN K T m o 8L 85 m PERN VIO o BU NOT ENERGIZED NEUTRAL SW START SOLENOID NOT IN NEUTRAL 1 NOT ENERGIZED BK 35 8 2 SVR 12 V SVQ SVL t em NES BU ac S ee EE E rc ETE NONO CRM Uk E Ey 5 i mw eu SVQ FAST RAISE SOLENOID GROUND FOLLOW ON wek gt gt NOT ENERGIZED 2 HEAD HIGH TRANSPORT 4 ED EE 904 HEAD HIGH OR OR 4 gt gt 01 2 OK LOWER NOT USED 1 PK BK R BK HEAD LOWERED y X oO 55 i i NOT ENERGIZED LATCHING RELAY e Ge GROUND Ht Be RD A otan 2 6 HEAD LOW Te 1 GN we T ems SW RELAY LATCH 1 E AERATOR CONTROL d BK a 5 ee Ll PK BK ern ig M Gy t VIO oed P Node 5 E Y 85 Cerea m PK REVERSE IN FORWARD NOT ENERGIZED E AERATION 4 Gy I 1 HEAD LOWERED T GN HEAD LOW LIMIT s Top HEAD LOWERED 4 ee uly TRANSPORT LIMIT 1 T IGN SWITCH HEAD LOWERED o CONNSFRONJ TRANSPORT LIMIT 2 HEAD LOWERED 02 y
29. SLOW idle speed position 6 Using a tachometer check that engine is operating at 1400 50 RPM 7 For additional information refer to the Kohler Engine Service Manual that is included at the end of this Chap ter ProCore 648 Page3 5 Kohler Engine This page is intentionally blank Kohler Engine Page 3 6 ProCore 648 Service and Repairs Cooling System To ensure proper engine cooling make sure the grass screen cooling fins and other external surfaces of the engine are kept clean at all times NOTE Perform this maintenance procedure at the in terval specified in the Operator s Manual IMPORTANT The engine that powers the ProCore 648 is air cooled Operating the engine with dirty or plugged cooling fins a blocked grass screen or a plugged or dirty blower housing will result in en gine overheating and engine damage 1 Park machine on a level surface fully raise coring head engage parking brake stop engine and remove key from the ignition switch IMPORTANT Never clean engine with pressurized water Water could enter and contaminate the fuel system 2 Clean cooling fins on both cylinder heads 3 Clean grass screen and blower housing of dirt and debris Fig 4 4 If blower housing removal is necessary for cooling system cleaning engine needs to be removed from ma chine see Engine Removal and Installation in this sec tion IMPORTANT Never operate engine without the blower housing installed
30. allow wheels to turn freely Hydraulic System Page4 32 Rev A C Attach a heavy chain between the rear of the ma chine frame and something immovable inthe shopto prevent the machine from moving during the bleed ing process IMPORTANT Make sure oil flow indicator arrow on the flow gauge is showing that oil will flow from the test port of traction line and through the tester D Connect inlet end of hydraulic tester with flow me ter and pressure gauges to test port in upper traction line Fig 27 Place outlet end oftester in a drain con tainer Make sure that flow control valve on the tester is fully closed E Check hydraulic reservoir level and fill if neces sary F Start engine and move traction lever to the for ward direction to allow the wheels to rotate slowly NOTE Bleeding the traction circuit might require approximately five 5 minutes of running IMPORTANT When bleeding the traction circuit tester valve should be barely open which will al low a slow stream of oil from tester outlet While traction lever is held in the forward direction wheels turning have second person slowly open valve on tester very slightly to allow air out of traction circuit Air in the traction circuit will be indicated by foamy oil coming from the outlet end of the tester H While bleeding the traction circuit if more than 5 gallon 1 9 liters of oil is removed close tester valve and release traction lever Check
31. bearing cups and cones for wear or damage Replace worn or damaged components Assembly Fig 7 1 If removed secure steering spindle to steering arm with four 4 cap screws 2 If bearing cups were removed from frame install new cups to frame 3 Install steering arm to frame A Pack bearing cones with grease Position lower bearing on steering spindle shaft B Slide steering shaft up through frame Position upper bearing and washer on steering spindle shaft C Install slotted hex nut onto steering spindle tight en completely and then back nut off slightly Retigh ten nut until drag is felt while rotating steering arm Back off nut to align spindle shaft hole with slotted hex nut Make sure that steering arm rotates freely after slotted hex nut has been tightened D Insert cotter pin through slotted hex nut and steering spindle shaft 4 Assemble steering components in the reverse order of disassembly using Figure 7 as a guide 5 Lower machine to ground Remove service latch from coring head before machine use 6 Make sure that steering components do not contact cables or wire harness Figure 8 3 Neutral prox switch 2 Reverse prox switch Chassis Traction Control Cable Removal 1 Remove traction control cable from hydraulic pump control Fig 10 and traction lever on handle and Fig 11 2 Remove traction control cable from machine noting routing of cable to aid in
32. biodegradable fluid such as Mobil EAL Envirosyn H Operate machine under normal operating conditions for at least four 4 hours be fore draining 1 Park machine on a level surface fully raise coring head engage parking brake stop engine and remove key from the ignition switch Secure coring head with service latch 2 Remove pump belt cover from machine see Opera tor s Manual NOTE The hydraulic reservoir will drain when the hy draulic oil filter is removed from the hydraulic manifold 3 Clean area around filter mounting area Fig 26 Re move filter from hydraulic manifold and drain reservoir into a suitable container Drain hydraulic system Drain all hoses tubes and components while the system is warm Discard filter 4 Inspect and clean reservoir see Hydraulic Reservoir in this section 5 Make sure filter mounting surface is clean Apply hy draulic oil to gasket on the new filter Screw filter on until gasket contacts mounting surface of manifold then tighten filter half a turn NOTE Use biodegradable fluid such as Mobil EAL En virosyn H for this step if you are changing to this type of fluid Use only hydraulic fluids specified in Operator s Manual Other fluids could cause system damage 6 Fill hydraulic reservoir 7 Disconnect and ground both spark plug wires to pre vent engine from starting 8 Turn ignition key switch to start position engage starter for ten 10 seconds to prime hydrau
33. bottom switches are mounted on a mounting bracket attached to the right rear frame Fig 30 The sensing plate for these switches is welded to the coring head H frame The neutral proximity switch is used in the starting circuit Figure 29 to make sure that the traction lever is in the neutral posi 1 Reverse proximity switch 3 Neutral proximity switch tion when starting the engine This switch is closed when 2 Reverse sensing plate 4 Neutral sensing plate the traction bail is in the neutral position and opens when the bail is moved to either the forward or reverse direc tion The reverse proximity switch is one of the components used in the OK to lower circuit that acts as an input for the aerator control module This proximity switch is closed when the traction lever is in either the neutral or reverse position When the traction lever is moved to the forward direction the reverse proximity switch opens The transport limit 1 proximity switch is closed when the coring head is fully raised and opens almost immedi ately as the coring head begins to lower This switch is used as an input for the aerator control module to indi cate that the coring head is in the transport raised posi k 3 A S SN Figure 30 tion Transport limit 1 switch operation can be 1 Switch mount bracket 3 Coring head H frame 2 Sensi lat monitored using the control module transport 1 input 2d LED The
34. correct installation 3 Disassemble traction control cable using Figure 9 as a guide Installation 1 Assemble traction control cable using Figure 9 as a guide Tighten lock nuts item 6 so that compression spring item 4 has a length from 6 750 to 6 880 17 2 to 17 4 cm 2 Route traction control cable from traction lever on handle to pump control noting original routing 3 After assembly make sure that steering components do not contact traction cable 4 Check and adjust traction drive for neutral see Op erator s Manual Chassis Page6 12 Rev Figure 9 1 Traction control cable 5 Override rod 2 Jam nut 6 Locknut 3 Spring retainer 7 Ball joint traction lever 4 Compression spring 8 Ball joint pump lever 1 Pump control 2 Traction control cable 3 Cable ball joint Figure 11 1 Traction lever 2 Cable ball joint ProCore 648 Chapter 7 TORO Coring Head Table of Contents GENERAL INFORMATION 2 Coring Head Operation 2 Coring Crankshaft 2 Coring Head Service Latch 3 Coring Head Adjustments 3 SERVICE AND REPAIRS 4 Rotolink Dampers 4 Stomper Arms 6 Coring Crankshaft Bearing Housings 8 Primary Drive 10 Secondary Drive Bel
35. d lt 2 45 1 3 4 56 7 8 ABCDEF SP9 5 5 5 3 5 5 2 2 9 7 m lt sp ORANGE PINK BLACK A BLUE WHITE B 30 1 TAN WHITE BLACK 85 2 D LATCHING P3 SP7 5 RELAY 87 4 YELLOW F 86 5 PINK gt 5 1 PINK BLACK H YELLOW 1 SP4 1 BLACK BLACK 2 2 BLACK 3 NEUTRAL SWITCH pol _ SP3 4 RELAY VIOLET 4 5 5 6 7 9 2 2 5 5 8 m m d x 3 lt gt a ui c z a B a 1 2 3 RAISE LOWER 15 SWITCH 5 TAN 6 7 A Y z 1 z PINK pam PINK z 8 2 ORANGE a REY 4 4 PINK BLACK 5 PINK 5 1 x m 5 5 a 1 5 8 m z 4 H m LOCKOUT LATCH 8 RELAY P25 ORANGE WHITE 5 GREEN PINK B BLACK 5E YELLOW P31 gt POT YELLOW pd BLUE A DIODE D2 P32 SP5 SP8 BLACK BLACK A DIODE D3 P33 B YELLOW z 5 5 x 5 x z x E 9 5 8 5 B 2 a 3 g 8 E gt m m a A B A B A B 12346 1 2 8 4 5 6 7 8 1 2 3 4 5 1 1 _ Ae BAS ProCore P7 P13 P26 P34 P29 P23 P20 J3 J4 P12 P10 P11 P19 P17 TRANSPORT AERATION 3 CLUTCH DIODE CLUTCH RELAY LIFT RESET ENGINE CONNECTOR GROUND B RAISE LOWER FAST RAISE TRANSPORT LIMIT 1 AERATION 4 EIME gS SWITCH D4 SWITCH SOLENOID SOLENOID SOLENOID SWITCH SWITCH SWITCH SVR SVL SVQ Page 8 12
36. for the cell temperature reading Voltage Tem iae re an ec 10 09C 4 49C 1 19C 6 79C 12 29C If the test voltage is below the minimum replace the battery If the test voltage is at or above the mini mum return the battery to service Electrical System 5 30 2 If a battery load tester is not available the battery can be tested by conducting a hydrometer test of the battery electrolyte IMPORTANT Make sure the area around the cells is clean before opening the battery caps A Measure the specific gravity of each cell with a hydrometer Draw electrolyte in and out of the hydrometer barrel prior to taking a reading to warm up the hydrometer At the same time take the tem perature of the cell B Temperature correct each cell reading For each 10 F 5 5 C above 80 F 26 79C add 0 004 to the specific gravity reading For each 109F 5 59C be low 809 26 79C subtract 0 004 from the specific gravity reading Example Cell Temperature 1009F Cell Gravity 1 245 1009F minus 809F equals 209F 37 79C minus 26 79C equals 11 09C 209F multiply by 0 004 10 F equals 0 008 119C multiply by 0 004 5 5 C equals 0 008 ADD conversion above 0 008 Correction to 809F 26 79C 1 253 C If the difference between the highest and lowest cell specific gravity is 0 050 or greater or the lowest cell specific gravity is less than 1 225 charge the bat tery Charge at the recommended rate and
37. from electrical outlet be fore connecting or disconnecting charger leads to or from battery posts IMPORTANT Do not remove battery filler caps while cleaning battery 2 Check battery condition weekly or after every 50 hours of operation Keep terminals and entire battery case clean because a dirty battery will discharge slowly A Clean battery by washing entire case with a solu tion of baking soda and water Rinse with clear water B Spray battery terminals with Battery Terminal Protector Toro Part No 107 0392 to prevent cable and terminal corrosion Petroleum jelly can be used as well Electrical System Page 5 28 4 Store battery in a cool atmosphere to avoid quick de terioration of the battery charge 5 To help prevent the battery from freezing make sure it is fully charged before storing the battery machine see Battery Service 3 Battery cables must be tight on terminals to provide good electrical contact Connecting cables to the wrong battery post could result in personal injury and or damage to the electrical system 4 If corrosion occurs at terminals disconnect cables Always disconnect negative cable first Clean clamps and terminals separately Reconnect cables with positive cable first Coat battery posts and cable connectors with Battery Terminal Protector Toro Part No 107 0392 or petroleum jelly to prevent corrosion 5 Check electrolyte level every 25 operating hour
38. machine on a level surface fully raise coring head stop engine and remove key from the ignition switch Secure coring head with service latch 2 Make sure parking brake is disengaged 3 Block front wheel Jack or hoist rear of machine from ground and support machine with blocking or jack stands see Operator s Manual and Jacking Instructions in Chapter 1 Safety 4 Remove rear wheel assembly see Wheel Removal in this section Be careful when removing extension spring from parking latch pivot The spring is under heavy load and may cause personal injury 5 Remove parking brake components as needed us ing Figure 4 as a guide 6 If parking latch disc requires removal A Loosen but do not remove nut that secures wheel hub to wheel motor shaft IMPORTANT To prevent damage to hydraulic motor DO NOT hit wheel hub or motor with a hammer dur ing wheel hub removal or installation B Loosen wheel hub assembly from motor shaft us ing wheel hub puller see Special Tools Once wheel hub is loose on shaft remove nut and wheel hub from motor shaft Locate and retrieve woodruff key from motor shaft C Remove wheel studs to allow separation of park ing latch disc wheel hub and bearing plate 7 Clean all parts Inspect parking latch bar and parking latch disc for excessive wear or damage Replace any damaged parts ProCore 648 Page 6 7 Installation Fig 4 Be careful when installing extension sp
39. s Manual Coring Head Page 7 8 3 If bearing housing for 1 and 2 stomper arms is to be removed remove secondary coring head drive belt see Secondary Drive Belt Removal in this section 4 Remove stomper arms on either side of bearing housing that is to be removed see Stomper Arm Re moval in this section 5 Drive Spring pins from bearing housing and coring head frame 6 Support bearing housing assembly to prevent it from falling Remove fasteners that secure bearing housing assembly to coring head frame Remove bearing hous ing assembly ProCore 648 7 Disassemble bearing housing assembly A Remove cap screw item 1 and flat washer item 2 that fasten crankarms together Take note of align ment of identification number on crankarm with tim ing mark on bearing housing Fig 9 B Slide crankarms from bearing housing C If necessary remove bearings and spacer from bearing housing Installation Fig 8 1 Install new bearings if they were removed from hous ing A Install new bearing in one side of housing by pressing on outer race of bearing B Position spacer into bearing housing C Install second new bearing by pressing on outer race of bearing Make sure that spacer is centered between bearings 2 Thoroughly apply antisieze lubricant to splines of crankarms 3 Install crankarms into bearing housing Make sure that correct identification number on crankarm is aligned with tim
40. shaft with two 2 socket head screws The extension spring is under tension and may cause personal injury during installation Use caution when installing the spring to the neutral lever D Install extension spring to the neutral lever Hydraulic System Page 4 40 7 Place two 2 flat washers to tops of studs on pump control assembly Position pump shield to pump and se cure with two 2 lock nuts 8 Lift idler pulley and install drive belt to the pump pulley Adjust drive belt tension see Operator s Manu al 9 Install pump belt cover to machine see Operator s Manual 10 Follow Hydraulic System Start up procedures 11 Check traction drive for neutral and adjust if needed see Operator s Manual 12 Operate machine and check hole spacing Adjust if needed see Operator s Manual ProCore 648 Hydraulic Traction Charge Pump Service 9 5 9 gt Figure 34 1 Retaining ring 12 Valve plate 23 Guide slot 2 Seal 13 Forward relief valve 24 Trunnion arm 3 Spacer 14 By pass valve 25 Ring 4 Pump shaft kit 15 Endcap kit 26 Adapter plate 5 Pump housing 16 Check ball 2 used 27 Flange head screw 4 used 6 Thrust washer 17 Check spring 2 used 28 Coupler 7 Spring block 18 Pin 2 used 29 O ring 8 Nut 4 used 19 Reverse relief valve 30 Gear pump P2 chargellift 9 Trunnion seal kit 20 Cylinder block kit 31 Washer 2 used 10 Pin 2 used 21 Thrust bearing 32
41. stop en gine remove key from the ignition switch and install the coring head service latch before per forming any service to coring head components ProCore 648 Page 7 Coring Head Service and Repairs Rotolink Dampers TARONA Lock nut Hardened D washer Flange head screw Stud Bumper plate Cap screw Figure 4 Lock nut Hardened washer Damper link Bearing Stomper arm Flange nut NOTE The rotolink damper assemblies for all stomper arms used on the ProCore 648 are identical Coring Head 7 4 150 to 170 ft Ib 203 to 230 N m Cap screw Rubber bumper Rotolink damper Damper standoff Damper top spacer ProCore 648 Disassembly Fig 4 1 Park machine on a level surface fully raise coring head engage parking brake stop engine and remove key from the ignition switch Secure coring head with service latch 2 Remove rotolink components as needed using Fig ure 4 as a guide ProCore 648 Page 7 5 Assembly Fig 4 1 If studs item 4 were removed from damper item 15 thread stud fully into damper 2 If bearings were removed from damper links press new bearings into links 3 Assemble all components before fully tightening any fasteners so there is no preload on rotolink damper com ponents Tighten fasteners in the following order A Secure damper links item 9 to stomper arm item 11 and dampe
42. the battery cables unless the test requires battery voltage Starting Problems Starter solenoid clicks but starter will not crank if solenoid clicks problem is not in safety interlock system Nothing happens when start attempt is made traction lever must be in neutral position for successful start Electrical System Page 5 8 For effective troubleshooting and repairs you must have a good understanding of the electrical circuits see Chapter 8 Electrical Diagrams and components used on this machine If the machine has any interlock switches by passed they must be reconnected for proper troubleshooting and safety Possible Causes Battery charge is low Battery cables are loose or corroded Battery ground to frame is loose or corroded Wiring at starter is faulty Starter solenoid is faulty Starter mounting bolts are loose or not supplying a sufficient ground for solenoid Starter is faulty Traction lever is not in the neutral position Battery cables are loose or corroded Battery ground to frame is loose or corroded Battery is dead Fuse F1 20 amp is open Wiring to start circuit components is loose corroded or damaged see Chapter 8 Electrical Diagrams Neutral proximity switch is out of adjustment or faulty Sensing plate on traction lever is loose Neutral switch relay is faulty Ignition switch is faulty Fuse block is faulty Starter solenoid is faulty ProCore 64
43. to extensive hydraulic component damage The charts that follow contain information to assist in troubleshooting There may possibly be more than one cause for a machine malfunction Refer to the Testing section of this Chapter for precau tions and specific test procedures Possible Cause Fitting s hose s or tube s are loose or damaged O ring s or seal s are missing or damaged Foaming hydraulic fluid Oil level in reservoir is low Hydraulic system has wrong kind of oil Pump suction line s has an air leak Hydraulic system operates hot Traction system pressure is high due to excessive load Oil level in reservoir is low Traction pump by pass valve is open or defective Excessive dirt and debris on hydraulic components Oil is contaminated or too light Charge pressure is low Air trapped in traction circuit Wheel motor s are worn or damaged Traction pump is worn or damaged Neutral is difficult to find or unit oper ates in one direction only damaged External control linkage is misadjusted disconnected binding or Excess air in the traction lines Traction pump is worn or damaged Traction response is sluggish Hydraulic oil is very cold Traction pump by pass valve is open or worn Engine speed is too low Pump drive belt is loose or worn Charge pressure is low Traction pump or wheel motor s are worn or damaged Hydraulic System Page 4 14
44. transport limit 2 proximity switch is closed when the coring head is fully raised and opens as the coring head is being lowered This switch is one of the compo nents in the lockout circuit used to provide current for the raise and lower solenoids The aeration 3 proximity switch is closed as the coring head is lowering to allow the electric clutch to be ener gized The switch opens as the coring head is raising The aeration 4 proximity switch is closed when the cor ing head is fully lowered and opens as the coring head begins to raise This switch is used as an input for the aerator control module to identify when the coring head is in the aerate position Aeration 4 switch operation can be monitored using the control module aerate 4 in put LED Transport limit 1 Transport limit 2 Aeration 3 ena Electrical System Page 5 22 Figure 31 4 Aeration 4 5 Switch mount bracket ProCore 648 Proximity Switch Test 1 Park machine on a level surface fully raise coring head engage parking brake stop engine and remove key from the ignition switch Secure coring head with service latch 2 Locate proximity switch to be tested Disconnect proximity switch from machine wiring harness 3 Check the continuity of the switch by connecting a multimeter ohms setting across the switch connector terminals NOTE Before checking switch continuity clean target end of switch to make sure that there is no met
45. 015625 0 397 33 64 0 515625 13 097 1 32 0 03125 0 794 17 32 0 53125 13 494 3 64 0 046875 1 191 35 64 0 546875 13 891 1 16 0 0625 1 588 9 16 0 5625 14 288 5 64 0 078125 1 984 37 64 0 578125 14 684 3 32 0 09375 2 381 19 32 0 59375 15 081 7 64 0 109275 2 778 39 64 0 609375 15 478 1 8 0 1250 3 175 5 8 0 6250 15 875 9 64 0 140625 3 572 41 64 0 640625 16 272 5 32 0 15625 3 969 21 32 0 65625 16 669 11 64 0 171875 4 366 43 64 0 671875 17 066 3 16 0 1875 4 762 11 16 0 6875 17 462 13 64 0 203125 5 159 45 64 0 703125 17 859 7 32 0 21875 5 556 23 32 0 71875 18 256 15 64 0 234375 5 953 47 64 0 734375 18 653 1 4 0 2500 6 350 3 4 0 7500 19 050 17 64 0 265625 6 747 49 64 0 765625 19 447 9 32 0 28125 7 144 25 32 0 78125 19 844 19 64 0 296875 7 541 51 64 0 796875 20 241 5 16 0 3125 7 938 13 16 0 8125 20 638 21 64 0 328125 8 334 53 64 0 828125 21 034 11 32 0 34375 8 731 27 32 0 84375 21 431 23 64 0 359375 9 128 55 64 0 859375 21 828 3 8 0 3750 9 525 7 8 0 8750 22 225 25 64 0 390625 9 922 57 64 0 890625 22 622 13 32 0 40625 10 319 29 32 0 90625 23 019 27 64 0 421875 10 716 59 64 0 921875 23 416 716 0 4375 11 112 15 1
46. 1 Set screw 2 Taper lock bushing 7 Jackshaft 12 Lock nut 2 used per bearing 3 Lock washer 8 Cap screw 2 used per bearing 13 Secondary pulley 4 Capscrew 9 Flange mount bearing 14 Secondary drive belt 5 Setscrew 10 Plug 15 Coring crankshaft Removal Fig 17 1 Park machine on a level surface fully raise coring head engage parking brake stop engine and remove key from the ignition switch Secure coring head with service latch 2 Remove belt cover and rear hood from machine see Operator s Manual 3 Remove primary and secondary drive belts from jackshaft pulleys see Primary Drive Belt Removal and Secondary Drive Belt Removal in this section 4 Loosen cap screws and lock nuts that secure flange mount bearings to machine frame Support jackshaft as sembly remove loosened cap screws and lock nuts and remove jackshaft assembly from machine Coring Head Page 7 14 5 Loosen taper lock bushings Fig 18 A Remove three 3 cap screws and lockwashers that secure taper lock bushing to pulley IMPORTANT Excessive or unequal pressure on the cap screws can break the taper lock bushing flange When removing taper lock bushing tighten screws progressively and evenly B Insert cap screws into threaded removal holes of the bushing Tighten screws progressively and even ly until the pulley is loose on the bushing 6 Loosen set screws item 5 that secure taper lock bushings to jackshaft Remove bushing
47. 12 from between frame and machine frame 16 Remove H frame from machine Assembly Fig 21 1 If upper links were disassembled install rod ends equally to make link assembly 17 720 to 17 780 45 0 to 45 2 cm long rod center to rod center Fig 26 IMPORTANT When installing pivot shaft to H frame make sure that both sides of H frame aligned with holes in machine frame before instal ling pivot shaft Coring Head Page 7 18 2 Position H frame to machine frame making sure that thrust washers are placed between H frame and ma chine frame Align both sides of H frame to pivot shaft holes in machine frame Slide pivot shaft into H frame and machine frame 3 Position coring head to allow alignment of both sides of H frame to pivot shaft holes in coring head frame Slide pivot shaft into H frame and coring head frame 4 Complete assembly of coring head to machine in the reverse order of disassembly Figure 25 1 Bearing housing 2 Lifting eyelet Figure 26 2 Rodend 1 Upper link ProCore 648 Chapter 8 TORO Electrical Diagrams Table of Contents ELECTRICAL SCHEMATIC Electrical Schematic 3 ELECTRICAL CIRCUIT DRAWINGS Start Engine 4 Lower Coring 5 Aerating Level Ground Surface 6 Aerating Low Spot in Turf Encountered 7 Aerating High Spot in Turf Enc
48. 3 proximity switch is faulty or out of adjustment Coring head does not lower Fuse F3 10 Amp or F4 2 Amp is are faulty Raise lower switch is faulty SVL valve solenoid is faulty Aerator Control Module is faulty OK to lower circuit is not functioning see OK to Lower Circuit in Circuit Operation section of this chapter Hydraulic problem exists see Chapter 4 Hydraulic System Coring head does not raise Fuse F3 10 Amp or F4 2 Amp is are faulty Lift reset switch needs to be reset Raise lower switch is faulty SVR or SVQ valve solenoid is faulty Aerator Control Module is faulty Hydraulic problem exists see Chapter 4 Hydraulic System Electric clutch does not engage Fuse F2 10 Amp is faulty Coring head is not lowered Clutch relay is faulty Aeration 3 proximity switch is faulty or out of adjustment Circuit wiring to electric clutch is loose corroded or damaged see Chapter 8 Electrical Diagrams Diode D3 is faulty Electric clutch is faulty Electric clutch is noisy Clutch is loose on engine crankshaft Clutch strap is loose or damaged Broken leaf spring s on clutch Failed clutch bearing s Clutch is slipping Lubricant has contaminated clutch lining material Gap between clutch rotor and armature is excessive Electrical System Page 5 10 ProCore 648 Electrical System Quick Checks Battery Test Open Circuit Test Use a multimeter to measure the voltage b
49. 6 0 9375 23 812 29 64 0 453125 11 509 61 64 0 953125 24 209 15 32 0 46875 11 906 31 32 0 96875 24 606 31 64 0 484375 12 303 63 64 0 984375 25 003 1 2 0 5000 12 700 1 1 000 25 400 1 0 03937 in 0 001 0 0254 mm U S to Metric Conversions To Convert Into Multiply By Linear Miles Kilometers 1 609 Measurement Yards Meters 0 9144 Feet Meters 0 3048 Feet Centimeters 30 48 Inches Meters 0 0254 Inches Centimeters 2 54 Inches Millimeters 25 4 Area Square Miles Square Kilometers 2 59 Square Feet Square Meters 0 0929 Square Inches Square Centimeters 6 452 Acre Hectare 0 4047 Volume Cubic Yards Cubic Meters 0 7646 Cubic Feet Cubic Meters 0 02832 Cubic Inches Cubic Centimeters 16 39 Weight Tons Short Metric Tons 0 9078 Pounds Kilograms 0 4536 Ounces Avdp Grams 28 3495 Pressure Pounds Sq In Kilopascal 6 895 Pounds Sq In Bar 0 069 Work Foot pounds Newton Meters 1 356 Foot pounds Kilogram Meters 0 1383 Inch pounds Kilogram Centimeters 1 152144 Liquid Volume Quarts Liters 0 9463 Gallons Liters 3 785 Liquid Flow Gallons Minute Liters Minute 3 785 Temperature Fahrenheit Celsius 1 Subract 32 2 Multiply by 5 9 Product Records and Maintenance Page2 2 Rev ProCore 648 Torque Specifications Recommended fastener torque values are listed in the following tables For critical applications as determined by Toro either the re
50. 6 amps above 6 hrs 12 hrs 18 hrs 24 hrs 250 10 amps 10 amps 10 amps 10 amps ProCore 648 Page 5 31 Do not charge a frozen battery because it can ex plode and cause injury Let the battery warm to 60 F 15 5 C before connecting to a charger Charge the battery in a well ventilated place to dissipate gases produced from charging These gases are explosive keep open flame and elec trical spark away from the battery Do not smoke Nausea may result if the gases are inhaled Un plug the charger from the electrical outlet before connecting or disconnecting the charger leads from the battery posts 3 Following the manufacturer s instructions con nect the charger cables to the battery Make sure a good connection is made 4 Charge the battery following the manufacturer s instructions 5 Occasionally check the temperature of the battery electrolyte If the temperature exceeds 125 F 51 69 or the electrolyte is violently gassing or spewing the charging rate must be lowered or temporarily stopped 6 Three hours prior to the end of the charging mea sure the specific gravity of a battery cell once per hour The battery is fully charged when the cells are gassing freely at a low charging rate and there is less than a 0 003 change in specific gravity for three consecutive readings Electrical System 6 Oo 2 5 Wu Electric Clutch Drive belt Electric clutch Hard
51. 8 Electrical Diagrams Diode Test The diodes Fig 37 can be individually tested using a digital multimeter diode test or ohms setting and the table to the right Figure 37 1 Diode 3 Female terminal 2 Male terminal Multimeter Multimeter Red Lead Black Lead Continuity on Terminal on Terminal 6 Oo 2 5 Wu ProCore 648 Page 5 27 Electrical System Service and Repairs NOTE See the Kohler Engine Service Manual for en gine component repair information Battery Storage If the machine will be stored for more than 30 days 1 Remove the battery and charge it fully see Battery Service 2 Either store battery on a shelf or on the machine 3 Leave cables disconnected if the battery is stored on the machine Battery Care 1 Battery electrolyte level must be properly main tained The top of the battery must be kept clean If the machine is stored in a location where temperatures are extremely high the battery will discharge more rapidly than if the machine is stored in a location where temper atures are cool Wear safety goggles and rubber gloves when working with electrolyte Charge battery in a well ventilated place so gasses produced while charging can dissipate Since the gases are explosive keep open flames and electrical sparks away from the battery do not smoke Nausea may result if the gases are inhaled Un plug battery charger
52. 8 Starting Problems continued Engine cranks but does not start Engine cranks but should not with the traction lever out of the neutral position General Run Problems Battery does not charge Engine kills during operation ProCore 648 5 9 Possible Causes Circuit wiring to engine magneto is grounded see Chapter 8 Electrical Diagrams Circuit wiring to carburetor solenoid is loose corroded or damaged see Chapter 8 Electrical Diagrams Engine or fuel system is malfunctioning see Chapter 3 Kohler Engine Engine may be too cold Neutral proximity switch is out of adjustment or faulty Neutral proximity switch wiring is faulty Sensing plate on traction lever is loose or damaged Possible Causes Wiring to the charging circuit components is loose corroded or damaged see Chapter 8 Electrical Diagrams Ignition switch is faulty Alternator is faulty see Chapter 3 Kohler Engine Battery is dead Ignition switch is faulty Circuit wiring to engine magneto is damaged see Chapter 8 Electrical Diagrams Circuit wiring to carburetor solenoid is loose corroded or damaged see Chapter 8 Electrical Diagrams Engine or fuel system is malfunctioning see Chapter 3 Kohler Engine Electrical System TO m E 9 Coring Head Operating Problems Problem Possible Causes Coring head runs but should not when raised Aeration
53. 8 1 2 in 1 50 0 25 60 66 ft lb 81 89 10 5 8 1 50 0 25 12 3 4 in 1 50 0 25 81 87 ft lb 110 117 eae Eini 121 131 ft lb 164 177 N m NOTE Installation torque values for non adjustable fit Figure 4 tings are listed in Figure 4 These torque values should only be used when a fitting can be accessed with a Socket Use of an offset wrench e g crowfoot wrench will affect torque wrench accuracy and should not be used Figure 3 Size F F F T SAE Straight Thread O Ring Port Adjustable Hydraulic System 1 Make sure both threads and sealing surfaces are free of burrs nicks scratches or any foreign material 2 Always replace the O ring seal when this type of fit ting shows signs of leakage 3 Lubricate the O ring with a light coating of oil Lock Nut 4 Turn back the jam nut as far as possible Make sure Washer the back up washer is not loose and is pushed up as far as possible Step 1 O Ring 5 Install the fitting into the port and tighten finger tight Figure 5 until the washer contacts the face of the port Step 2 6 To put the fitting in the desired position unscrew it by the required amount but no more than one full turn Step 3 7 Hold the fitting in the desired position with a wrench and turn the jam nut with another wrench to the correct Flats From Finger Tight F F F T Step 4 Size F F F T 4 1 4 in nominal hose or tubing
54. 8 Page 7 17 Coring Head 8 Disconnect upper end of lift cylinder from coring head frame Figs 22 and 23 A Remove retaining ring from one end of cylinder pin that secures lift cylinder to coring head frame B Pull cylinder pin from coring head frame and lift cylinder Locate and retrieve two 2 thrust washers and two 2 spacers as pin is removed C Rotate lift cylinder toward front of machine 9 Disconnect wire harness connectors from limit switches on depth actuator assembly 10 Remove proximity switch bracket from machine frame Fig 24 Position switch bracket with proximity switches still attached away from H frame 11 Remove right rear wheel from machine see Wheel Removal in Service and Repairs section of Chapter 6 Chassis Make sure that machine is supported well with jackstands or blocking The coring head assembly weighs approximate ly 650 pounds 294 8 kg Make sure that proper lift or hoist is used to support coring head during repairs 12 Using suitable lift or hoist support coring head using lifting eyelets on coring crankshaft as lift points Fig 25 Once coring head is well supported remove service latch from coring head 13 Remove upper link assemblies from machine frame and coring head frame 14 Remove flange nuts item 15 and carriage screws item 13 that secure end of pivot shafts to machine 15 Carefully slide pivot shafts from H frame Locate and retrieve thrust washers item
55. AD BEING LOWERED 4 3 oo Bs 9 TRANSPORT LIMIT M T HEAD BEING LOWERED IGN SWITCH ak CONN FRONT Tee une BEING LOWERED 02 y LOCKOUT RELAY BK ge sw ull 0 LOCKOUT LATCH RELAY OR 5 Rao maser ee 741 Do PUES gar ee T T nn a LIFT RESET ENERGIZED 648 ED Coring Head ec CR c TEM Manual Raise Lower Switch Pressed to Lower _ CLUTCH RELAY Power Current otli es S GY Control Current F2 10A i 0 i 03 CLUTCH 85 86 BU BN D Y AERATION 3 1 NOT ENERGIZED HEAD BEING LOWERED 8 5 ENGINE CONN FRONT BU R VIO 4 SPARK PLUG AC GN OIL BU 3 STA 1 RT SPARK PLUG 0 IGNITION MODULES LOW OIL PRESSURE MAG oe OIL 1 STARTER aBK CARBURETOR HOUR METER ProCore 648 Aerator Aerator Control Module Coring Head Fully Lowered
56. Cap screw 2 used 11 O ring 22 Swash plate NOTE For repair of the hydraulic traction charge pump see the HYDRO GEAR BDP 10A 16A 21L HY DROSTATIC PUMPS SERVICE AND REPAIR MANU AL hydrostat and the SAUER DANFOSS GROUP 2 GEAR PUMPS AND MOTORS SERVICE MANUAL gear pump at the end of this chapter ProCore 648 Page 4 41 Hydraulic System Wheel Motors 190 to 230 ft lb 258 to 312 45 to 55 ft lb 190 to 230 ft lb 61 to 75 N m 2 75 25810312 N m 45 to 55 ft Ib FEN 61 10 75 N m 715 lt e Figure 35 1 Rear wheel motor LH shown 8 Bearing plate 15 Wheel weight adapter 2 Woodruff key 9 Lug nut 16 Stud 3 Parking latch support 2 used 10 Tire and wheel assembly 17 Thrust washer 4 Stud 4 used per wheel 11 Cap screw 4 used per rear motor 18 Front wheel motor 5 Parking latch disc 2 used 12 Lock nut 4 used per motor 19 Front fork 6 Wheel hub 13 Frame 20 Cap screw 4 used 7 Lock nut 14 Front wheel weight Removal Fig 35 1 Park machine on a level surface fully raise coring head engage parking brake stop engine and remove key from the ignition switch Secure coring head with Operate all hydraulic controls to relieve system service latch pressure and avoid injury from pressurized hy draulic oil See Relieving Hydraulic System Pres sure in the General Information section of this chapter Hydraulic System Page 4 42 ProCore 648 2 Remove wheel from machine see Wheel Remova
57. DO NOT use front wheel motor as a jacking point 2 Position jack securely under the front of the frame Fig 1 3 Jack front of machine off the ground 4 Position jack stands or hardwood blocks under the front of the frame to support the machine Figure 2 Jacking the Rear End 1 Rear wheel 2 Frame jacking point 1 Chock front tire to prevent the machine from moving Install service latch to secure coring head IMPORTANT To prevent wheel motor damage DO NOT use rear wheel motor as a jacking point 2 Place jack securely under the frame plate just inside of the rear wheel Fig 2 NOTE If available a hoist can be used to lift the rear of the ProCore 648 Use eyelets in coring head bearing housings as hoist attachment points Fig 3 3 Jack or lift rear of machine off the ground 4 Position jack stands or hardwood blocks under the frame to support the machine Figure 3 1 Bearing housing 2 Lifting eyelet Safety 1 4 648 Safety and Instruction Decals Numerous safety and instruction decals are affixed to the ProCore 648 If any decal becomes illegible or dam aged install a new decal Part numbers for replacement decals are listed in your Parts Catalog Order replace ment decals from your Authorized Toro Distributor ProCore 648 Page 1 5 Safety This page is intentionally blank Safety Page 1 6 ProCore 648 Chapter 2 TORO Product Records and Maintenance
58. E SOLENOID rc EA NOT IN NEUTRAL 1 ENERGIZED BK ota 2 A SVR BK 2 LASS SEIEN 17 BU 2 1 FLOAT ic 9 5 5 EUM m cec gj BN E riora m MM 2 6 IGN SW I AST RAISE SOLENOI o GROUND FOLLOW NOT ENERGIZED 2 HEAD HIGH TRANSPORT 4 o o lt 3 EDI St HEAD HIGH LIMIT OR 01 OR PK BK R BK HEAD LOWERED t y me K LOWER NOT USED 4 A Fd 2222 Fe 2 AERATE GROUND NOT ENERGIZED START 8455 Y eo r gt BK amp t 528781 ce HERD toi 2 decani elem EE T m C 214 lo d tss din T L NEUTRAL SW RELAY LATCH i 2 H 12 V SVR MODULE z BK T 5955 LL LL y PK BK e 5 E ND S iiit EN Y EET SI PK IN FORWARD NOT ENERGIZED E E EET E AERATION 4 I 1 HEAD LOWERED J 1 4 HEAD LOW LIMIT s CLOSED TURF GUARD 4 BK vio oo 1 TRANSPORT LIMIT 1 IGN SWITCH 2 HEAD LOWERED CONN FRONT TRANSPORT LIMIT 2 J D4 EE a i F2 10 03 J CLUTCH Y BU u
59. Figure 2 1 Tire and wheel assembly 5 Weight stud 9 Lock nut 2 Lugnut 6 Thrust washer 10 Wheel hub 3 Front wheel weight 7 Locknut 11 Parking latch disc 4 Wheel weight adapter 8 Bearing plate 12 Wheel stud Chassis Page 6 4 648 Wheel Removal Fig 2 1 Park machine on a level surface fully raise coring head engage parking brake stop engine and remove key from the ignition switch Secure coring head with service latch 2 Jack machine from ground and support machine with blocking or jack stands see Operator s Manual and Jacking Instructions in Chapter 1 Safety 3 4 If rear wheel is to be removed A Loosen and remove four 4 lug nuts from wheel to be removed B Pull wheel from machine If front wheel is to be removed A Remove two 2 lock nuts and thrust washers that secure wheel weight to wheel To prevent personal injury make sure that wheel weight is supported as it is removed from the machine Wheel weight weighs approximately 73 pounds 33 1 kg B Carefully slide wheel weight from weight studs C Loosen and remove two 2 lug nuts and two 2 wheel weight adapters with weight studs D Pull wheel from machine Wheel Installation Fig 2 1 ProCore 648 If rear wheel was removed A Position rear wheel to wheel hub B Secure wheel to machine with four 4 lug nuts Torque lug nuts from 45 to 55 ft lb 61 to 75 N m 2 3 from co
60. Gauge LIFT CYLINDER CYL eed CONTROL MANIFOLD TEST CONNECTION FOR REAR WHEEL MOTOR SHOWN FRONT WHEEL FORWARD ATN gt 5 gt 1 P PORTN 4 t Working Pressure Low Pressure Charge Return or Suction Flow Direction Figure 24 NOTE Over a period of time a wheel motor can wear internally A worn motor will be less efficient and eventu ally will allow the wheel motor to stall under heavy load conditions Continued operation with a worn inefficient motor can generate excessive heat cause damage to seals and other components in the hydraulic system and affect overall machine performance Hydraulic System 4 28 Rev C 648 Procedure for Wheel Motor Efficiency Test 1 Make sure hydraulic oil is at normal operating tem perature by operating the machine for approximately 10 minutes Make sure the hydraulic reservoir is full 2 Make sure that traction lever is adjusted to the neu tral position see Operator s Manual 3 Park machine on a level surface with the coring head fully raised Make sure engine is off and the parking brake is engaged Secure coring head with service latch 4 Read Precautions For Hydraulic Testing in this sec tion Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hy drau
61. LUTCH ENGAGED CLUTCH NOT ENERGIZED AERATION 3 ENERGIZED TO LOWER RCUIT ENERGIZED BU gt AERATION 3 CLUTC g Ny _ ENERGIZED HEAD LOWERED CONTROL CURRENT CLUTCH CURRENT Figure 3 Electrical System 5 6 ProCore 648 Special Tools Multimeter The multimeter can test electrical components and cir cuits for current amps resistance ohms or voltage NOTE Toro recommends the use of a DIGITAL Volt Ohm Amp multimeter when testing electrical circuits The high impedance internal resistance of a digital me ter in the voltage mode will make sure that excess cur rent is not allowed through the meter This excess current can cause damage to circuits not designed to carry it Figure 4 Battery Terminal Protector Battery Terminal Protector Toro Part No 107 0392 is an aerosol spray that should be used on battery termi nals to reduce corrosion problems Apply terminal pro tector after battery cable has been secured to battery terminal Figure 5 6 TO 5 E 9 o Battery Hydrometer Use the Battery Hydrometer when measuring specific gravity of battery electrolyte Obtain this tool locally Figure 6 ProCore 648 5 7 Electrical System Troubleshooting A CAUTION Remove all jewelry especially rings and watches before doing any electrical trouble shooting or testing Disconnect
62. OLD FRONT WHEEL eS PORT MP Working Pressure Low Pressure Charge Return or Suction Flow Direction Figure 15 Hydraulic System 4 20 Rev C 648 Procedure for Coring Head Raise Lower Relief R1 Pressure Test 1 Make sure hydraulic oil is at normal operating tem perature by operating the machine for approximately 10 minutes 2 Park machine on a level surface with the coring head fully raised Make sure engine is off and the parking brake is engaged 3 Read Precautions For Hydraulic Testing in this sec tion Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hy draulic oil 4 Connect pressure gauge to the hydraulic control manifold G1 port quick fitting Fig 14 5 Remove rear hood see Operator s Manual 6 Locate and disconnect proximity switch 1 This Switch is secured to the switch mounting bracket located on right rear frame plate 7 Make sure that traction lever is in the neutral position and the parking brake is engaged 8 With proximity switch 1 disconnected system pres sure will increase to relief R1 pressure shortly after the engine is started 9 Start and run engine at full speed 3400 50 RPM Watch the pressure gauge and note pressure when the relief valve R1 opens 10 Shut off engine Record measured relief valve R1 pressure 11 Pressure gauge should re
63. OTE For repair of the wheel motors see the SAUER DANFOSS OMEW HYDRAULIC MOTOR SERVICE MANUAL at the end of this chapter ProCore 648 This is intentionally blank 2 0 ESA 648 4 45 Hydraulic System Hydraulic Lift Control Manifold Figure 38 1 Main frame 3 Hydraulic lift control manifold 5 Flange nut 2 used 2 Cap screws 2 used 4 Hydraulic oil filter Hydraulic System Page 4 46 ProCore 648 Removal Fig 38 1 Park machine on a level surface fully raise coring head engage parking brake stop engine and remove key from the ignition switch Secure coring head with service latch Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hy draulic oil See Relieving Hydraulic System Pres sure in the General Information section of this chapter NOTE The ports on the manifold are marked for easy identification of components Example P is the pump connection port and R1 is the location for the relief valve See Hydraulic Schematic to identify the function of the hydraulic lines and cartridge valves at each manifold port location 2 Disconnect solenoid valve electrical connectors NOTE The hydraulic reservoir will drain when the hy draulic oil filter is removed from the hydraulic manifold 3 Clean area around hydraulic filter mounting area Remove filter from hydraulic manifold and drain reser voir int
64. ROSTATIC PUMPS SERVICE AND REPAIR MANUAL SAUER DANFOSS GROUP 2 GEAR PUMPS AND MO TORS SERVICE MANUAL SAUER DANFOSS OMEW HYDRAULIC MOTOR SERVICE MANUAL Rev C Hydraulic System 5 5 gt 20 I Specifications Item Description Traction Pump P1 Displacement at full stroke per revolution Forward relief pressure Reverse relief pressure Variable displacement piston pump 976 Cubic Inches 16 cc 2900 PSI 200 Bar 2900 PSI 200 Bar Charge Lift Pump P2 Displacement per revolution Charge Pressure Gear pump 37 Cubic Inches 6 1 cc 40 PSI 2 8 Bar Lift System Relief R1 Pressure 1000 PSI 69 Bar Front Wheel Motor Displacement Orbital rotor motor 24 Cubic Inches 393 cc Rear Wheel Motors Displacement Orbital rotor motor 12 Cubic Inches 197 cc Hydraulic Filter Spin on cartridge type Hydraulic Oil See Operator s Manual Hydraulic Reservoir Capacity 1 75 U S Gal 6 6 L Total Hydraulic System Capacity 3 U S Gal 11 4 L Approximate Hydraulic System Page 4 2 ProCore 648 This is intentionally blank 2 0 ESA 648 4 3 Hydraulic System General Information Hydraulic Hoses Hydraulic hoses are subject to extreme conditions such as pressure differentials during operation and exposure to weather sun chemicals very warm storage condi tions
65. Shoulder screw 11 Hydraulic adapter 17 Hydraulic barb fitting 5 Tank strap 12 O ring 18 Hydraulic tee fitting 6 Cap screw 13 Hydraulic tube 19 O ring 7 Jclip Inspecting Reservoir Fig 47 3 Replace any hydraulic hose tube or fitting if dam aged or leaking 1 Clean hydraulic reservoir with solvent 4 Make sure cap screw item 6 that secures tank strap 2 Inspect reservoir for leaks cracks or other damage is tight Hydraulic System Page 4 54 ProCore 648 TORO Table of Contents ELECTRICAL DIAGRAMS 1 CIRCUIT 2 OK to Lower Circuit 2 Lockout 4 Electric Clutch Circuit 6 SPECIAL TOOLS 7 TROUBLESHOOTING 8 Starting Problems 8 General Run Problems 9 Coring Head Operating Problems 10 ELECTRICAL SYSTEM QUICK CHECKS 11 Battery Test Open Circuit Test 11 Charging System Test 11 Check Operation of Interlock Switches 12 COMPONENT 13 Ignition Switch 13 Engine Oil Pressure Indicator Light 14 Hour 14 Electrical Diagrams The electrical schematic electrical circuit drawings an
66. TART 27 FUSE BLOCK P24 LOCKOUT RELAY aaa EERE Pb ACM 2 P9 ACM 1 P29 CLUTCH RELAY P26 CLUTCH TO SPARK PLUG FROM J1 FOLD END OF WIRE BACK 1 INCH AND SECURE WITH HEAT SHRINK Ji B ProCore 648 Wire Harness Drawing Page 8 11 NEUTRAL SW RELAY P8 2 GROUND FOLLOW ess SWITCH HEAD LOW 18 LIMIT SWITCH HEAD HIGH P14 LIMIT SWITCH NEUTRAL Ree SWITCH 648 Wire Harness Diagram LOW OIL REVERSE START IGNITION SWITCH FUSE BLOCK MAGNETO PRESSURE SWITCH S P27 ACM 1 P5 P16 P4 J5 P9 1A 1B 2A 2B A B 12345 1
67. TERMINAL 1 Electrical System GROUND PK OR TO AERATOR CONTROL MODULE OK TO LOWER 1 1 1 1 1 1 1 4 ER 8 ENERGIZED IN MIDDLE AERATE POSITION 2 AND 3 CLOSED NOT ENERGIZED GROUND TO LOCKOUT AERATION 3 CIRCUIT PROX SWITCH CONTROL CURRENT OK TO LOWER Figure 1 ProCore 648 5 3 Electrical System Lockout Circuit Fig 2 The lockout circuit is used on the ProCore to provide cur rent for the raise and lower hydraulic solenoid valves SVL SVR and SVQ This circuit is composed of the transport limit 2 proximity switch the lockout relay the lockout latch relay the lift reset switch and diode D2 When this circuit is closed current is provided to the aer ator control module to allow energizing of the solenoid valves Lockout circuit protection is provided by fuse F3 Coring Head Raised With the coring head in the raised position the transport limit 2 proximity switch is closed which completes the lockout circuit Hydraulic solenoid valve operation is possible at this time which allows the coring head to be lowered and aeration to occur Aerating Once the lockout circuit has initially been closed by transport limit 2 proximity switch the lockout latch relay and diode D2 allow a latch circuit to keep the lockout relay energized and hydraulic solenoid valve operation to continue whil
68. Table of Contents PRODUCT RECORDS 1 Standard Torque for Dry Zinc Plated and 9 S MAINTENANCE 1 Steel Fasteners Inch Series 4 EQUIVALENTS AND CONVERSIONS 2 Standard Torque for Dry Zinc Plated and 5 Decimal and Millimeter Equivalents 2 Steel Fasteners Metric Fasteners 5 E 2 U S to Metric Conversions 2 Other Torque Specifications 6 TORQUE SPECIFICATIONS 3 Conversion Factors 6 Fastener Identification 3 Product Records Insert Operator s Manual and Parts Catalog for your ProCore 648 at the end of this chapter Additionally if any optional equipment or accessories have been installed to your ProCore insert the Installation Instruc tions Operator s Manuals and Parts Catalogs for those options at the end of this chapter Maintenance Maintenance procedures and recommended service in tervals for the ProCore 648 are covered in the Opera tor s Manual Refer to that publication when performing regular equipment maintenance Refer to the Engine Operator s Manual for additional engine specific main tenance procedures ProCore 648 Page 2 1 Product Records and Maintenance Decimal and Millimeter Equivalents Equivalents and Conversions Fractions Decimals mm Fractions Decimals mm 1 64 0
69. W vos Ep MEM E GN NOT ENERGIZED NEUTRAL SW START qu T NOT IN NEUTRAL 1 BK eed 2 SVR 12 V SVQ 5 1 1 BU BK 42 I 9 aae ra FLOAT SVG 14 ote LE EA et ee i ee 4 5 yw 3 M w 26 sw nr sve t 1 0 GROUND FOLLOW W BK 2 HEAD HIGH TRANSPORT 1 de aum p e J 01 2 OK LOWER NOT USED 14 PK BK CLOSED BY TURF GUARD Ye A eS STOP G M A 2 GROUND mE _LATCHING RELAY Y oe 528791 25 uw n j qu a S GN 1 NEUTRAL SW RELAY LATCH 1 2 H 12 V SVR M MODULE o Bk 7 armas 6 Le a7 MANUAL RAISE LOWER othe ENERGIZED NEUTRAL POSITION 1 85 REVERSE NOT ENERGIZED 1 IN FORWARD J ee an ee a i Iy il ll lM ll i i i I ii ii I ii ii i ii i i ii i ii AERATION 4 I 1 HEAD LOWERED T 9 N HEAD LOW LIMIT 5 OR W 2 HEAD LOWERED 3 e o 1 TRANSPORT LIMIT 1 IGN SWITCH HEAD LOWERED CONN FRONT BK 04 GY F2 10A 03 J CLUTCH Y
70. act this value from from the measured value of the component you are testing 4 Measure resistance between the two coil connector terminals Resistance of the solenoid coil should be approximately 8 7 ohms 5 Reconnect electrical connector to the solenoid 6 If solenoid coil needs replacement see Solenoid Valve Coil in the Service and Repairs section of this chapter 1 Lift control manifold 2 SVL solenoid coil 1 Control module 2 SVR solenoid LED ProCore 648 Page 5 19 Figure 23 3 SVQ solenoid coil 4 SVR solenoid coil Figure 24 3 SVQ solenoid LED 4 SVL solenoid LED Electrical System SE ov Head Low and Head High Limit Switches The head low and head high limit switches are attached to the coring depth control housing Fig 25 These switches are normally open and close when the switch actuator in the housing is rotated past the switch The head low and head high limit switches provide inputs for the True Core ground following system on the Pro Core 648 The Aerator Control Module monitors the operation of the head low and head high limit switches With the cor ing head raised and the ignition switch in the ON position engine not running the Module head high input LED should be illuminated and the head low input LED should not be illuminated By slowly raising the outer turf guard the head high input LED should go out If the out er turf guard continues to be raised
71. ad approximately 1000 PSI 69 Bar 12 1 measured relief pressure is incorrect adjust relief valve R1 as follows NOTE Do not remove lift relief valve from the hydraulic manifold for adjustment A Remove the cap from the relief valve Fig 17 B If measured relief pressure is too high decrease relief valve pressure setting by using an allen wrench to turn adjustment socket counterclockwise A 1 8 turn on the socket will make a measurable change in relief pressure ProCore 648 Page 4 21 C If measured relief pressure is too low check for restriction in gear pump intake line or leakage in lift cylinder If pump intake line is not restricted and lift cylinder is not leaking increase the relief valve pres sure setting Use an allen wrench and turn adjust ment socket clockwise A 1 8 turn on the socket will make a measurable change in relief pressure D Reinstall cap on relief valve after adjustment E Repeat steps 9 through 11 above until the relief valve pressure setting is correct F If the relief valve pressure setting cannot be ad justed to specification the relief valve R1 gear pump or lift cylinder should be suspected of wear or damage 13 When testing is complete disconnect pressure gauge from the hydraulic manifold G1 fitting Reconnect proximity switch 1 Install rear hood OD Figure 16 3 Relief valve R1 1 Hydraulic manifold 2 G1 port quick fitting Figure 17 1 Reli
72. afety instructions Before Operating 1 Read and understand the contents of the Operator s Manual before starting and operating the machine Be come familiar with the controls and know how to stop the machine and engine quickly Additional copies of the Operator s Manual are available on the internet at www Toro com 2 Keep all shields safety devices and decals in place If a shield safety device or decal is defective illegible or damaged repair or replace it before operating the machine Also tighten any loose nuts bolts or screws to ensure machine is in safe operating condition 3 Assure interlock switches are adjusted correctly so engine cannot be started unless traction lever is in NEU TRAL and coring head is DISENGAGED While Operating 1 Operator should be standing at the side console when starting the engine and at the handle when operat ing the machine Stay away from the coring head when it is engaged 2 Before starting the engine A Engage the parking brake B Make sure traction lever is in neutral 3 After engine is started release parking brake and apply no pressure to traction lever Machine must not move If movement is evident the traction linkage is ad justed incorrectly Shut engine off and adjust traction linkage until machine does not move when traction lever is released see Operator s Manual 4 Do not run engine in a confined area without ade quate ventilation Exhaust fumes are hazar
73. allic de bris on the switch that could prevent correct switch op eration 4 With the sensing plate positioned near the target end of the switch there should be continuity across the switch terminals 5 When the sensing plate is positioned away from the target end of the switch there should be no continuity across the switch terminals 6 Replace proximity switch as needed Reconnect switch to machine wiring harness Proximity Switch Installation When installing a proximity switch to the machine place tab on switch plate into switch mounting hole nearest target end of switch Fig 32 Secure proximity switch and switch plate to switch mount with carriage screw and lock nut The switch mounting bracket that retains the transport limit and aeration proximity switches Fig 30 should be mounted to allow from 030 to 090 8 to 2 3 mm clear ance between the switch targets and sensing plate on the coring head H frame 1 Carriage screw 2 Switch mount 3 Proximity switch ProCore 648 Page 5 23 Figure 32 4 Switch plate 5 Locknut Electrical System 6 m 9 5 Aerator Control Module The ProCore 648 is equipped with an Aerator Control Module to monitor and control electrical components re quired for safe operation This Module is located on the inside of the console cover Fig 33 Inputs from the start ignition head low limit head high limit transport limit 1 pro
74. ange nuts Fig 22 item 6 that secure the spring plates Fig 22 item 5 for both extension springs C Using a 1 2 breaker bar hold spring plate to pre vent it from moving Remove upper flange nut and carriage screw Fig 22 item 4 from spring plate and coring head frame D Using lower carriage screw and flange nut as a pivot carefully release tension on extension spring Fig 22 item 3 by rotating spring plate with breaker bar E Remove hair pin Fig 22 item 3 and clevis pin Fig 22 item 2 that secure spring shackle Fig 22 item 1 to spring plate Position extension spring away from coring head frame 6 Start engine and allow coring head to fully raise Turn engine off Secure coring head with service latch 7 Lower coring head onto service latch to allow lift cyl inder to be disconnected from coring head Turn key switch to ON engine not running Move traction lever to forward direction and depress lower switch on handle to lower coring head onto service latch Return key switch to OFF and remove key from the ignition switch 1 Shackle 7 Flange nut 2 Clevis pin 8 Cylinder pin 3 Hair pin 9 Spacer 4 Extension spring 10 Thrust washer 5 Carriage screw 11 Retaining ring 6 Spring plate 12 Lift cylinder Figure 23 1 Lift cylinder shaft 3 Cylinder pin 2 Thrust washer 4 Spacer E 6 Figure 24 1 Proximity switch bracket 2 Machine frame ProCore 64
75. anufacturers may result in non conformance with the safety standards and the warranty may be voided 17 When changing tires or performing other service use correct blocks hoists and jacks Make sure ma chine is parked on a solid level floor such as a concrete floor Prior to raising the machine remove any attach ments that may interfere with the safe and proper raising of the machine Always chock or block wheels Use jack stands or solid wood blocks to support the raised ma chine If the machine is not properly supported by blocks or jack stands the machine may move or fall which may result in personal injury see Jacking Instructions Safety Jacking Instructions When changing attachments tires or perform ing other service use correct blocks hoists and jacks Make sure machine is parked on a solid level surface such as a concrete floor Prior to raising machine remove any attach ments that may interfere with the safe and prop er raising of the machine Always chock or block wheels Use jack stands or solid wood blocks to support the raised machine If the ma chine is not properly supported by blocks or jack stands the machine may move or fall which may result in personal injury 1 Front wheel 2 Frame jacking point Jacking the Front End 1 Set parking brake and chock rear tires to prevent the machine from moving Install service latch to secure coring head IMPORTANT To prevent wheel motor damage
76. ardened washer and cap screw Hold hardened washer with pliers to pre vent crankshaft from turning and torque cap screw from 50 to 55 ft lb 67 8 to 74 6 3 Install primary drive belt coring head see Primary Drive Belt in the Service and Repairs section of Chapter 7 Coring Head 4 Plug wiring harness connector into clutch Make sure to secure wire harness away from rotating machine components 5 Install muffler heat shield see Exhaust System in the Service and Repairs section of Chapter 3 Kohler En gine 6 Install pump belt cover to machine see Operator s Manual 1 Electric clutch 2 screw 3 Harness connector ProCore 648 Page 5 33 Figure 40 4 Clutch strap 5 Hardened washer Electrical System oOo 9 Solenoid Valve Coil A solenoid valve coil on the hydraulic lift control manifold Fig 41 can be replaced without opening the hydraulic system Removal 1 Park machine on a level surface fully raise coring head engage parking brake stop engine and remove key from the ignition switch Secure coring head with service latch 2 Disconnect the wiring harness electrical connector from the solenoid coil to be replaced 3 Remove the nut from the spool assembly 4 Slide the coil assembly from the spool assembly Dis card the coil assembly 5 Clean any corrosion or dirt from the spool assembly Installation 1 Slide new coil assembly onto the s
77. arwasher between engine and wire con nectors and secure with flange head screw D Plug machine harness connector to electric clutch E Connect red wire and positive battery cable to the starter motor solenoid stud Fig 9 7 After engine installation verify pulley alignment across engine and hydraulic pump pulley faces with a straight edge If necessary loosen two 2 set screws on hydraulic pump pulley and adjust location of pulley Re tighten pulley set screws after adjustment 8 Install hydraulic pump drive belt see Pump Drive Belt in the Service and Repairs section of Chapter 4 Hydraulic System 9 Adjust hydraulic pump drive belt tension see Opera tor s Manual 10 Install primary drive belt coring head see Primary Drive Belt in the Service and Repairs section of Chapter 7 Coring Head 11 Remove plug installed in fuel hose during disassem bly Connect fuel hose to the fuel filter and secure with hose clamp 12 Install exhaust system see Exhaust System Instal lation in this section 13 engine oil level see Operator s Manual 14 Check all wires control cables and hoses to make sure that they are not contacted by rotating or moving parts 15 Connect positive and then negative battery cables at the battery 16 Install pump belt cover to machine see Operator s Manual 17 fuel shut off valve under the fuel tank 18 Return coring head service latch to st
78. at secure rotolink damper for 1 stomper arm see Rotolink Damper Removal in this section Lower rotolink damper from coring head frame 5 Remove secondary drive belt from coring crankshaft pulley 6 Route drive belt down through coring head frame and around lower end of 1 stomper arm to remove sec ondary drive belt from machine Fig 15 and 16 Installation Fig 12 1 Route secondary drive belt around lower end of 1 stomper arm and up through coring head frame Fig 15 and 16 2 Position drive belt to coring crankshaft pulley 3 Lift idler pulley to allow installation of belt to secon dary drive pulley Fig 14 Carefully lower idler pulley to tension drive belt 4 Raise rotolink damper for 1 stomper arm to coring head frame Make sure that damper standoff and top spacer are on damper studs Secure damper to coring head frame with two 2 hardened D washers and lock nuts see Rotolink Damper Installation in this section 5 Install belt cover and rear hood to machine see Op erator s Manual 6 Remove service latch from coring head before using machine Figure 14 1 Secondary drive pulley 3 Secondary drive belt 2 Idler pulley Figure 15 1 Secondary drive belt 2 1 stomper arm Figure 16 Uo 6 1 Secondary drive belt 2 1 rotolink damper 8 648 7 13 Coring Head Coring Head Drive Jackshaft Figure 17 1 Primary pulley 6 Woodruff key 1
79. ave sufficient force to penetrate the skin and cause serious injury If fluid is injected into the skin it must be surgi cally removed within a few hours by a doctor familiar with this type of injury Gangrene may result from such an injury Nut Sleeve Figure 1 wrench Use another wrench to tighten the nut to the cor Final rect Flats From Finger Tight F F F T The markings on Position the nut and fitting body will verify that the connection has Mark Nut been tightened and Body Initial Size FRET Extend Line Position 4 1 4 in nominal hose or tubing 0 75 0 25 i i i i 6 3 8 in 05025 Finger Tight After Proper Tightening 8 1 2 in 0 75 0 25 10 5 8 in 1 00 0 25 Figure 2 12 3 4 in 0 75 0 25 16 1 in 0 75 0 25 Hydraulic System 4 4 ProCore 648 SAE Straight Thread O Ring Port Non adjustable 1 Make sure both threads and sealing surfaces are free of burrs nicks scratches or any foreign material 2 Always replace the O ring seal when this type of fit ting shows signs of leakage 3 Lubricate the O ring with a light coating of oil 4 Install the fitting into the port and tighten it down full length until finger tight 5 Tighten the fitting to the correct Flats From Finger TT Tight F F F T Fitting Size Installation Torque 4 9 10 ft Ib 12 13 N m 20 21 ft lb 27 28 4 1 4 in nominal hose or tubing 1 00 0 25 6 3 8 in 1505025
80. c components Always keep in mind the need for cleanliness when working on hydraulic equipment Hydraulic system contamination will cause excessive wear of hydraulic components 2 Put caps or plugs on any hydraulic lines left open or exposed during testing or removal of components 3 The engine must be in good operating condition Use a tachometer when making a hydraulic test Engine speed will affect the accuracy of hydraulic test results 4 Because the hydraulic pump is belt driven check for proper pump belt adjustment before performing any hy draulic test Check pump speed with a phototac when performing hydraulic pump flow tests 5 To prevent damage to tester or components the inlet and the outlet hoses must be properly connected and not reversed when using tester with flow and pressure capabilities 6 When using hydraulic tester with flow and pressure capabilities completely open load valve in hydraulic tester before starting engine This will minimize the pos sibility of component damage 7 Install fittings finger tight far enough to insure that they are not cross threaded before tightening with a wrench 8 To prevent hose or tester damage position the tester hoses so that moving machine parts will not make con tact with them 9 Check and adjust the oil level in the reservoir after connecting hydraulic test equipment 10 Check the control linkage for improper adjustment binding or broken parts Make su
81. cations Special Tools Service and Repairs Chapter 7 Coring Head General Information Service and Repairs Chapter 8 Electrical Diagrams Electrical Schematic Electrical Circuit Drawings Wire Harness Drawings 2 UO gt EJ a Electrical 6 o Electrical and Maintenance Hydraulic System System Diagrams This page is intentionally blank ProCore 648 Chapter 1 TORO Safety Table of Contents SAFETY INSTRUCTIONS 2 Before Operating 2 While 2 Maintenance and Service 3 JACKING INSTRUCTIONS 4 SAFETY AND INSTRUCTION DECALS 5 ProCore 648 Page 1 1 Safety Safety Instructions The ProCore 648 is designed and tested to offer safe service when operated and maintained properly Al though hazard control and accident prevention partially are dependent upon the design and configuration of the machine these factors are also dependent upon the awareness concern and proper training of the person nel involved in the operation transport maintenance and storage of the machine Improper use or mainte nance of the machine can result in injury or death To re duce the potential for injury or death comply with the following s
82. ch is shown in the chart below With the use of a multimeter ohms setting the switch functions may be tested to determine whether continuity exists between the various terminals for each switch position Verify continuity between switch termi nals SWITCH NORMAL OTHER CIRCUITS CIRCUITS POSITION MOMENTARY ON RESET Electrical System Page 5 18 Figure 21 1 Lift reset switch Figure 22 ProCore 648 Solenoid Valve Coil The hydraulic system on the ProCore 648 uses three 3 solenoid valve coils on the hydraulic lift control manifold Fig 23 The aerator control module provides current to the solenoid valve coils based on the position of several inputs A LED on the aerator control module will be illu minated when the solenoid valve coils are energized Fig 24 NOTE The solenoid does not have to be removed from the cartridge valve for testing 1 Make sure ignition switch is in the OFF position Un plug solenoid valve electrical connector 2 Apply 12VDC source directly to the solenoid Listen for solenoid to switch on 3 Remove 12VDC source from the solenoid Listen for solenoid to switch off NOTE Prior to taking small resistance readings with a digital multimeter short the test leads together The me ter will display a small resistance value usually 0 5 ohms or less This resistance is due to the internal re sistance of the meter and test leads Subtr
83. commended torque or a torque that is unique to the application is clearly identified and spe cified in this Service Manual These Torque Specifications for the installation and tightening of fasteners shall apply to all fasteners which do not have a specific requirement identified in this Ser vice Manual The following factors shall be considered when applying torque cleanliness of the fastener use of a thread sealant e g Loctite degree of lubrication on the fastener presence of a prevailing torque feature hardness of the surface underneath the fastener s head or similar condition which affects the installation Fastener Identification Grade 1 Grade 5 Inch Series Bolts and Screws Figure 1 ProCore 648 2 3 As noted in the following tables torque values should be reduced by 25 for lubricated fasteners to achieve the similar stress as a dry fastener Torque values may also have to be reduced when the fastener is threaded into aluminum or brass The specific torque value should be determined based on the aluminum or brass material strength fastener size length of thread en gagement etc The standard method of verifying torque shall be per formed by marking a line on the fastener head or nut and mating part then back off fastener 1 4 of a turn Measure the torque required to tighten the fastener until the lines match up Class 8 8 Class 10 9 Metric Bolts and Screws Figure 2 Product Records an
84. current for the electric clutch which rotates the cor ing crankshaft This circuit is composed of the aeration 3 proximity switch the clutch relay the electric clutch and diode D3 The electric clutch circuit relies on the op eration of the OK to lower circuit for completing the clutch circuit See OK to Lower Circuit in this section Electric clutch circuit protection is provided by fuse F2 Not Aerating Clutch not Engaged Whenever the coring head is in the raised position the aeration 3 proximity switch is open and the clutch relay is not energized The electric clutch will not be energized So rotation of the coring crankshaft does not occur TO IGNITION SWITCH GROUND TERMINAL L NOT AERATING CLUTCH NOT ENGAGED Aerating Clutch Engaged The clutch relay will be energized as the coring head is lowered to the point when the aeration 3 proximity switch closes This closed proximity switch provides complete circuit if the OK to lower circuit is closed Once the clutch relay is energized current is provided to the clutch and rotation of the coring crankshaft be gins The clutch will continue to be energized until either A The coring head is raised which opens the aera tion 43 proximity switch B The to lower circuit opens e g the operator releases the traction lever while aerating LOWER CIRCUIT NOT ENERGIZED TO IGNITION SWITCH GROUND TERMINAL L AERATING C
85. d wire harness drawings for the ProCore 648 are located in Chapter 8 Electrical Diagrams ProCore 648 5 1 Chapter 5 Electrical System Relays ceo ere ted 15 Manual Raise Lower Switch 16 Ground Follow Switch 17 Lift Reset Switch 18 Solenoid Valve 19 Head Low and Head High Limit Switches 20 FUSESE dus dettes tent ae co UTR 21 Proximity Switches 22 Aerator Control Module 24 Electric Clutch 26 Diode Assemblies 27 SERVICE AND REPAIRS 28 Battery Storage 28 Battery 28 Battery Service 29 Electric Cl tch oer eerie 32 Solenoid Valve 34 Electrical System 6 m 9 5 Circuit Operation NOTE This section provides information concerning three sequential electrical circuits that are used on the ProCore 648 Use these descriptions along with the electrical diagrams and schematics found in Chapter 8 Electrical Diagrams to better understand circuit opera tion OK to Lower Circuit Fig 1 The OK to lower circuit is one of the inputs used by the aerator control module to allow current ou
86. d Maintenance Product Records 6 5 5 6 Standard Torque for Dry Zinc Plated and Steel Fasteners Inch Series Grade 1 5 amp SAE Grade 1 Bolts Screws Studs amp SAE Grade 5 Bolts Screws Studs amp SAE Grade 8 Bolts Screws Studs amp Thread Size 8 with Thin Sems with Regular Height Nuts Sems with Regular Height Nuts Sems with Regular Height Nuts Height Nuts SAE J995 Grade 2 or Stronger Nuts SAE J995 Grade 2 or Stronger Nuts SAE J995 Grade 5 or Stronger Nuts 147 23 282 30 339 56 599 79 100 10 1125 100 140 15 1580 170 734 113 115 10 1300 100 160 15 1800 170 1186 169 200 25 2250 280 300 30 3390 340 1446 192 225 25 2540 280 325 30 3670 340 6 32 UNC 6 40 UNF 8 32 UNC 8 36 UNF 10 24 UNC 10 32 UNF 1 4 20 UNC 48 7 1 4 28 UNF 65 10 5 16 18 UNC 115 15 105 17 5 16 24 UNF 138 17 128 17 A ES m A N I N N o A o N a I I I I N N N N mens mere 16 2 3 8 24 UNF NOTE Reduce torque values listed in the table above NOTE The nominal torque values listed above for by 25 for lubricated fasteners Lubricated fasteners Grade 5 and 8 fasteners are based on 75 of the mini are defined as threads coat
87. d engagement etc ProCore 648 26 3 38 4 ft lb 52 5 53 5 ft lb 72 7 N m 66 7 ft lb 90 10 N m 92 9 ft lb 125 12 N m 166 15 ft lb 225 20 N m 229 22 ft lb 310 30 325 33 ft lb 440 45 450 37 ft lb 610 50 2 5 27 2 ft lb 36 3 N m NOTE The nominal torque values listed above are based on 75 of the minimum proof load specified in SAE J1199 The tolerance is approximately 10 of the nominal torque value Product Records and Maintenance Product Records o 7 2 i 52 c Other Torque Specifications SAE Grade 8 Steel Set Screws Wheel Bolts and Lug Nuts Thread Size Grade 5 Ib E 1 2 20 10 ft lb 108 14 5 6 18 UNC 215 35 145 20 in Ib Grade 5 Ib 14 b 3 8 16 UNC 35 10 ft lb 18 3 ft lb M12 X 1 25 Class 8 8 50 10 ft ib M12 X 1 5 80 10 108 14 E qe For steel wheels and non lubricated fasteners Thread Cutting Screws Thread Cutting Screws Zinc Plated Steel Zinc Plated Steel Type 1 Type 23 or Type F Thread Threads per Inch Baseline Torque Thread Size Baseline Torque Type A Type B No 6 32 UNC 20 5 inIb 1 20 5 in Ib No 8 32 UNC 30 5 in lIb 1 1 No 10 24 UNC 38 7 in lb 1 4 20 UNC 85 15 in lb 5 16 18 UNC 110 20 in lb Hole size material strength material thic
88. dous and could possibly be deadly Safety Page1 2 Rev C To reduce the potential for injury or death comply with the following safety instructions 4 Since gasoline is highly flammable handle it careful ly A Store fuel in containers specifically designed for this purpose B Do not remove machine fuel tank cap while en gine is hot or running C Do not smoke while handling fuel D Fill fuel tank outdoors and only to within an inch of the top of the tank not the filler neck Do not overfill the fuel tank E Wipe up any spilled fuel 5 Do not touch engine muffler or exhaust pipe while engine is running or soon after it is stopped These areas could be hot enough to cause burns 6 Before leaving the operator s position A Ensure that traction lever is in neutral B Raise coring head and wait for coring head to stop C Set parking brake Stop engine and remove key from ignition switch 7 Anytime the machine is parked short or long term install the service latch to secure the coring head in the raised position This eliminates the risk of the coring head accidentally lowering to the ground 8 Do not park on slopes unless wheels are chocked or blocked ProCore 648 7 Anytime the machine is parked short long term install the service latch to secure the coring head in the raised position This eliminates the risk of the coring head accidentally lowering to the ground Maintenance a
89. e ground cable connect a digital multimeter set to amps between the negative battery post and the negative ground cable connector The reading should be less than 0 1 amp If the reading is 0 1 amp or more the machine s electrical system should be tested and repaired 5 After battery cables have been connected to battery make sure that speed selector lever does not come with in 1 inch 25 4 mm of either battery cable when moved through its entire range of motion Also check that bat tery cables do not contact rotating screen on engine ProCore 648 Page 5 29 Figure 38 1 Negative battery cable 2 Positive battery cable Inspection and Maintenance 1 Check for cracks in battery case Replace battery if cracked or leaking 2 Check battery terminal posts for corrosion Use wire brush to clean corrosion from posts IMPORTANT Before cleaning the battery tape or block vent holes to the filler caps and make sure the caps are on tightly 3 Check for signs of wetness or leakage on the top of the battery which might indicate a loose or missing filler cap overcharging loose terminal post or overfilling Also check battery case for dirt and oil Clean the bat tery with a solution of baking soda and water then rinse it with clean water 4 Check that the cover seal is not broken away Re place the battery if the seal is broken or leaking 5 Check the electrolyte level in each cell If the level is below th
90. e aerating Electrical System 5 4 Coring Head Stranded If the coring head is stranded in the lowered position e g the engine runs out of gas while aerating the transport limit 2 proximity switch will be open and will prevent the relays in the lockout circuit from energizing In this situation no current will be available to the sole noid valves so the coring head cannot be raised Press ing the lift reset switch provides the necessary ground path for completing the lockout circuit Once the lockout circuit is closed solenoid valve operation is resumed to allow the coring head to raise ProCore 648 TO IGNITION SWITCH TERMINAL L K CONTROL MODULE ENERGIZED TERMINAL A LIFT RESET NOT PRESSED GROUND NT TO IGNITION SWITCH TERMINAL L TO ELECTRIC CLUTCH TO AERATOR CONTROL MODULE IUE p TO IGNITION SWITCH TERMINAL A LL w ProCore 648 TO IGNITION SWITCH TERMINAL L TO ELECTRIC CLUTCH TO AERATOR CONTROL MODULE 4 lt pres TO IGNITION SWITCH TERMINAL A Figure 2 5 5 TO ELECTRIC CLUTCH CONTROL CURRENT POWER CURRENT Electrical System Electrical System Electric Clutch Circuit Fig 3 The electric clutch circuit is used on the ProCore to pro vide
91. e nut cap screw 4 Washer head screw 1 Extension spring 2 Socket head screw Hydraulic System Installation Fig 31 1 Install hydraulic fittings with new o rings to the hy draulic pump Orientate the fittings as noted during dis assembly Support hydraulic pump when installing it to the pump support to prevent the pump from falling and causing personal injury 2 Position hydraulic pump assembly to the frame pump support Secure pump to the pump support with two 2 flange head screws and flange nuts 3 Make sure the bore of the pump pulley is clean Apply anti seize lubricant to the hydraulic pump shaft Posi tion key to pump shaft and slide pulley onto pump shaft with the pulley hub toward the pump Position pulley to the marked position on the pump shaft 4 Apply Loctite 242 or equivalent to pulley set screws and secure pulley to pump shaft with two 2 set screws 5 Remove any caps or plugs that were placed in pump openings hydraulic hoses or hydraulic tubes during the pump removal procedure Connect hydraulic hoses and tubes to hydraulic pump 6 Install hydraulic pump controls Fig 32 and 33 to the pump as follows A Carefully position pump control assembly to pump Make sure pump lever with attached trunnion clamp is placed over pump trunnion shaft B Secure control bracket to hydraulic pump with two 2 cap screws with flange nuts and washer head Screw C Secure pump lever to pump trunnion
92. e tops of the plates in any cell fill all cells with distilled water between the minimum and maximum fill lines Charge at 15 to 25 amps for 15 minutes to allow sufficient mixing of the electrolyte Electrical System 6 Oo 2 5 Wu Testing 1 To properly test a battery perform a high discharge test using an adjustable load tester This is one of the most reliable means of testing a battery as it simulates the cold cranking test A commercial battery load tester is required to perform this test caution Follow the manufacturer s instructions when us ing a battery load tester A Check the voltage across the battery terminals prior to testing the battery If the voltage is less than 12 4 VDC recharge the battery B If the battery has been charged apply a 150 amp load for 15 seconds to remove the surface charge Use a battery load tester following the manufactur er s instructions C Make sure battery terminals are free of corrosion D Measure the temperature of the center cell E Connect a battery load tester to the battery termi nals following the manufacturer s instructions Connect a digital multimeter to the battery terminals F Apply a test load of one half the Cranking Perfor mance see Battery Specifications rating of the bat tery for 15 seconds G Take a voltage reading at 15 seconds then re move the load H Using the table below determine the minimum voltage
93. ear gloves and use caution 9 To reduce potential fire hazard keep engine area free of excessive grease grass leaves and dirt 10 If engine must be running to perform maintenance or make an adjustment keep hands feet clothing and oth er parts of the body away from all moving machine parts Keep bystanders away ProCore 648 Page 1 3 8 Do not park on slopes unless wheels are chocked or blocked 11 Do not overspeed the engine by changing governor setting To assure safety and accuracy check maximum engine speed with a tachometer 12 Shut engine off before checking or adding oil to the engine crankcase 13 Disconnect battery before servicing the machine Disconnect negative battery cable first and positive bat tery cable last If battery voltage is required for trouble shooting or test procedures temporarily connect the battery Reconnect positive battery cable first and nega tive battery cable last 14 Battery acid is poisonous and can cause burns Avoid contact with skin eyes and clothing Protect your face eyes and clothing when working with a battery 15 Battery gases can explode Keep cigarettes sparks and flames away from the battery 16 At the time of manufacture the machine conformed to all applicable safety standards To assure optimum performance and continued safety certification of the machine use genuine Toro replacement parts and ac cessories Replacement parts and accessories made by other m
94. ed with a lubricant such as mum proof load specified in SAE J429 The tolerance is oil graphite or thread sealant such as Loctite approximately 10 of the nominal torque value Thin height nuts include jam nuts NOTE Torque values may have to be reduced when installing fasteners into threaded aluminum or brass The specific torque value should be determined based on the fastener size the aluminum or base material strength length of thread engagement etc Product Records and Maintenance Page2 4 ProCore 648 Standard Torque for Dry Zinc Plated and Steel Fasteners Metric Fasteners Thread Size 5 X 0 8 Regular Height Nuts 57 5 in lb 96 9 in Ib Class 8 8 Bolts Screws and Studs with Class 8 or Stronger Nuts 640 60 N cm 78 7 in lb 885 80 N cm 1018 100 N cm Class 10 9 Bolts Screws and Studs with Regular Height Nuts Class 10 or Stronger Nuts 133 18 in lb 1500 150 N cm M6 X 1 0 M8 X 1 25 19 2 ft lb M10 X 1 5 M12 X 1 75 M16 X 2 0 M20 X 2 5 NOTE Reduce torque values listed in the table above by 25 for lubricated fasteners Lubricated fasteners are defined as threads coated with a lubricant such as oil graphite or thread sealant such as Loctite NOTE Torque values may have to be reduced when installing fasteners into threaded aluminum or brass The specific torque value should be determined based on the fastener size the aluminum or base material strength length of threa
95. ef valve cap 2 Adjustment socket Hydraulic System E 5 52 Traction Piston Pump P1 Flow Test Using Tester With Flow Meter and Pressure Gauge LIFT CYLINDER CYL feof AND t BPORT 2 e z BOTTOM 5 CONTROL MANIFOLD TESTER FRONT N P Ponr M gt _ M2 V Working Pressure Low Pressure Charge Return or Suction Flow Direction Figure 18 Procedure for Traction Piston Pump P1 Flow Test 1 Make sure hydraulic oil is at normal operating tem perature by operating the machine for approximately 10 minutes 2 Parkmachine ona level surface with the coring head fully raised Make sure engine is off and parking brake is disengaged Secure coring head with service latch Hydraulic System Page 4 22 Rev C 3 Read Precautions For Hydraulic Testing in this sec tion 4 Remove pump control assembly from traction pump see Hydraulic Traction Charge Pump Removal in the Service and Repairs section of this chapter Position pump control assembly away from pump 5 Make sure that hydraulic pump drive belt is adjusted properly see Operator s Manual ProCore 648 6 Lift or jack machine so all wheels are off the floor to allow flow through the traction circuit Support machine with jackstands or blocking 7 Attach a heavy chain to the rear of the machine frame and some
96. ened washer Cap screw Flange nut Flat washer Brake grommet Cap screw Spacer C D Ov Ei Electrical System 50 to 55 ft Ib 67 8 74 6 Figure 39 Clutch strap Idler mounting bracket Lock nut Cap screw Hardened washer Idler pulley Torsion spring Spacer 5 32 18 19 20 21 22 Flat washer 24 25 Flange bushing Pivot sleeve Idler spacer Washer Idler arm Cap screw Flange nut ProCore 648 Removal Fig 39 1 Park machine on a level surface fully raise coring head engage parking brake stop engine and remove key from the ignition switch Secure coring head with service latch 2 Remove pump belt cover from machine see Opera tor s Manual 3 Remove muffler heat shield see Exhaust System in the Service and Repairs section of Chapter 3 Kohler Engine 4 Unplug wiring harness connector from clutch 5 Remove primary drive belt coring head see Prima ry Drive Belt in the Service and Repairs section of Chap ter 7 Coring Head 6 Hold hardened washer with pliers to prevent engine crankshaft from turning Remove cap screw and hard ened washer that secure clutch to engine crankshaft 7 Slide clutch from engine crankshaft Installation Fig 39 1 Apply antisieze lubricant to engine crankshaft Align clutch hub with engine crankshaft keyway and slide clutch onto crankshaft 2 Secure clutch to crankshaft with h
97. er TOR4079 This kit includes a variety of O ring Face Seal fittings to enable connection of test gauges to the ProCore 648 hy draulic system The kit includes tee s unions reducers plugs caps and male test fittings Wheel Hub Puller Part Number TOR4097 The wheel hub puller allows safe removal of the wheel hub from the shaft of wheel motors TORO TEST FITTING KIT NO TOR4079 TOOL NUMBER TOOL NUMBER Union 1 ea Sire Toro No No 10No 8 TORSOTSS Reducer 1 ea Sie Tero No 10 TORTS 12 8 1094076 Test Cap Fitting 2 ea 10 10940716 OR4G79 10 ri me en 4 Bade ann oss Qe ea No Tote xm SOR di pee WW Pipe 4079 23 Figure 11 2 5 5 gt Figure 12 ProCore 648 Page 4 13 Hydraulic System Troubleshooting The cause of an improperly functioning hydraulic sys tem is best diagnosed with the use of proper testing equipment and a thorough understanding of the com plete hydraulic system A hydraulic system with an excessive increase in heat or noise has a potential for failure Should either of these conditions be noticed immediately stop the machine turn off the engine locate the cause of the trouble and correct it before allowing the machine to be used again Problem Hydraulic oil leaks Continued use of an improperly functioning hydraulic system could lead
98. etween the battery terminals Set the multimeter to the DC volts setting The battery should be at a temperature of 60 to 1009 F 16 to 38 C The ignition key should be in the OFF position and all accessories turned off Connect the positive me ter lead to the positive battery post and the negative meter lead to the negative battery post NOTE This test provides a relative condition of the bat tery Load testing of the battery will provide additional and more accurate information Charging System Test This is a simple test used to determine if the charging System is functioning It will tell you if a charging system has an output but not its capacity Tool required Digital multimeter set to DC volts Test instructions Connect the positive meter lead to the positive battery post and the negative meter lead to the negative battery post Leave the test leads con nected and record the battery voltage NOTE Upon starting the engine the battery voltage will drop and then should increase once the engine is running NOTE Depending upon the condition of the battery charge and battery temperature the charging system voltage will increase at different rates as the battery charges ProCore 648 Page 5 11 Voltage Measured Battery Charge Level 12 68 v or higher Fully charged 10096 12 45 v 7596 charged 12 24 v 5096 charged 12 06 v 2596 charged 11 89 v 096 charged Start the engine and r
99. f component failure was Severe or system is contaminated see Flush Hydraulic System 2 Lubricate O rings and seals with clean hydraulic oil before installing hydraulic components 3 Make sure caps or plugs are removed from the hy draulic tubes hydraulic fittings and components before reconnecting 4 Use proper tightening methods when installing hy draulic hoses and fittings see Hydraulic Fitting Installa tion in the General Information section of this chapter 5 After repairs check control linkages and cables for proper adjustment binding and or broken parts 6 After disconnecting or replacing any hydraulic com ponents operate machine functions slowly until air is out of system see Hydraulic System Start Up in this sec tion 7 Check for hydraulic oil leaks Shut off engine and cor rect leaks if necessary Check oil level in hydraulic reser voir and add correct oil if necessary Check hydraulic lines and hoses daily for leaks kinked lines loose mounting supports wear loose fittings weather deterioration and or chemical deterioration Make all necessary repairs before operating machine ProCore 648 Flush Hydraulic System IMPORTANT Flush the hydraulic system any time there is a severe component failure or the system is contaminated oil appears milky or black or con tains metal particles IMPORTANT Flush hydraulic system when chang Ing from petroleum base hydraulic fluid such as Mobil 424 to
100. g item 4 backup ring item 5 seal item 7 and wiper item 9 with hydraulic oil Install seal ing components to the head IMPORTANT Do not clamp vise jaws against rod surface Protect rod surface before mounting in vise 2 Mount rod securely in a vise by clamping vise on the pivot end of the shaft Carefully slide head assembly onto the rod Install retaining ring item 1 3 Remove rod assembly from vise IMPORTANT Prevent damage when clamping the tube into a vise clamp on the pivot end only Do not close vise enough to distort tube 4 Mount tube in a vise so that the rod end tilts up slight ly 5 Coat all internal lift cylinder parts with a light coating of hydraulic oil Slide rod and head assembly into tube being careful not to damage the seals 6 Secure head in tube by installing retaining ring item 6 Align key slot in head with the access groove in the tube Rotate head clockwise as far as the retaining ring will allow The offset end of the retaining ring will be against the left side of the tube groove as shown in Fig ure 46 Spanner wrench Retaining ring Offset end against left side of barrel groove after installing Figure 46 ProCore 648 Page 4 53 Hydraulic System Se 52 zo Hydraulic Reservoir Figure 47 1 Hydraulic reservoir 8 Flat washer 14 Hydraulic tube 2 Dipstick 9 Frame 15 Suction hose 3 Cap 10 O ring 16 Hose clamp 4
101. ged 6 Start engine and operate engine at full speed 3400 50 RPM 7 Pressure gauge should read approximately 40 PSI 2 8 Bar Record pressure reading 8 Turn off engine 9 If specification is not met inspect proportional valve PV in control manifold 10 A dynamic charge pressure test can be performed as follows A Leave pressure gauge connected to hydraulic control manifold G2 port B Disengage parking brake Start engine and oper ate at full speed 3400 50 RPM Move the traction lever fully forward ProCore 648 Page 4 19 C While machine is moving monitor the charge pressure reading on the pressure gauge do not acti vate the lift control while monitoring pressure D The charge pressure should drop no more than 1596 from initial test reading Step 8 above A pres sure drop of more than 1596 indicates a traction cir cuit problem e g damaged or leaking proportional valve PV worn or damaged piston pump P1 11 Shut off engine 12 Disconnect pressure gauge from hydraulic control manifold port G2 Figure 14 2 G2 port quick fitting 1 Hydraulic manifold Hydraulic System 2 5 5 gt Coring Head Raise Lower Relief R1 Pressure Test Using Pressure Gauge LIFT CYLINDER 14 PRESSURE B SVL GAUGE _ ENERGIZED Gi ENERGIZED SVQ ENERGIZED CONTROL MANIF
102. gine with four hex nuts Torque hex nuts from 17 to 21 ft lb 23 1 to 28 5 IMPORTANT Finger tighten all exhaust system fasteners before securing so there is no preload on exhaust components 2 Position muffler clamps over exhaust elbow and muffler inlets 3 Slide exhaust elbow onto exhaust manifold and then slide muffler onto elbow 4 Secure muffler to frame with two 2 carriage screws and flange nuts 5 Tighten muffler clamps 6 Position exhaust heat shield to machine and secure with flange head screw and two 2 cap screws with lock washers 7 Return coring head service latch to stored position before using machine Kohler Engine 8 1 Engine 8 Cap screw 4 used 15 Carriage screw 2 used 2 Negative battery cable 9 Frame 16 Heat shield 3 Wire harness ground 10 Flange nut 2 used 17 Lock washer 2 used 4 Flange screw 11 Muffler bracket 18 Cap screw 2 used 5 Lock washer 12 Flange head screw 3 used 19 Flange nut 6 used 6 Exhaust manifold 13 Muffler clamp 2 used 20 Muffler 7 Hexnut 4 used 14 Exhaust elbow 21 Starter cable Removal Fig 8 1 Park machine on a level surface fully raise coring head engage parking brake stop engine and remove key from the ignition switch Secure coring head with service latch Chock wheels to keep the machine from moving 2 Disconnect negative and then positive battery cables at the battery
103. hapter 3 Kohler Engine 6 Remove two 2 cap screws that secure cable guide to steering arm Position cables and wire harness away from steering arm 7 Support control handle Remove three 3 lock nuts that secure control handle to steering arm Slide control handle from steering arm taking care to not damage control cables or wiring harness that will stay attached to machine Position handle away from steering arm 8 Support steering arm Remove cotter pin and slotted hex nut from upper end of steering spindle Lower steer ing arm from frame 9 If necessary remove steering spindle from steering arm 10 If necessary remove control handle from machine A Remove six 6 washer head screws that secure lower handle cover to control handle Remove lower handle cover B Remove four 4 screws that secure handle con trol cover to control handle Unplug harness connec tors from low oil pressure light and raise lower switch on cover C Unplug harness connectors from neutral relay latching relay neutral proximity switch and reverse proximity switch on control handle D Disconnect parking brake cable from brake lever see Parking Brake Cable Removal in this section ProCore 648 Page 6 11 E Remove lock nut and cap screw that secure trac tion control cable to control lever Locate and retrieve two 2 flat washers Loosen jam nut that secures parking brake cable to underside of control handle 11 Inspect
104. his rocker switch is one of the components in the OK to lower circuit which is one of the aerator control module inputs See OK to Lower Cir cuit in the Circuit Operation section of this chapter for additional raise lower switch information The switch terminals are marked as shown in Figure 17 The circuitry of the raise lower switch is shown in the chart below With the use of a multimeter ohms setting the switch functions may be tested to determine whether continuity exists between the various terminals for each switch position Verify continuity between switch termi nals SWITCH OTHER NORMAL CIRCUITS POSITION CIRCUITS RAISE NONE NONE MIDDLE AERATE NONE LOWER MOMENTARY 2 3 Electrical System 5 16 Figure 16 1 Manual raise lower switch Figure 17 ProCore 648 Ground Follow Switch The ground follow switch is located on the side of the control panel Fig 18 This rocker switch allows the True Core ground following system to be turned on off The switch is retained in position by a cap screw and nut placed in the switch guard to prevent accidental switch movement In the normal upper switch position the True Core ground following system is ON The True Core ground following system is OFF when the switch is in the lower position The switch terminals are marked as shown in Figure 19 The circuitry of the ground follow switch is sh
105. hydraulic oil reser voir level and fill if necessary Continue with bleeding procedure Whenallevidence offoamy oil has been evacuat ed from the traction circuit close tester valve re lease traction lever and stop engine J Remove tester from traction circuit test port Check hydraulic reservoir level and fill if necessary K Ifthe hydrostat or a wheel motor was replaced or rebuilt start engine and operate the traction system so the wheels rotate slowly for 10 minutes L Lower machine to ground Remove chain from rear of machine ProCore 648 10 Start engine and operate the traction system at vary ing speeds for a 10 minute period 11 Stop the machine Check hydraulic reservoir level and fill if necessary Check hydraulic components for leaks and tighten any loose connections Figure 27 1 Test port 2 Hydraulic manifold 9 2 x gt 648 4 33 Rev A Hydraulic System Hydraulic Pump Drive Belt Anti seize lubricant Figure 27 1 Flange nut 2 used 7 Spring bracket 13 Hydraulic pump pulley 2 Hydraulic traction charge pump 8 Idler support bracket 14 Pump drive belt 3 Key 9 Idler pulley 15 L bracket 4 Engine 10 Flange nut 16 Flange head screw 5 Engine pulley 11 Tensioning spring 17 Flange head screw 2 used 6 Flange head screw 12 Set screw Hydraulic System Page 4 34 ProCore 648 Drive Belt Removal Fig 27 1 Park machine on a level
106. inder and coring head are held in place True Core Ground Following System When aerating with the ground follow switch in the ON position the True Core Ground Following System hy draulically adjusts the coring head position to ensure aerating depth consistency over undulating surfaces The head high limit and head low limit switches on the depth actuator assembly are opened or closed depend ing on movement of the turf guards over ground irregu larities These switches are used as inputs for the aerator control module to energize or de energize sole noid valves SVR and SVL in the hydraulic manifold As these solenoid valves are energized or de energized the coring head is raised or lowered as described above The control manifold orifice ORF1 restricts oil flow to and from the lift cylinder to allow more accurate ground following Solenoid valve SVQ is always de energized when coring head is in the lowered aerating position If the ground follow switch is turned to the OFF position the coring head lowers to the manual coring head stops and the ground following operation is not functional So lenoid valve SVL is always energized while aerating when the ground follow switch is in the OFF position Hydraulic System 5 gt 20 n Special Tools Order these special tools from your Toro Distributor Hydraulic Pressure Test Kit Toro Part Number TOR47009 Use to take various pressure reading
107. iness when working on hydraulic equipment Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hy draulic oil See Relieving Hydraulic System Pres sure in the General Information section of this chapter 3 Put caps or plugs on any hydraulic lines hydraulic fit tings or hydraulic components left open or exposed to prevent hydraulic system contamination 4 Put labels on disconnected hydraulic lines and hoses for proper installation after repairs are completed 5 Note the position of hydraulic fittings especially el bow fittings on hydraulic components before removal Mark parts if necessary to make sure they will be aligned properly when reinstalling hydraulic hoses and tubes Check Hydraulic Lines and Hoses Keep body and hands away from pin hole leaks or nozzles that eject hydraulic fluid under high pressure Use paper or cardboard not hands to search for leaks Hydraulic fluid escaping under pressure can have sufficient force to penetrate the skin and cause serious injury If fluid is in jected into the skin it must be surgically re moved within a few hours by a doctor familiar with this type of injury Gangrene may result from such an injury Hydraulic System Page 4 30 After Repair or Replacement of Components 1 Check oil level in the hydraulic reservoir and add cor rect oil if necessary Drain and refill hydraulic system reservoir and change oil filter i
108. ing mark on bearing housing Fig 9 4 Install cap screw item 1 and flat washer item 2 to retain crankarms Do not fully tighten cap screw 5 Drive new spring pins into coring head frame holes 6 Position bearing housing assembly to coring head frame and secure with four 4 cap screws eight 8 hardened washers and four 4 lock nuts Torque fasten ers from 70 to 80 ft lb 95 to 108 7 Install stomper arms to crankarms on either side of bearing housing see Stomper Arm Installation in this section Do not fully tighten fasteners NOTE With 1 crankarm aligned with cast mark on bearing housing all subsequent crankarm cast timing numbers must be in line from 1 to 6 8 Once all components have been installed fully tight D Lock nuts that secure rotolink dampers to frame see Rotolink Damper Installation in this section 9 After assembly rotate coring crankshaft by hand to make sure that no binding occurs 10 If removed install secondary coring head drive belt see Secondary Drive Belt Installation in this section 11 Install rear hood see Operators Manual Disen gage service latch before machine use Figure 9 1 Housing timing mark 2 Crankarm position 150 to 170 ft lb 203 to 230 N m ES 70to80ft lb 95 to 108 N m Figure 10 1 Coupling 3 sh 5 Coupling plat en fasteners in the following order Tighten fasteners to 2 2 6 Cap screw 4 used the torque s
109. into a drain pan by slowly pumping the cylinder rod Plug port and clean the outside of the lift cylinder IMPORTANT Prevent damage when clamping the lift cylinder into a vise clamp on the pivot only Do not close vise enough to distort tube 2 Mount lift cylinder in a vise so that the shaft end tilts up slightly 3 Rotate head item 8 with a spanner wrench and re move retaining ring item 6 as shown in Figure 45 4 Grasp end of rod extract rod and head by carefully twisting and pulling on the rod IMPORTANT Do not clamp vise jaws against rod surface Protect rod surface before mounting in vise Hydraulic System 5 Backup ring 6 Retaining ring Page 4 52 7 Seal 8 Head 9 Wiper 5 Mount rod securely in a vise by clamping vise on the flats of the pivot Remove retaining ring item 1 and carefully slide head from the shaft 6 Remove and discard o ring item 4 backup ring item 5 seal item 7 and wiper item 9 from the head Spanner wrench Retaining ring Figure 45 ProCore 648 Inspection A CAUTION Use eye protection such as goggles when using compressed air 1 Wash all parts in solvent Dry parts with compressed air 2 Inspect internal surface of tube for deep scratches out of roundness and bending Replace if worn or damaged 3 Inspect rod and head for excessive pitting scoring or wear Replace any worn or damaged parts Assembly Fig 44 1 Coat new o rin
110. ise and the coring crankshaft should stop rotating 3 If the coring head is stranded in the lowered position the coring head will not raise unless the lift reset switch is depressed ProCore 648 Component Testing For accurate resistance and or continuity checks elec trically disconnect the component being tested from the circuit e g unplug the ignition switch connector before doing a continuity check NOTE Electrical troubleshooting of any 12 Volt power connection can be performed through voltage drop tests without disconnecting the component Ignition Switch The ignition key switch has three positions OFF RUN and START Fig 7 The terminals are marked as shown in Figure 8 Testing The circuitry of the ignition switch is shown in the chart below With the use of a multimeter ohms setting the Switch functions may be tested to determine whether continuity exists between the various terminals for each switch position Unplug wire harness connectors from switch and verify continuity between switch terminals Reconnect the har ness connectors to the switch after testing CIRCUIT RUN B L A START The Aerator Control Module monitors the operation of the ignition switch If the ignition switch is in the ON posi tion the Module power input LED should be illuminated If the ignition switch is in the START position the Module start output LED should also be illuminated POSITION OFF ProC
111. isplay a small resistance value usually 0 5 ohms or less This resistance is due to the internal resistance of the meter and test leads Subtract this val ue from the measured value of the component you are testing 1 Locate relay to be tested Disconnect the machine wire harness connector from the relay 2 Using a multimeter ohms setting measure coil re sistance between terminals 85 and 86 Fig 15 Resist ance should be between 70 and 90 ohms 3 Connect multimeter ohms setting leads to relay ter minals 30 and 87 Ground terminal 86 and apply 12 VDC to terminal 85 The relay should make and break continuity between terminals 30 and 87 as 12 VDC is mm applied and removed from terminal 85 Figure 14 1 Traction lever 2 Relay Int 4 Disconnect voltage from terminal 85 and multimeter lead from terminal 87 SE o0 9 5 Connect multimeter ohms setting leads to relay ter minals 30 and 87A Apply 12 VDC to terminal 85 The relay should make and break continuity between termi 30 86 nals 30 and 87A 12 VDC is applied and removed NS M from terminal 85 85 87a 87 6 Disconnect voltage and multimeter leads from the relay terminals Reconnect relay to machine wire har ness Figure 15 ProCore 648 Page 5 15 Electrical System Manual Raise Lower Switch The manual raise lower switch is located on the handle control panel Fig 16 T
112. kness amp finish must be considered when determining specific torque 3 8 16 UNC 200 100 in lb values All torque values are based on non lubricated 2 16 71 fasteners Conversion Factors in lb X 11 2985 X 0 08851 in Ib ft lb 1 3558 N m N m X 0 7376 Product Records and Maintenance Page2 6 ProCore 648 Table of Contents INTRODUCTION SPECIFICATIONS GENERAL INFORMATION Fuel Shutoff Valve ADJUSTMENTS Adjust Choke Control Adjust Engine Speed ProCore 648 Chapter 3 Kohler Engine SERVICE AND REPAIRS 7 Cooling System 7 Fuel System 8 Exhaust System 10 Engine cer 12 Belt Tensioners 16 KOHLER ENGINE SERVICE MANUAL Page 3 1 Kohler Engine Introduction This Chapter gives information about specifications and repair of the Kohler engine used in the ProCore 648 General engine maintenance procedures are described in your Operator s Manual Information on engine trou bleshooting testing disassembly and reassembly is identified in the Kohler Engine Service Manual that is in cluded at the end of this section Kohler Engine Page 3 2 Most repairs and adjustments require tools which are commonly available in many service shops Special
113. l in Service and Repairs section of Chapter 6 Chassis IMPORTANT To prevent damage to hydraulic motor DO NOT hit wheel hub or motor with a hammer dur ing wheel hub removal or installation 3 Loosen nut that secures wheel hub to motor shaft Use wheel hub puller see Special Tools to free wheel hub assembly from motor shaft Remove nut and hub assembly from motor shaft Locate and retrieve wood ruff key from motor shaft A Front wheel hub assembly includes wheel hub bearing plate and wheel studs B Rear wheel hub assembly includes wheel hub bearing plate parking latch disc and wheel studs 4 Clean wheel motor and hydraulic connections Label hydraulic lines for assembly purposes 5 Disconnect hydraulic lines from hydraulic fittings on motor to be removed Allow hydraulic oil to drain from lines into a suitable container Put caps or plugs on open hydraulic lines and fittings to prevent contamination 6 If rear wheel motor is being removed pull hair pin that secures parking latch link to parking latch bar Fig 36 Slide link from bar and position link away from park ing latch support 7 Support wheel motor Remove four 4 cap screws and lock nuts that secure motor to frame If rear wheel motor is being removed remove parking latch support and parking latch bar Pull wheel motor from the ma chine NOTE If hydraulic fittings are to be removed from wheel motor note correct orientation of fittings before
114. lic oil 5 Attach a heavy chain between the rear of the ma chine frame and an immovable object to prevent the ma chine from moving during testing 6 If front wheel motor requires testing A Both rear wheel motors should have hydraulic lines connected Block up both rear wheels off the ground Release parking brake so rear wheels can turn B Position front wheel on the ground Immobilize front wheel to prevent it from turning 7 lf a rear wheel motor requires testing A Disconnect both hydraulic lines from rear wheel motor that is not being tested Cap disconnected hy draulic lines and plug wheel motor ports to prevent contamination B Front wheel motor should have hydraulic lines connected Block up front wheel off the ground C Make sure parking brake is engaged to prevent rear wheel rotation 8 Clean hose fitting and disconnect hose from upper 90 fitting on traction pump Fig 25 ProCore 648 Page 4 29 IMPORTANT Make sure oil flow indicator arrow on the flow gauge is showing that the oil will flow from the wheel motor through the tester and into the traction pump fitting 9 Install hydraulic tester with flow meter and pressure gauges between the disconnected hose and traction pump Make sure flow control valve on the tester is fully open 10 Start engine and move throttle to full speed 3400 50 RPM Use extreme caution when performing test The tire s on the ground will be trying t
115. lic pumps Repeat this step again ProCore 648 Page 4 31 9 Reattach both spark plug wires 10 Start engine and let it idle at low speed for a minimum of two 2 minutes 11 Increase engine speed to high idle for minimum of one 1 minute under no load 12 Lower and raise coring head several times 13 Shut off engine and check for hydraulic oil leaks Check oil level in hydraulic reservoir and add correct oil if necessary 14 Install pump belt cover to machine see Operator s Manual 15 Operate the machine for two 2 hours under normal operating conditions 16 Check condition of hydraulic oil If the fluid shows any signs of contamination or if you are changing to biode gradable fluid repeat steps 1 through 13 again 17 Resume normal operation and follow recommended maintenance intervals Figure 26 2 Hydraulic manifold Hydraulic filter Hydraulic System 9 5 5 gt lt gt Hydraulic System Start up NOTE Wheninitially starting the hydraulic system with new or rebuilt components such as the hydraulic pump wheel motors or lift cylinder itis importantthat this start up procedure be used This procedure reduces the chance of damaging the hydraulic system or its compo nents from not purging the system of air 1 After the hydraulic system components have been properly installed and if the hydraulic pump was rebuilt orreplaced make sure traction pum
116. linder rod extends the cylinder and raises the coring head When the raise input ends e g coring head is fully raised or raise lower switch is released solenoid valves SVR and SVQ in the hydraulic manifold are de energized The valve shift of SVR allows flow return to the reservoir The valve shift of SVQ removes the by pass to orifice ORF1 The load holding check valve in solenoid valve SVL prevents oil flow from the lift cylinder Without flow to or from the lift cylinder the cylinder and coring head positions are held in place Lower Coring Head When the coring head is to be lowered e g raise lower switch is pressed to lower solenoid valves SVQ and SVL in the hydraulic manifold are energized The valve shift of SVQ allows oil flow to bypass the control man ifold orifice ORF1 for more immediate cylinder move ment The valve shift of SVL allows a path for oil flow from the lift cylinder The weight of the coring head and tension of the weight transfer springs cause the lift cylin der to retract and the coring head to lower Cil flowing from the retracting lift cylinder returns to the reservoir ProCore 648 Page 4 11 When the coring head reaches the aerating position so lenoid valves SVQ and SVL in the hydraulic manifold are de energized The valve shift of SVQ removes the by pass to orifice ORF1 The valve shift of SVL prevents oil flow from the lift cylinder Without flow from the lift cyl inder the cyl
117. location for forward di rection relief would be at the hydraulic hose connec tion to the front wheel motor P1 port B For reverse direction relief pressure test discon nect hose from upper 90 fitting NOTE An alternate testing location for reverse di rection relief would be at the diagnostic port on the hydraulic tube between the rear wheel motors 8 Install Tee fitting with pressure gauge between the traction pump and the disconnected hose 9 Check and adjust the oil level in the reservoir after connecting pressure gauge ProCore 648 4 25 10 One person should operate the machine while another person reads the gauge 11 Make sure that parking brake is engaged Start and run engine at full speed 3400 50 RPM Use extreme caution when conducting test The front wheel of the machine will be trying to move the machine 12 Slowly move traction lever fully in direction of relief valve to be tested forward or reverse IMPORTANT DO NOT hold system at relief for more than 4 seconds 13 Watch the pressure gauge and record pressure when the traction circuit relief valve opens TESTER READING pressure approximately 2900 PSI in both forward and reverse direction 14 Release traction lever and turn off engine Record re sults of hydraulic pressure test 15 If traction pressure is too low inspect relief valves in piston traction pump see the HYDRO GEAR BDP 10A 16A 21L HYDROSTATIC PUMPS SERVICE
118. loosening the fittings 8 If required remove hydraulic fittings and o rings from the wheel motor Discard o rings Installation Fig 35 1 If removed install hydraulic fittings with new o rings into the wheel motor Orientate the fittings as noted dur ing disassembly 2 Position and support wheel motor to the frame A On front wheel motor insert four 4 cap screws through front fork holes and then through motor flange Secure motor to front fork with lock nuts B On rear wheel motor insert four 4 cap screws through holes in parking latch support with parking latch bar installed and then through motor flange and frame Secure motor to frame with lock nuts ProCore 648 Page 4 43 3 If rear wheel motor was removed slide parking latch link through parking latch bar and secure with hair pin Fig 36 4 Remove caps or plugs that were put on any hydraulic lines or fittings during disassembly 5 Install hydraulic lines to hydraulic fittings on wheel motor Tighten connections 6 Make sure that wheel motor shaft and wheel hub ta per are thoroughly cleaned 7 Install woodruff key into motor shaft keyslot Slide wheel hub assembly onto motor shaft Secure wheel hub to motor shaft with nut Torque nut from 190 to 230 ft lbs 258 to 312 A Front hub assembly includes wheel hub bearing plate and wheel studs B Rear hub assembly includes wheel hub bearing plate parking latch disc and wheel
119. ls 1 5 Chapter 2 Product Records and Maintenance Product Records 2 1 2 1 Equivalents and Conversions 2 2 Torque Specifications 2 3 Chapter 3 Kohler Engine Introduction 3 2 Specifications 3 3 General Information 3 4 Adjustments 3 5 Service and Repairs 3 7 KOHLER ENGINE SERVICE MANUAL Chapter 4 Hydraulic System Specifications 4 2 General Information 4 4 Hydraulic Schematic 4 7 Hydraulic Flow Diagrams 4 8 Special Tools 4 12 Troubleshooting 4 14 TESNO x ceste 4 17 Service and Repairs 4 30 HYDRO GEAR BDP 10A 16A 21L HYDROSTATIC PUMPS SERVICE AND REPAIR MANUAL SAUER DANFOSS GROUP 2 GEAR PUMPS AND MOTORS SERVICE MANUAL SAUER DANFOSS OMEW HYDRAULIC MOTOR SERVICE MANUAL ProCore 648 Chapter 5 Electrical System Electrical Diagrams Circuit Operation Special Tools Troubleshooting Electrical System Quick Checks Component Testing Service and Repairs Chapter 6 Chassis Specifi
120. m To clean fuel tank flush tank out with clean solvent Make sure tank is free of contaminates and debris Kohler Engine Page 3 8 ProCore 648 Fuel Tank Removal Fig 5 1 Park machine on a level surface fully raise coring head engage parking brake stop engine and remove key from the ignition switch Secure coring head with service latch 2 Close tank fuel shut off valve Disconnect fuel hose from the fuel filter Fig 6 3 Use shut off valve to empty fuel tank into a suitable container 4 Remove fuel tank using Figure 5 as a guide Fuel Tank Installation Fig 5 1 Install fuel tank to frame using Figure 5 as a guide Apply anti seize lubricant to fuel tank cap screws and torque screws from 30 to 60 3 4 to 6 8 N m 2 Connect fuel hose to the fuel filter 3 Fill fuel tank see Operator s Manual Open fuel shut off valve 4 Return coring head service latch to stored position before using machine 1 Fuel shut off valve 2 Fuel filter ProCore 648 Page 3 9 Figure 6 3 Fuel hose Kohler Engine Exhaust System 1 TZ tao NS 20 N AS SRV 29 lt lt LAS THN BS RENA Y 7 Figure 7 Lock washer 2 used Cap screw 2 used Flange nut 2 used Heat shield Muffler 11 12 13 14 15 75 5 5 9 lt 0 x95 2 9Oa2 Z x o9
121. move traction lever to both forward and reverse directions Hydraulic System Page4 6 Figure 7 1 By pass valve location Figure 8 2 Hydraulic reservoir cap 1 Hydraulic reservoir To relieve lift system pressure turn key switch to ON engine not running Move traction lever to forward di rection and depress lower switch on handle to lower cor ing head onto service latch Return key switch to OFF when pressure has been relieved Remove key from the ignition switch ProCore 648 Hydraulic Schematic gt ORF1 gt CYLINDER CYL SVR G1 e 17 a SVL e Ds es eo e A lore DAES Scere n ae nem ON oe d c ue achte Ste A CONTROL P CHG G2 T MANIFOLD 9 EN FRONT 5 gt WHEEL 20 B PORT em rI FORWARD BOTTOM ra M14 e PORT 7 i AYN M2 e e A PORT TOP _ COMPONENT CIR GPM PSI P1 98 10 5 2900 P2 37 44 PV 40 R1 1000 R2 40 1 23 8 M2 12 1 2 M3 12 1 3 i ORF1 5 050 ProCore 648 Hydraulic Schematic All solenoids are shown as de energized ProCore 648 Page 4 7 Rev C Hydraulic System Hydraulic Flow Diagrams
122. nd Service 1 Before servicing or making adjustments position machine on level surface raise coring head set parking brake stop engine and remove key from the ignition Switch Install the service latch to secure the coring head in the raised position 2 Make sure machine is in safe operating condition by keeping all nuts bolts and screws tight 3 Never store the machine or fuel container inside where there is an open flame such as near a water heat er or furnace 4 Make sure all hydraulic line connectors are tight and all hydraulic hoses and lines are in good condition be fore applying pressure to the hydraulic system 5 Keep body and hands away from pin hole leaks in hy draulic lines that eject high pressure hydraulic fluid Use cardboard or paper to find hydraulic leaks Hydraulic fluid escaping under pressure can penetrate skin and cause injury Hydraulic fluid accidentally injected into the skin must be surgically removed within a few hours by a doctor familiar with this form of injury or gangrene may result 6 Before disconnecting any hydraulic component or performing any work on the hydraulic system all pres sure in system must be relieved See Relieving Hydrau lic System Pressure in the General Information section of Chapter 4 Hydraulic System 7 f major repairs are ever needed or assistance is de sired contact an Authorized Toro Distributor 8 Use care when checking or servicing the coring head w
123. ne on a level surface fully raise coring head engage parking brake stop engine and remove key from the ignition switch Secure coring head with service latch 2 Remove rear hood see Operator s Manual 3 Remove two 2 lock nuts and hardened D washers that secure rotolink damper to coring head frame see Rotolink Dampers in this section 4 If outside stomper arm 1 or 6 is to be removed A If 1 stomper arm is being removed remove sec ondary coring head drive belt see Secondary Drive Belt Removal in this section B Remove cap screw and flat washer that retain stomper arm to coring crankshaft C If 6 stomper arm is being removed remove spacer tube item 12 from coring crankshaft D Support stomper arm assembly to prevent it from falling during removal Slide stomper arm from cor ing crankshaft Carefully lower stomper arm assem bly from frame 5 inside stomper arm 2 3 4 or 5 is to be re moved A Remove fasteners that secure coupling plate to coupling on stomper to be removed Fig 7 B Remove cap screw and flat washer that secures coupling and stomper arm to coring crankshaft C Slide coupling from coring crankshaft Locate and retrieve square key D Support stomper arm assembly to prevent it from falling during removal Slide stomper arm from cor ing crankshaft Carefully lower stomper arm assem bly from frame 6 If necessary remove retaining ring and ball bearing from
124. ng Head 5 6 lt Secondary Drive Belt Figure 12 1 Secondary drive belt 6 Idler pulley 11 Flange nut 2 used 2 Cap screw Idler pivot tube 12 Idler spring arm 3 Secondary pulley 8 Idler arm 13 Extension spring 2 used 4 screw 9 Lock nut 14 Coring crankshaft pulley 5 Flange bushing 10 Carriage screw 2 used 15 1 stomper arm Removal Fig 12 1 Park machine on a level surface fully raise coring head engage parking brake stop engine and remove key from the ignition switch Secure coring head with service latch 2 Remove belt cover and rear hood from machine see Operator s Manual lt Be careful when lifting the idler pulley The idler EI 2 1 Extension springs 3 Upper flange nut pulley is spring loaded and may cause personal 2 Spring arm 4 1 2 drive hole injury Coring Head Page 7 12 ProCore 648 NOTE If desired extension spring tension can be moved from idler pulley by loosening two 2 flange nuts that secure spring arm to frame Use 1 2 drive breaker bar inserted into spring arm to hold arm remove upper carriage screw and flange nut and rotate spring arm to relax spring Fig 13 3 Lift idler pulley to release tension on secondary drive belt Fig 14 While holding idler away from belt remove belt from secondary drive pulley Carefully lower idler pulley 4 Loosen and remove two 2 lock nuts and hardened D washers th
125. ning ring 4 Carriage screw 4 used 10 Thrust washer 5 Spring plate 2 used 11 Cylinder pin 6 Flange nut 4 used 12 Spacer 2 used Removal Fig 41 4 ite 1 Park machine on a level surface fully raise coring head engage parking brake stop engine and remove key from the ignition switch Secure coring head with service latch 2 Remove rear hood see Operator s Manual 3 Remove tine heads from stomper arms to allow cor ing head to be fully lowered The extension spring is under tension and may cause personal injury during removal Use cau tion when disconnecting spring from machine 13 Lift cylinder 14 O ring 15 Hydraulic fitting 16 O ring 17 Hydraulic hose 18 Coring head frame Disconnect the lower end of one extension spring m 2 from frame A Remove service latch from coring head Turn key switch to ON engine not running Move traction le ver to forward direction and depress lower switch on handle to fully lower coring head B Loosen but do not remove both flange nuts item 6 that secure the spring plate item 5 for one of the extension springs C Using a 1 2 breaker bar hold spring plate item 5 to prevent it from moving and remove upper flange nut and carriage screw item 4 from spring plate and coring head frame Fig 42 D Using lower carriage screw and flange nut as a pivot carefully release tension on extension spring by rotating spring plate with breaker bar
126. o a suitable container Discard filter 4 Clean manifold and hydraulic connections Discon nect hydraulic lines Label all connections for assembly 5 Allow hydraulic lines to drain into a suitable contain er Put caps or plugs on disconnected hoses and fittings to prevent contamination Discard any removed rings 6 Remove two 2 cap screws and flange nuts that se cure hydraulic manifold to the frame mounting bracket 7 Remove hydraulic manifold from the machine 8 Remove hydraulic fittings from manifold as needed Fig 39 Installation Fig 38 1 Position hydraulic manifold to the frame mounting bracket Install two 2 cap screws and flange nuts but do not tighten 2 Make sure all hydraulic connections ports and fit tings are clean ProCore 648 Page 4 47 3 Remove caps or plugs that were put on any hydraulic lines or fittings during disassembly 4 Lightly oil new o rings for hydraulic fitting and hose locations 5 Correctly connect hydraulic fittings and lines to the manifold Tighten all hydraulic fittings and connections 6 Secure hydraulic manifold by tightening two 2 cap screws and flange nuts 7 Reconnect solenoid valve electrical connectors 8 Follow Hydraulic System Start up procedures 1 Hydraulic manifold 8 Barbed fitting 2 O ring 9 O ring 3 Hydraulic fitting 10 Hydraulic oil filter 4 O ring 11 Dust cap 2 used 5 O ring 12 Quick fitting 2 used 6 H
127. o move the machine forward 11 Slowly push traction lever in forward direction until 1000 PSI is displayed on the pressure gauge Make sure that wheel motor being tested does not rotate 12 Wheel motor internal leakage will be shown on flow meter in GPM Flow should be less than 1 5 GPM for the tested wheel motor 13 Release traction lever and turn off engine Record re sults of hydraulic flow test 14 11 specifications are not met the tested wheel motor needs to be repaired or replaced as necessary 15 Reconnect hydraulic lines to wheel motor 16 If additional wheel motor s require testing complete steps 6 to 14 for the remaining wheel motor s 17 Disconnect tester from machine Reconnect hose to pump connection be i _ Figure 25 1 Upper 90 fitting 2 Lower 45 fitting Hydraulic System Se E 5 gt 20 lt Service and Repairs General Precautions for Removing and Installing Hydraulic System Components Before Repair or Replacement of Components 1 Before removing any parts from the hydraulic sys tem park machine on a level surface fully raise coring head engage parking brake stop engine and remove key from the ignition switch Secure coring head with service latch 2 Clean machine before disconnecting removing or disassembling any hydraulic components Make sure hydraulic components hoses connections and fittings are cleaned thoroughly Always keep in mind the need for cleanl
128. or mishandling during operation and mainte nance These conditions can cause damage or premature deterioration Some hoses are more suscep tible to these conditions than others Inspect the hoses frequently for signs of deterioration or damage When replacing a hydraulic hose be sure that the hose is straight not twisted before tightening the fittings This can be done by observing the imprint on the hose Use two wrenches hold the hose straight with one wrench and tighten the hose swivel nut onto the fitting with the other wrench Hydraulic Fitting Installation O Ring Face Seal 1 Make sure both threads and sealing surfaces are free of burrs nicks scratches or any foreign material 2 Make sure the O ring is installed and properly seated in the groove It is recommended that the O ring be replaced any time the connection is opened 3 Lubricate the O ring with a light coating of oil 4 Put the tube and nut squarely into position on the face seal end of the fitting and tighten the nut until finger tight 5 Mark the nut and fitting body Hold the body with a Before disconnecting or performing any work on hydraulic system relieve all pressure in system See Relieving Hydraulic System Pres sure in this section Keep body and hands away from pin hole leaks or nozzles that eject hydraulic fluid under high pressure Use paper or cardboard not hands to search for leaks Hydraulic fluid escaping under pressure can h
129. or to the torsion spring of the idler pulley The spring is under heavy load and may cause personal injury 5 Push down on the spring end and unhook the spring from the idler mounting bracket 6 Loosen and remove cap screw item 8 flat washers item 6 and flange nut item 5 that secure clutch strap item 10 to clutch Position clutch strap away from clutch 7 Unplug machine wire harness connector from clutch 8 Remove primary drive belt from pulleys and ma chine ProCore 648 Page 7 11 Installation Fig 11 1 Position drive belt to machine pulleys Make sure that belt is routed under idler pulley 2 Position clutch strap item 10 to clutch and secure with cap screw item 8 flat washers item 6 and flange nut item 5 3 Plug machine wire harness connector into clutch Be careful when removing or applying tension from or to the torsion spring of the idler pulley The spring is under heavy load and may cause personal injury 4 Insert nut driver or small piece of pipe onto the end of the torsion spring item 16 of the idler pulley Push down on the spring end and hook the spring on the idler mounting bracket to tension the idler pulley 5 Install exhaust system shield see Exhaust System Installation in the Service and Repairs section of Chap ter 3 Kohler Engine 6 Install belt cover see Operator s Manual 7 Remove service latch from coring head before using machine Cori
130. ore 648 Page 5 13 NOTE See the Kohler Engine Service Manual for en gine component testing information When testing electrical components for continu ity with a multimeter ohms setting make sure that power to the circuit has been disconnected SWITCH LOCK WASHER Figure 9 Electrical System TO Oo 2 o Wu Engine Oil Pressure Indicator Light The engine oil pressure indicator light is located on the handle control panel Fig 10 The indicator light should come on when the ignition switch is in the ON position with the engine not running Also it should light with the engine running if the engine oil pressure is insufficient IMPORTANT If the engine oil pressure indicator light comes on when the engine is running shut en gine off immediately Testing 1 Turn the ignition switch to ON The engine oil pres sure indicator light should be on 2 If the light is not on locate the oil pressure switch on the engine and disconnect the wire from the switch Ground the disconnected wire to the engine block 3 If the light comes on the oil pressure switch is faulty 4 If the light does not come on check the indicator light and indicating circuit see Electrical Schematic in Chap ter 8 Electrical Diagrams Testing Indicator Light 1 Apply 12 VDC to terminal 1A Fig 11 2 Ground terminal 1B Fig 11 3 Indicator light should illuminate NOTE Fo
131. ored position before using machine ProCore 648 This page is intentionally blank ProCore 648 Page 3 15 Kohler Engine Belt Tensioners Engine Hydraulic pump drive pulley Electric clutch Flange nut Hardened washer Cap screw Flat washer Grommet Spacer 10 Cap screw 11 Clutch strap 12 Cap screw o0 Kohler Engine 41 to 49 ft Ib 55 6 to 66 4 Figure 12 13 Flange nut 14 Flat washer 15 Idler arm assembly 16 Washer 17 spacer 18 arm spacer 19 Torsion spring 20 Idler pulley 21 Hardened washer 22 Cap screw 23 Cap screw Page 3 16 41 to 49 ft lb 2 55 6 to 66 4 N m 23 6 lt 50 to 55 ft lb 67 8 to 74 6 Spacer 750 long Idler mounting bracket Spacer 560 long Lock nut Idler support Flange head screw Spring bracket Spring Flange head screw Idler pulley Bracket fastens to machine frame ProCore 648 Removal Fig 12 1 Release tension on idler torsion spring item 19 Be careful when removing or applying tension from or to the torsion spring of the idler pulley The spring is under heavy load and may cause personal injury A Insert nut driver or small piece of pipe onto the end of the torsion spring B Push down on the spring end and unhook the spring from the idler mounting bracket 2 Remove belt tensioner components from engine as needed using Figure 12 a
132. ountered 8 Raise Coring Head 9 Transport n EE 10 WIRE HARNESS DRAWINGS Wire Harness Drawing 11 Wire Harness 12 rA ua ProCore 648 Page 8 1 Electrical Diagrams This is intentionally blank Electrical Diagrams Page 8 2 648 Electrical Schematic All relays and solenoids are shown as de energized All ground wires are black aBK 1 SPARK PLUG SPARK PLUG HOUR METER HR 3 Raio 2 IGNITION 4 GN MODULES ENGINE CONN FRONT VIO REG 4 GN OIL AC BU 3 START i MAG GN 01 5 CARBURETOR SW ITCH p R 6 Low OIL Aen F GU 2 20 IGN SWITCH OFF PK
133. ousing Figure 25 1 Head high switch 3 Depth control housing 2 Head low switch Figure 26 1 Control module 3 Head high LED 2 Headlow LED Electrical System Page 5 20 ProCore 648 Fuses The fuse block is located behind the console cover Fig 27 Identification Function and Wiring The fuses are held in the fuse block Use Figure 28 to identify each individual fuse and its correct amperage Each fuse holder has the following functions Fuse 1 20 Amp Supplies power to ignition switch terminal B Fuse 2 10 Amp Supplies power to electric clutch Fuse 3 10 Amp Supplies power from ignition switch terminal S Figure 27 Fuse 4 2 Amp Supplies power to aerator control module Testing Remove fuses from the fuse block for testing Fuse should have continuity between fuse terminals 9 on 9 Figure 28 648 5 21 Electrical System Proximity Switches The ProCore 648 uses six 6 identical proximity Switches These switches are normally open switches that close when a sensing plate is positioned near the target end of the switch Fig 32 The reverse and neutral proximity switches are mounted on the control handle under the handle con sole Fig 29 They use sensing plates pinned to the traction lever The transport limit 1 top and 2 switches and aeration 3 and 4
134. ow control valve on tester until pressure gauge reads 1000 PSI As flow control valve is being closed engine speed will drop to approximately 3200 RPM Verify that pump speed is approximately 2500 RPM with a phototac Observe flow gauge TESTER READING A pump in good condition should have a flow of approximately 9 5 GPM 15 flow control valve on tester return trunnion shaft to the neutral position and turn off engine Record results of hydraulic flow test 16 If flow is less than 7 6 GPM or a pressure of 1000 PSI cannot be obtained consider that a pump problem ex ists NOTE Forward traction circuit relief pressure can be determined with the same tester connections as this test See TEST NO 4 Traction Circuit Relief Pressure 17 When testing is complete disconnect tester from lower 45 fitting and hydraulic hose Reconnect hose to fitting Secure pump control assembly to traction pump see Hydraulic Traction Charge Pump Installation in the Service and Repairs section of this chapter Figure 19 1 Lower 459 fitting 2 Hydraulic hose Hydraulic System E 5 52 Traction Circuit Relief Pressure Test Using Tester With Flow Meter and Pressure Gauge LIFT CYLINDER CONTROL MANIFOLD PRESSURE GAUGE FORWARD port Working Pressure Low Pressure Charge NOTE FORWARD TRACTION CIRCUIT Ret
135. own in the chart below With the use of a multimeter ohms setting the switch functions may be tested to determine whether continuity exists between the various terminals for each Switch position Verify continuity between switch termi nals Figure 18 1 Ground follow switch 3 Switch guard 2 Cap screw amp nut SWITCH NORMAL OTHER POSITION CIRCUITS CIRCUITS UP ON DOWN The Aerator Control Module monitors the operation of the ground follow switch If the ground follow switch is in the ON up position the Control Module ground follow LED should be illuminated when the ignition switch is ON Fig 20 If the ground follow switch is in the OFF lower position the Module ground follow output LED should not be illuminated Figure 19 2 oOo 9 Figure 20 1 Control module 2 Ground follow LED ProCore 648 Page 5 17 Electrical System Lift Reset Switch The lift reset switch is located on the control panel Fig 21 This momentary rocker switch raises the coring head in instances when the coring head has been stranded in the aerating lowered position e g engine runs out of gas coring head stuck By depressing the lift reset switch the coring head lift system will reset the coring head will raise fully and normal coring head op eration can resume The switch terminals are marked as shown in Figure 19 The circuitry of the lift reset swit
136. p housing is atleast half full of clean hydraulic oil see Operator s Manual for oil specifications 2 Make sure all hydraulic connections and lines are se cured tightly 3 Make sure hydraulic reservoir is full Add correct oil if necessary see Operator s Manual Drain flush and refill hydraulic system reservoir and change oil filter if component failure was severe or if system is contami nated 4 After repairs check control linkage for proper adjust ment binding or broken parts Correct any problems be fore proceeding 5 Disconnectand ground both engine spark plug wires to prevent engine from starting 6 Make sure traction lever is in neutral Turn ignition key switch to start engage starter for ten 10 seconds to prime hydraulic pump Repeat this step again 7 Reattach both spark plug wires 8 Apply parking brake and make sure traction lever is in neutral Start engine and run at low idle The charge pump should pick up oil and fill the hydraulic system 9 If traction circuit was repaired e g hydrostat or wheel motor was replaced bleed the traction circuit to evacuate air from the circuit NOTE Before bleeding the traction circuit review the following procedure steps A through L completely A Stop engine and relieve pressure in traction cir cuit by moving traction lever to both forward and re verse direction B Jack up machine from floor and support machine with jack stands or blocking to
137. p screw lock washer 3 Set screw 2 Threaded hole Figure 19 1 Flange mount bearing 2 Jackshaft Figure 20 1 Flange mount bearing 3 Setscrew 2 Jackshaft Coring Head 6 Coring Head Pivot H Frame Figure 21 1 Coring frame 6 Jamnut LH thread 11 2 H frame 7 Upper link 12 3 Hexnut 8 Jamnut 13 4 Lock washer 9 Rodend 14 5 Rod end LH thread 10 Flange bushing 4 used 15 Coring Head Page 7 16 Main frame Thrust washer Carriage screw Pivot shaft Flange nut ProCore 648 Disassembly Fig 21 1 Park machine on a level surface fully raise coring head engage parking brake stop engine and remove key from the ignition switch Secure coring head with service latch 2 Remove belt cover and rear hood from machine see Operator s Manual 3 Chock wheels to prevent the machine from moving 4 Remove tine heads from stomper arms to allow cor ing head to be fully lowered The extension springs are under tension and may cause personal injury during removal Use caution when disconnecting springs from ma chine 5 Disconnect the upper end of both extension springs from spring plates on coring head frame Fig 22 A Remove service latch from coring head Turn key Switch to ON engine not running Move traction le ver to forward direction and depress lower switch on handle to fully lower coring head B Loosen but do not remove both fl
138. pecifications identified in Figures 8 and 10 3 Coupling 2 shown 7 Lock nut 2 used 4 Cap screw 2 used 8 Flat washer 2 used A Cap screws that fasten crankarms B Cap screws that secure top and bottom of stomp er arms C Cap screws that secure coupling plates Fig 10 ProCore 648 Page 7 9 Coring Head 6 Primary Drive Belt Primary drive belt Electric clutch Hardened washer Cap screw Flange nut Flat washer Brake grommet Cap screw Spacer i Coring Head 50 to 55 ft Ib a 67 8 to 74 6 N m Figure 11 Clutch strap Idler mounting bracket Lock nut Cap screw Hardened washer Idler pulley Torsion spring Spacer Page 7 10 18 19 20 21 22 Flat washer 24 25 Flange bushing Pivot sleeve Idler spacer Washer arm Cap screw Flange nut ProCore 648 Removal Fig 11 1 Park machine on a level surface fully raise coring head engage parking brake stop engine and remove key from the ignition switch Secure coring head with service latch 2 Remove belt cover see Operator s Manual 3 Remove exhaust system shield see Exhaust Sys tem Removal in the Service and Repairs section of Chapter 3 Kohler Engine 4 Insert nut driver or small piece of pipe onto the end of the torsion spring item 16 of the idler pulley Be careful when removing or applying tension from
139. pool assembly 2 Install the nut onto the spool assembly and torque nut 5 ft lb 6 8 do not over tighten 3 Connect the solenoid coil to the machine wiring har ness Figure 41 1 Solenoid valve coil SVL 4 Nut 2 Solenoid valve coil SVQ 5 Nut 3 Solenoid valve coil SVR Electrical System Page 5 34 ProCore 648 Chapter 6 TORO Chassis Table of Contents SPECIFICATIONS 2 SPECIALE TOOLS 3 SERVICE AND REPAIRS 4 Wheels rinse dawns we Ee aE 4 Parking Brake 6 Parking Brake Cable 8 Steering Assembly 10 Traction Control Cable 12 ProCore 648 Page 6 1 Chassis Specifications Item Description Front and Rear Tires Size Pressure 19 x 10 5 8 2 Ply Tubeless 12 PSI 83 Bar Wheel lug nut torque 45 to 55 ft lb 61 to 75 N m Wheel hub nut torque 190 to 230 ft lb 258 to 312 Chassis Page 6 2 ProCore 648 Special Tools Order special tools from your Toro Distributor Wheel Hub Puller Part Number TOR4097 The wheel hub puller allows safe removal of the wheel hub from the shaft of wheel motors Figure 1 ProCore 648 Page 6 3 Rev C Chassis Service and Repairs Wheels 45 to 55 ft lb 61 to 75 N m 45 to 55 ft lb 61 to 75 N m
140. position The OK to lower input LED should be illuminated when the OK to lower circuit is closed see OK to Lower Cir cuit in the Circuit Operation section of this chapter Electrical System Page 5 24 Power input LED SVL output LED SVR output LED SVQ output LED Head low input LED 1 2 3 4 5 2 Control module Head high input LED Transport 1 input LED Aerate 4 input LED Ground follow ON LED OK to lower input LED ProCore 648 Control Module Outputs 1 The SVQ output LED will be illuminated in two situa tions A Both OK to lower and transport 1 LED s are not illuminated B OK to lower LED is illuminated and aerate 4 LED is not illuminated 2 The SVL output LED will be illuminated in three situa tions A OK to lower LED is illuminated and ground fol low LED is not illuminated B Both OK to lower and ground follow LED s are illuminated and aerate 4 LED is not illuminated C OK to lower ground follow aerate 4 and head high limit LED s are all illuminated ProCore 648 Page 5 25 3 The SVR output LED will be illuminated in two situa tions A Both OK to lower and transport 1 LED s are not illuminated B OK to lower ground follow aerate 4 and head low limit LED s are all illuminated Electrical System 6 m 9 5 Electric Clutch An electric clutch is used to engage the coring head on the ProCore
141. r Discard o ring Installation Fig 41 1 If removed install hydraulic fitting and new o ring into lift cylinder 2 Position lift cylinder to the machine mounting points Make sure the port of the lift cylinder faces the front of the machine 3 Align lower lift cylinder mounting hole with frame mount Install cylinder pin and secure with retaining ring 4 Align upper lift cylinder pivot with slots in the coring head frame Install cylinder pin making sure that a spacer is on each side of the cylinder pivot and a thrust washer is positioned between coring head frame and re taining ring Fig 43 Secure with retaining ring 5 Remove plugs from disconnected hose and fitting 6 Connect hydraulic hose with new o ring to hydraulic fitting on lift cylinder Tighten hose connection 7 Install disconnected extension spring to machine in reverse order of disassembly 8 Install rear hood 9 Install tine heads to stomper arms see Operator s Manual 10 Follow Hydraulic System Start up procedures 2 5 5 gt lt Figure 42 1 Extension spring 3 Lower carriage screw 2 Upper carriage screw 4 1 2 drive hole Figure 43 1 Lift cylinder shaft 3 Cylinder pin 2 Thrust washer 4 Spacer ProCore 648 Page 4 51 Hydraulic System Lift Cylinder Service Figure 44 1 Retaining ring 4 O ring 2 Cylinder tube 3 Rod Disassembly Fig 44 1 Remove oil from the lift cylinder
142. r item 15 Torque lock nuts item 7 from 150 to 170 ft lb 203 to 230 B Tighten two 2 flange nuts item 12 that secure damper links C Tighten two 2 lock nuts item 1 that secure damper to frame 4 After assembly rotate coring crankshaft by hand to make sure that no binding occurs NOTE If using longer solid tines damper top spacer item 17 might not be installed see Operator s Manu al 5 If damper standoff item 16 and top spacer item 16 are both installed on rotolink damper rubber bumpers item 16 should contact bumper plates item 5 If only damper standoff item 16 is used rubber bumpers should contact frame bumper plates moved forward 6 Remove service latch from coring head before using machine Coring Head 5 6 lt Stomper Arms 150 to 170 ft Ib 203 to 230 N m ANTISIEZE LUBRICANT STOMPER ARMS 1 AND 2 SHOWN Figure 5 1 Coring frame 5 Ball bearing 9 Crankarm 2 screw 6 Stomper arm 10 Square key 3 Flat washer 7 Pulley 11 Coupling 4 Retaining ring 8 Bearing housing 12 Spacer tube NOTE The six 6 stomper arms used on the ProCore 648 are identical Coring crankshaft positions are identi fied as 1 through 6 The 1 position is on the right pulley side of the coring crankshaft Fig 6 Figure 6 1 1 position 2 6 position Coring Head Page 7 6 648 Removal Fig 5 1 Park machi
143. r Circuits The gear pump P2 is attached to the traction pump P1 and is directly coupled to it The gear pump supplies hydraulic flow for maintaining charge pressure of 40 PSI 2 8 Bar to the low pressure side of the traction circuit and also for raising the aerator coring head The gear pump takes its suction from the hydraulic reservoir Maximum lift lower circuit pressure is limited to 1000 PSI 69 Bar by relief valve R1 in the lift control manifold Flow from gear pump P2 goes to the lift control man ifold port P and is directed to pressure compensating valve PV Valve PV ensures that sufficient hydraulic flow is always available to the traction circuit for charge oil When not raising the coring head gear pump flow in excess of charge circuit needs is directed to the hydrau lic oil filter and then returns to the hydraulic reservoir Raise Coring Head When the coring head is to be raised e g traction lever is released from forward or raise lower switch is pressed to raise solenoid valves SVR and SVQ in the hydraulic manifold are energized The valve shift of SVR prevents gear pump flow return to the reservoir The valve shift of SVQ allows oil flow to bypass the control manifold orifice ORF1 for more immediate cylinder movement flows through the load holding check valve in solenoid valve SVL to direct gear pump flow out of control man ifold port CYL to the lift cylinder Hydraulic pressure against the lift cy
144. r engine oil pressure switch information refer to the Kohler Engine Service Manual at the end of Chap ter 3 Engine Hour Meter The hour meter used on the ProCore 648 uses an induc tive pickup wire connected to the rear spark plug wire to sense when the engine is running The hour meter should increase 1 10 of an hour every six 6 minutes of engine running time The hour meter uses its own internal battery and there fore is not connected to the ProCore 12 volt electrical system The hour meter battery is not replaceable Electrical System Page 5 14 Figure 10 1 Oil pressure indicator light 1B 1A BACK OF INDICATOR LIGHT Figure 11 Figure 12 1 Hour meter ProCore 648 Relays Six 6 relays are used on the ProCore 648 Four 4 of these relays are attached under the control panel next to the battery Fig 13 lockout relay clutch relay neutral switch start relay and lockout latch relay The remain ing two 2 relays are attached under the handle console Fig 14 neutral switch latch relay and latching relay The six relays are identical The relays are identified by a tag on the wire harness relay connector See the Circuit Operation section of this Chapter for in formation on relay operation Testing NOTE Prior to taking small resistance readings with a Figure 13 digital multimeter short the meter test leads together 1 Battery 2 Relay location The meter will d
145. r heads B Remove four 4 cap screws and flange nuts that secure the engine to the machine frame One person should operate lift or hoist while another person guides the engine out of the ma chine IMPORTANT Make sure not to damage the engine fuel hoses hydraulic lines electrical harness or other parts while removing the engine C Remove engine from the machine 11 needed remove electric clutch see Electric Clutch in the Service and Repairs section of Chapter 5 Electri cal System and hydraulic pump drive pulley from en gine Fig 11 12 11 needed remove belt tensioning components from engine see Belt Tensioners in this section Figure 9 1 Solenoid stud 3 Harness red wire 2 Positive battery cable Figure 10 1 Flange head screw 3 Negative battery cable 2 Wire harness ground Anti seize Lubricant 3 50 to 55 ft lb 67 8 to 74 6 N m Figure 11 1 Engine 4 Hardened washer 2 Pump pulley 5 Cap screw 3 Electric clutch ProCore 648 Page 3 13 Kohler Engine Installation Fig 8 1 Locate machine on a level surface with key removed from the ignition switch Chock wheels to keep the ma chine from moving 2 Make sure that all parts removed from the engine during maintenance or rebuilding are reinstalled to the engine 3 If electric clutch and hydraulic pump drive pulley were removed from engine crankshaft Fig 11 A Apply anti seize lubricant to crankshaft
146. r should be secured to third hole from out er end of traction lever Fig 30 2 Place two 2 flat washers to tops of studs on pump control assembly Position pump shield to pump and se cure with two 2 lock nuts 3 Install pump belt cover to machine see Operator s Manual 4 Check traction drive for neutral and adjust if needed see Operator s Manual 5 Operate machine and verify hole spacing accuracy Adjust if needed see Operator s Manual ProCore 648 gt 1 4 37 Figure 29 7 Trunnion clamp 8 Socket hd screw 2 used 9 Washer head screw 10 Lock nut 11 Pump shield Hydraulic pump Cap screw 2 used Control bracket Flange nut 2 used Flat washer Pump lever 2 5 5 gt lt Figure 30 2 Rod end location Damper Hydraulic System Hydraulic Traction Charge Pump Anti seize lubricant Figure 31 1 Hydraulic traction charge pump 11 Flange nut 21 O ring 2 O ring 12 Tensioning spring 22 Flange nut 2 used 3 O ring 13 Set screw 23 45 hydraulic fitting 4 90 hydraulic fitting 14 Pump pulley 24 O ring 5 Engine 15 Pump drive belt 25 O ring 6 Engine pulley 16 L bracket 26 Hydraulic adapter 7 Flange head screw 17 Flange head screw 27 O ring 8 Spring bracket 18 Flange head screw 2 used 28 90 hydraulic fitting 9 Idler support bracket 19 O ring 29 Hydraulic fitting 10 Idler pulley 20 90 hydraulic fitting 30 Ke
147. re control linkage is functioning properly before conducting hydraulic tests 11 All hydraulic tests should be made with the hydraulic oil at normal operating temperature Hydraulic System E 5 52 Charge Pressure Test Using Pressure Gauge LIFT CYLINDER ere CONTROL MANIFOLD 4 t FRONT WHEEL PORT oN P 14 PPOR 7 el P PORT P PORT SOS M2 Working Pressure Low Pressure Charge Return or Suction Flow Direction Figure 13 Hydraulic System 4 18 Rev C 648 Procedure for Charge Pressure Test 1 Make sure hydraulic oil is at normal operating tem perature by operating the machine for approximately 10 minutes 2 Park machine on a level surface with the coring head fully raised Make sure engine is off and the parking brake is engaged Secure coring head with service latch 3 Read Precautions For Hydraulic Testing in this sec tion Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hy draulic oil 4 Connect pressure gauge to the hydraulic control manifold G2 port quick fitting Fig 14 If using pressure gauge with hose make sure that hose is free of the left rear wheel after installation 5 Make sure that traction lever is in neutral and the parking brake is enga
148. ring head before machine use 6 5 If front wheel was removed A If weight studs were removed from wheel weight adapters thread studs fully into the correct end of the adapter Fig 3 B Position front wheel to wheel hub C Secure wheel to machine with two 2 lug nuts and two 2 wheel weight adapters Torque wheel fasteners from 45 to 55 ft lb 61 to 75 To prevent personal injury make sure that wheel weight is supported as it is installed to the machine Wheel weight weighs approxi mately 73 pounds 33 1 kg D Carefully slide wheel weight to wheel E Secure wheel weight with two 2 thrust washers and lock nuts Lower machine to ground Remove service latch WHEEL STUD 500 20 UNF 2B WEIGHT STUD 500 13 UNC 2B Figure 3 Chassis Parking Brake Extension spring Bushing Retaining ring Parking latch pivot Flange nut Shoulder bolt Compression spring Parking latch clevis Chassis 10 11 12 13 Tire and wheel assembly 15 Figure 4 Hair pin Parking latch link Roll pin Parking latch bar Lock nut Lug nut 4 used per wheel Page 6 6 190 to 230 ft lb 258 to 312 45 to 55 ft lb 61 to 75 N m Bearing plate Wheel hub Parking latch disc Drive stud 4 used per wheel Woodruff key Parking brake cable Clevis pin ProCore 648 Removal Fig 4 1 Park
149. ring to parking latch pivot The spring is under heavy load and may cause personal injury 1 Install removed parking brake components using Figure 4 as a guide 2 If wheel hub assembly was removed A Make sure that wheel studs are installed through parking latch disc wheel hub and bearing plate B Make sure that wheel motor shaft and wheel hub taper are thoroughly cleaned C Position woodruff key into wheel motor shaft D Install wheel hub assembly to wheel motor shaft and secure with nut Torque nut from 190 to 230 ft lb 258 to 312 N m 3 Install wheel assembly see Wheel Installation in this section 4 Lower machine to ground Remove service latch from coring head before machine use Chassis Parking Brake Cable Figure 5 1 Control handle 6 Flange nut 11 Bushing 2 Grommet 7 Brake cable 12 Brake spacer 3 Steering arm 8 Flat washer 13 Cap screw 4 Lower handle cover 9 Cotter pin 14 Knob 5 Washer head screw 6 used 10 Brake lever Chassis Page 6 8 648 Removal Fig 3 1 Park machine on a level surface fully raise coring head stop engine and remove key from the ignition switch Secure coring head with service latch Make sure that parking brake is not engaged 2 Remove six 6 washer head screws that secure low er handle cover to control handle Remove lower handle cover 3 Loosen jam nut that secures parking brake cable to underside of control handle
150. roblems in the hydraulic system is by using hydraulic test equipment such as pressure gauges and flow meters in the circuits during various operational checks see Special Tools section in this Chapter Failure to use gauges with recommended pres sure PSI Bar rating as listed test procedures could result in damage to gauge and possible personal injury from leaking hot oil Before Performing Hydraulic Tests All obvious areas such as oil supply filter binding link age loose fasteners improper adjustments or improper operation must be checked before assuming that a hy draulic component is the source of the problem being experienced Precautions For Hydraulic Testing Before disconnecting or performing any work on the hydraulic system all pressure in the system must be relieved See Relieving Hydrau lic System Pressure in the General Information section of this chapter Keep body and hands away from pin hole leaks or nozzles that eject hydraulic fluid under high pressure Use paper or cardboard not hands to search for leaks Hydraulic fluid escaping under pressure can have sufficient force to penetrate skin and cause serious injury If fluid is injected into the skin it must be surgically removed within a few hours by a doctor familiar with this type of injury Gangrene may result from such an injury ProCore 648 Page 4 17 1 Thoroughly clean the machine before disconnecting or disassembling any hydrauli
151. rque from 180 to 200 in Ib 20 3 to 22 6 in three equal steps and in a circular pattern to secure primary pulley and taper lock bushing 6 Position jackshaft to align primary pulley and electric clutch pulley on engine 7 Using the blind hole in flange mount bearing locking collars as a striking point lock collars to jackshaft by ro tating the collars with a punch in the direction of jack shaft rotation Fig 20 Tighten set screw item 11 to secure each bearing locking collar to jackshaft 8 Position secondary pulley on jackshaft to align sec ondary pulley and coring head pulley Secure in position with taper lock bushing set screw IMPORTANT When tightening bushing cap screws tighten in three equal steps and in a circular pattern 9 Secure taper lock bushing by tightening three 3 cap screws to a torque from 180 to 200 in Ib 20 3 to 22 6 in three equal steps and in a circular pattern to se cure secondary pulley and taper lock bushing ProCore 648 Page 7 15 10 Install primary and secondary drive belts to jackshaft pulleys see Primary Drive Belt Installation and Secon dary Drive Belt Installation in this section 11 Check that belt alignment is still correct If needed readjust pulley location on jackshaft 12 Install belt cover and rear hood to machine see Op erators Manual Remove service latch from coring head before using machine ROTATION t DIRECTION Si Figure 18 1 Ca
152. s and every 30 days if machine is in storage 6 Maintain cell electrolyte level with distilled or demin eralized water Do not fill cells above the fill line ProCore 648 Battery Service The battery is the heart of the electrical system With regular and proper service battery life can be extended Additionally battery and electrical component failure can be prevented When working with batteries use extreme cau tion to avoid splashing or spilling electrolyte Electrolyte can destroy clothing and burn skin or eyes Always wear safety goggles and a face shield when working with batteries Battery Specifications BCI Group Size UI 300 CCA at 0 F 18 Reserve Capacity of 28 minutes at 809 27 Dimensions including terminal posts and handle Length 7 7 inches 19 6 cm Width 5 2 inches 13 2 cm Height 7 2 inches 18 3 cm Electrolyte Specific Gravity Fully charged 1 265 corrected to 80 F 26 79C Discharged less than 1 240 Removal and Installation Fig 38 1 Loosen and remove negative cable from battery After negative cable is removed loosen and remove positive cable 2 Remove wing nuts and washers that secure battery hold down rod Slide hold down rod away from battery 3 Carefully remove battery from machine 4 Install battery in reverse order making sure to con nect positive cable to battery before connecting neg ative cable NOTE Before connecting the negativ
153. s a guide ProCore 648 Page 3 17 Installation Fig 12 1 Install belt tensioner components to engine using Figure 12 as a guide 2 Install the hydraulic pump drive belt and primary drive belt coring head 3 Apply tension to idler torsion spring item 19 A Insert nut driver or small piece of pipe onto the end of the torsion spring B Push down on the spring end and hook the spring under the idler mounting bracket notch Release the spring slowly to lock it into place 4 Adjust the hydraulic pump drive belt see Operator s Manual and primary drive belt coring head see Pri mary Drive Belt in the Service and Repairs section of Chapter 7 Coring Head Kohler Engine This page is intentionally blank Kohler Engine 3 18 ProCore 648 TORO Table of Contents SPECIFICATIONS 2 GENERAL INFORMATION 4 Hydraulic Hoses 4 Hydraulic Fitting Installation 4 Pushing Pulling Machine 6 Check Hydraulic Fluid 6 Relieving Hydraulic System Pressure 6 HYDRAULIC SCHEMATIC 7 HYDRAULIC FLOW DIAGRAMS 8 Traction 8 Coring Head Raise Lower Circuits 10 SPECIAL TOOLS cte eene Ee 12 Hydraulic Pressure Test Kit 12 Hydraulic Tester Pre
154. s and pulleys from the jackshaft Locate and retrieve woodruff keys item 6 that locate bushings on jackshaft ProCore 648 NOTE Jackshaft rotates counterclockwise as viewed from right side of machine Fig 18 7 Loosen set screw that secures each flange mount bearing locking collar to jackshaft Using the blind hole in bearing collar as a striking point unlock collar from jackshaft by rotating the collar in the opposite direction of jackshaft rotation with a punch Fig 19 8 Slide flange mount bearings from jackshaft Installation Fig 17 1 Make sure that tapered surfaces of pulleys and taper lock bushings are thoroughly clean no oil grease dirt rust etc 2 Slide flange mount bearings onto jackshaft 3 Place woodruff keys item 6 in jackshaft Slide pul leys and taper lock bushings onto jackshaft making sure that tapered surfaces of pulley and bushing align Align threaded holes of pulley with non threaded holes of bushing Loosely install three 3 cap screws with lock washers to both bushing and pulley assemblies 4 Position jackshaft assembly to machine frame Se cure flange mount bearings to frame with cap screws and lock nuts IMPORTANT When tightening bushing cap screws tighten in three equal steps and in a circular pattern to prevent bushing flange damage 5 Align taper lock bushing in primary pulley flush with end of jackshaft and secure with set screw Tighten three 3 cap screws to a to
155. s for diagnostic tests Quick disconnect fittings provided attach directly to mating fittings on machine test ports without tools A high pressure hose is provided for remote readings Contains one each 1000 PSI 70 Bar 5000 PSI 350 Bar and 10000 PSI 700 Bar gauges Use gauges as recommended in Testing section of this chapter Hydraulic Tester Pressure and Flow Toro Part Number TOR214678 This tester requires O ring Face Seal ORFS adapter fittings for use on this machine see Hydraulic Test Fit ting Kit 4079 in this section 1 INLET HOSE Hose connected from the system cir cuit to the inlet side of the hydraulic tester 2 LOAD VALVE A simulated working load is created in the circuit by turning the valve to restrict flow 3 LOWPRESSURE GAUGE Low range gauge to pro vide accurate reading at low pressure 0 to 1000 PSI A protector valve cuts out when pressure is about to exceed the normal range for the gauge The cutout pressure is adjustable 4 HIGH PRESSURE GAUGE High range gauge which accommodates pressures beyond the capacity of the low pressure gauge 0 to 5 000 PSI 5 FLOW METER This meter measures actual oil flow in the operating circuit with a gauge rated at 15 GPM 6 OUTLET HOSE A hose from the outlet side of the hydraulic tester connects to the hydraulic system circuit Hydraulic System Page4 12 Rev C Figure 9 Figure 10 ProCore 648 Hydraulic Test Fitting Kit Part Numb
156. sed suddenly 6 Clean cartridge valve by submerging valve in clean mineral spirits to flush out contamination Particles as fine as talcum powder can affect the operation of high pressure hydraulic valves If cartridge design allows use a wood or plastic probe to push the internal spool in and out 20 to 30 times to flush out contamination Be ex tremely careful not to damage cartridge Use com pressed air for cleaning 7 Reinstall the cartridge valve A Lubricate new seal kit components with clean hy draulic oil and install on valve The o rings sealing rings and backup rings must be arranged properly on the cartridge valve for proper operation and sealing IMPORTANT Use care when handling the valve cartridge Slight bending or distortion of the stem tube can cause binding and malfunction B Thread cartridge valve carefully into correct man ifold port The valve should go in easily without bind ing C Torque cartridge valve using a deep socket to val ues identified in Figure 40 8 If solenoid cartridge was removed carefully install solenoid coil onto the cartridge valve Install nut and torque nut to 5 ft lb 6 8 9 After assembly if problems still exist remove valve and clean again or replace valve Hydraulic System 2 55 Ow ESA zo Lift Cylinder Figure 41 1 Main frame 7 Clevis pin 4 used 2 Shackle 4 used 8 Hair pin 4 used 3 Extension spring 2 used 9 Retai
157. ssure and Flow 12 Hydraulic Test Fitting 13 Wheel Hub Puller 13 TROUBLESHOOTING 14 TESTING D eerte ae EAR 17 Charge Pressure 18 Coring Head Raise Lower Relief R1 Pressure Test 20 Traction Piston Pump P1 Flow Test 22 Traction Circuit Relief Pressure Test 24 Gear Pump P2 Flow Test 26 Wheel Motor Efficiency Test 28 ProCore 648 Page 4 1 Chapter 4 Hydraulic System SERVICE AND REPAIRS 30 General Precautions for Removing and Installing Hydraulic System Components 30 Check Hydraulic Lines and Hoses 30 Flush Hydraulic System 31 Hydraulic System Start up 32 Hydraulic Pump Drive 34 Hydraulic Pump Control Assembly 36 Hydraulic Traction Charge Pump 38 Hydraulic Traction Charge Pump Service 41 Wheel 5 42 Wheel Motor Service 44 Hydraulic Lift Control Manifold 46 Hydraulic Lift Control Manifold Service 48 Lift Cylinder 50 Lift Cylinder Service 52 Hydraulic Reservoir 54 HYDRO GEAR BDP 10A 16A 21L HYD
158. stomper arm 7 f necessary remove tines and tine holders from stomper arm see Operator s Manual 8 Remove rotolink damper components as needed see Rotolink Dampers in this section Installation Fig 5 and 7 1 If removed install ball bearing into upper end of stomper arm and secure with retaining ring 2 Install any rotolink damper components that were re moved during disassembly see Rotolink Dampers in this section 3 Thoroughly apply antisieze lubricant to stomper arm shaft surface on coring crankshaft 4 Raise stomper arm assembly up through frame Slide stomper arm bearing onto coring crankshaft 5 Secure stomper arm to coring crankshaft in the re verse order of disassembly A Torque 5 8 cap screws from 150 to 170 ft lb 203 to 230 N m B Torque 1 2 cap screws from 70 to 80 ft lb 95 to 108 6 Secure rotolink damper to coring head frame with lock nut and hardened D washer see Rotolink Dampers in this section 7 After assembly rotate coring crankshaft by hand to make sure that no binding occurs 8 If removed install tine holders and tines to stomper arm see Operator s Manual 9 If removed install secondary coring head drive belt see Secondary Drive Belt Installation in this section 10 Install rear hood see Operators Manual Disen gage service latch before machine use 150 to 170 ft lb 203 to 230 N m E 4 70to80ft Ib 95 to 108 Figure 7 1
159. studs 8 Install wheel to machine see Wheel Installation in Service and Repairs section of Chapter 6 Chassis Tighten lug nuts from 45 to 55 ft lb 61 to 75 9 Follow Hydraulic System Start up procedures Figure 36 1 Parking latch link 2 Hair pin 3 Parking latch bar 4 Parking latch support 5 Wheel motor shaft Hydraulic System 5 5E Ga 52 zo Wheel Motor Service Figure 37 1 Dust seal 9 O ring 16 Cardan shaft 2 Housing 10 Spring washer 17 O ring 3 O ring 11 Balance plate 18 Gearwheel set 4 Shaft seal 12 Disc valve 19 End cover 5 Axial needle bearing 13 Needle bearing 20 Name plate 6 Bearing race 14 Bearing race 21 Washer 7 used 7 Needle bearing 15 Distributor plate 22 Cap screws 7 used 8 Shaft NOTE The three wheel motors on the ProCore 648 are similar in construction but are different from each other The front wheel motor 24 c i per revolution has a differ ent displacement than the rear motors and has a count er clockwise direction for the forward direction The right and left rear wheel motors have the same displace ment 12 c i per revolution but have different rotation for the forward direction the right rear has a clockwise drive direction for forward and the left rear has a count er clockwise direction Displacement and primary rota tion forward direction are identified on the motor name plate Hydraulic System Page 4 44 N
160. surface fully raise coring head engage parking brake stop engine and remove key from the ignition switch Secure coring head with service latch 2 Remove pump belt cover from machine see Opera tor s Manual 3 Remove coring head primary drive belt from electric clutch see Primary Drive Belt Removal in Service and Repairs section of Chapter 7 Coring Head 4 Loosen the flange head screw item 6 and flange nut item 10 that secure the drive belt idler pulley item 11 Lift idler pulley to allow removal of drive belt from the pul leys and the machine ProCore 648 Page 4 35 Drive Belt Installation Fig 27 1 Install pump drive belt to pulleys 2 Lift idler pulley and insert pump drive belt under idler 3 Allow tensioning spring to apply tension to idler pulley Tighten flange head screw item 6 and flange nut item 10 to secure belt adjustment 4 Install coring head primary drive belt to electric clutch see Primary Drive Belt Installation in Service and Re pairs section of Chapter 7 Coring Head 5 Install pump belt cover to machine see Operator s Manual Hydraulic System 9 5 gt Hydraulic Pump Control Assembly Hydraulic pump Cap screw 2 used Flange nut Lock nut Flange nut 2 used Control bracket Washer head screw Lock nut Extension spring 10 Speed selector pivot 11 Retaining ring 12 Swivel 13 Cap screw o o m OON Hydraulic System
161. t 12 Coring Head Drive Jackshaft 14 Coring Head Pivot H Frame 16 5 6 lt 648 Page 7 1 Coring Head General Information Coring Head Operation The coring head of the Procore 648 consists of a frame that pivots for aerating depth control a coring crank shaft stomper arms with rotolinks to provide vertical tine motion turf holders tine holders and aerating tines Drive for the coring head comes from the engine mounted electric clutch through a primary and secon dary drive belt The primary drive belt drives a jackshaft which in turn drives the coring crankshaft with the secon dary drive belt Each of these drive belts is tensioned by a spring loaded idler pulley The coring crankshaft is composed of multiple crank arms bearings bearing housings and couplings For assembly purposes proper component position is iden tified by alignment marks on bearing housings and num bers cast into crankarms Crankshaft journals are timed to ensure minimal vibration Aerating depth control is based on tine choice and han dled automatically by the TrueCore ground following system Manual depth control aeration can be per formed by turning the TrueCore System off and ad justing the coring head manual spacers to obtain the desired aerating depth 1 2 increments Turf holders are used to prevent damage to the turf as the
162. t P proportional valve PV and man ifold port CHG and past the charge circuit check valve in the return side of the traction circuit Proportional valve PV ensures that sufficient gear pump flow is al ways available for the charge oil needs of the traction cir cuit Gear pump flow in excess of charge circuit needs is available to raise lower the coring head After charge and raise lower requirements are met excess P2 flow is directed to the hydraulic reservoir through the hydrau lic oil filter Forward Direction With the engine running and the traction lever in the neu tral position the traction pump supplies no flow to the wheel motors When the traction lever is moved to the forward position the linkage from the lever positions the swash plate in the traction pump so oil flows out the low er port of the pump flow from the pump is directed to the wheel motors front motor first and then rear mo tors and turns them in the forward direction Maximum forward traction pressure is limited by a 2900 PSI 200 Bar relief valve located in the bottom of the pump as sembly Oil flowing from the rear wheel motors returns to the top port of the traction pump and is continuously pumped out the bottom port as long as the traction lever is held in the forward direction ProCore 648 4 9 Reverse Direction The traction circuit operates essentially the same in re verse as it does in the forward direction However the flo
163. test leads Subtract this val ue from from the measured value of the component you are testing 5 Using a multimeter ohms setting verify clutch coil resistance between the two terminals of the clutch wire connector Coil resistance should be 1 75 to 1 93 ohms 6 If coil resistance is incorrect replace clutch 7 Measure gap between clutch rotor and armature Fig 36 Gap should be less than 125 3 18 mm This gap is not adjustable and increases as clutch compo nents wear If gap exceeds 125 3 18 mm replace clutch Electrical System Page 5 26 8 As an additional test apply 12 volts to the terminals of the clutch The clutch should engage If clutch does not engage when voltage is applied replace clutch 9 If clutch removal is necessary see Electric Clutch in the Service and Repairs section of this chapter 10 Install exhaust system shield see Exhaust System Installation in the Service and Repairs section of Chap ter 3 Kohler Engine 11 Install pump belt cover to machine see Operator s Manual Figure 35 1 Electric clutch Figure 36 2 Feeler gauge 1 Electric clutch ProCore 648 Diode Assemblies Diodes D1 D2 and D3 provide logic for the latch relays used in the ProCore 648 Diode D4 is used for circuit protection from voltage spikes when the electric clutch is de energized The diodes plug into the wiring har ness at various locations see Wire Harness Drawings in Chapter
164. thing immovable in the shop to prevent the machine from moving during testing Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hy draulic oil 8 Clean hose fitting and disconnect hydraulic hose from the lower 45 fitting on the rear side of the traction pump Fig 19 NOTE An alternate testing location would be at the hy draulic hose connection to the P1 port of the front wheel motor IMPORTANT Make sure oil flow indicator arrow on the flow meter is showing that the oil will flow from the traction pump through the tester and into the disconnected hose 9 Install hydraulic tester with flow meter and pressure gauges in series with the traction pump and the discon nected hose Make sure flow control valve on the tester is fully open 10 Check and adjust the oil level in the reservoir after connecting hydraulic tester 11 One person should operate the machine while another person reads the tester 12 Start and run engine at full speed 3400 50 RPM Use extreme caution when conducting test The wheels of the machine will be trying to move the machine forward IMPORTANT Do not rotate the traction pump trun nion shaft clockwise reverse during testing 13 Using a wrench slowly rotate traction pump trunnion shaft counter clockwise to the fully forward position ProCore 648 Page 4 23 Rev B 14 While holding trunnion shaft fully counter clockwise close fl
165. time giv en in Charging or until all cells specific gravity is 1 225 or greater with the difference in specific gravity between the highest and lowest cell less than 0 050 If these charging conditions can not be met replace the battery ProCore 648 Charging To minimize possible damage to the battery and allow the battery to be fully charged the slow charging meth od is presented here This charging method can be ac complished with a constant current battery charger which is available in most shops Follow the manufacturer s instructions when us ing a battery charger NOTE Using specific gravity of the battery cells is the most accurate method of determining battery condition 1 Determine the battery charge level from either its specific gravity or open circuit voltage Level Voltage 2 Determine the charging time and rate using the manufacturer s battery charger instructions or the following table Specific Gravity 1 265 1 225 1 190 1 155 1 120 Battery Reserve Capacity Minutes 80 or less 3 8 hrs 7 5 hrs 11 3 hrs 15 3 amps 3amps 81 to 125 5 3hrs 10 5 hrs 15 8hrs 21 hrs 4 4amps 4 amps 4 amps Battery Charge Level Percent of Fully Charged 126 to 5 5 hrs 11 hrs 16 5hrs 22 hrs 170 2 2 2 5 amps 5 amps 5 amps 5 amps 171 to 5 8hrs 11 5 hrs 17 3hrs 23 hrs 250 6 amps 6 amps 6 amps
166. tines are lifted from the ground Turf holders also provide inputs for the TrueCore ground following sys tem A variety of tines tine heads and turf holders are avail able for use on the ProCore 648 See the Operator s Manual for available options Coring Crankshaft The coring crankshaft assembly is composed of six 6 crankarms One of the crankarms is incorporated into the crankshaft pulley The crankarms need to be timed for proper aerating operation For assembly purposes crankshaft positions are identified as 1 through 6 The 1 position is on the right pulley side of the crankshaft Fig 2 The crankshaft position is cast into the crankarms to assist in correct crankshaft assembly The crankshaft assembly is supported with three identi cal bearing housing assemblies The six stomper arms and rotolink dampers used on the ProCore 648 are the same for all positions Coring Head Page 7 2 Figure 1 Figure 2 2 6 position ProCore 648 Coring Head Service Latch Whenever service is to be performed on coring head components fully raise coring head and install service latch Fig 3 Before using machine remove service latch from coring head Figure 3 1 Service latch in raised locked position Coring Head Adjustments See Operator s Manual for adjustment procedures for the coring head on the ProCore 648 Never work on the coring head with the engine running Always fully raise coring head
167. tools are described in the Kohler Engine Service Manu al The use of some specialized test equipment is ex plained However the cost of the test equipment and the specialized nature of some repairs may dictate that the work be done at an engine repair facility Service and repair parts for Kohler engines are supplied through your local Kohler dealer or distributor ProCore 648 Specifications Item Description Make Designation Kohler 235 4 stroke V Twin Air Cooled OHV Number of Cylinders Bore x Stroke 3 15 x 2 64 80 mm x 67 mm Total Displacement 41 1 Cubic Inches 674 cc Compression Ratio 8 5 1 Dry Weight approximate 90 Pounds 41 Kilograms Fuel Unleaded Regular Gasoline Minimum 87 Octane Fuel Tank Capacity 7 5 U S Gallons 28 4 Liters Governor Mechanical Idle Speed no load 1400 50 RPM High Idle no load 3400 50 RPM Engine Oil See Operator s Manual Oil Pump Gear driven trochoid type Crankcase Capacity 2 U S Quart 1 9 Liters with filter Starter 12 VDC ProCore 648 3 3 Kohler Engine General Information Fuel Shutoff Valve The fuel shutoff valve located under the fuel tank Fig 1 should be closed when removing the fuel tank or en gine from the machine Additionally close the shutoff valve if the machine is being transported on a trailer or
168. tput to the raise and lower hydraulic solenoid valves SVL SVR and SVQ This circuit is composed of the manual raise lower switch the neutral switch latch relay the latching relay the reverse proximity switch and diode D1 OK to lower circuit protection is provided by fuse Traction Lever in Neutral or Reverse When the traction lever is in either the neutral or reverse position the reverse proximity switch is closed which al lows the neutral switch latch relay to be energized This energized relay prevents an OK to lower input for the aerator control so the coring head remains in the raised position The OK to lower LED on the aerator control module will not be illuminated Begin Aerating Traction Lever in Forward To begin aerating the operator moves the traction lever to the forward direction which opens the reverse proxim ity switch and de energizes the neutral switch latch relay When the manual raise lower switch is pressed to the lower position a complete circuit is formed to allow the latching relay to be energized which allows an OK to lower input for the aerator control The OK to lower LED on the aerator control module will be illuminated The aerator control module will provide output to the SVQ and SVL solenoid valves to lower the coring head Electrical System Page 5 2 Aerating Traction Lever in Forward Once the OK to lower circuit has initially been closed by the manual raise lo
169. trol Current F2 10A 0 i 03 CLUTCH Y BU BN D Y ENERGIZED ea AERATION 3 NOT ENERGIZED HEAD LOWERED Page 8 9 aBK vw SPARK PLUG SPARK PLUG METER IGNITION Lon i 4 MODULES s ENGINE CONN FRONT AC GN OIL BU 5 START ProCore 648 Aerator CARBURETOR EN OIL STARTER Q ITCH Aerator Control Module PRESSURE IGN SWITCH RUN OFF RUN START NEUTRAL SW RELAY START K jT a olaa D ERE PO EC 1 1 BU een OU P CEP e LAS NEUTRAL SW START SVR RAISE SOLENOID GN NOT ENERGIZED NOT IN NEUTRAL NOT ENERGIZED gK BK BU 2 SVR 12 V 7 SVQ T 2 1 FLOAT SVG 7 5 5 BN AA MN 2 IGN SW I SVL 14 SVQ FAST RAISE SOLENOID GROUND FOLLOW ON w k NOT ENERGIZED 2 HEAD HIGH TRANSPORT 1
170. ug torque 120 in Ib 13 6 ProCore 648 Hydraulic Manifold Service 1 Make sure the manifold is clean before removing any cartridge valve 2 If solenoid cartridge is being serviced remove nut securing solenoid to the cartridge valve Carefully slide solenoid off the valve Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hy draulic oil See Relieving Hydraulic System Pres sure in the General Information section of this chapter IMPORTANT Use care when handling the cartridge valve Slight bending or distortion of the stem tube can cause binding and malfunction 3 Remove cartridge valve with a deep socket wrench Note correct location for o rings sealing rings and backup rings Remove and discard seal kit from valve 4 Visually inspect the manifold port for damage to the sealing surfaces damaged threads and contamination 5 Visually inspect cartridge valve for damaged sealing surfaces and contamination A Contamination may cause valves to stick or hang up Contamination can become lodged in small valve orifices or seal areas causing malfunction B If valve sealing surfaces appear pitted or dam aged the hydraulic system may be overheating or there may be water in the system A CAUTION Use eye protection such as goggles when using compressed air for cartridge valve cleaning ProCore 648 Page 4 49 caution stored fluid to be relea
171. un at 3400 RPM high idle Allow the battery to charge for at least 3 minutes Record the battery voltage Test results should be example At least 0 50 volt over initial battery voltage 12 25 12 80 v 0 55 v Initial Battery Voltage Battery Voltage after 3 Minute Charge Difference Electrical System 6 m Oo 2 5 Wu Check Operation of Safety Interlock System Do not disconnect interlock switches They are for the operator s protection Check operation of the switches daily to make sure the interlock system is operating correctly If a switch is not operating properly adjust or replace it before operating the machine Interlock switch operation is described in the ProCore 648 Operator s Manual The ProCore is equipped with an Aerator Control Module which monitors interlock switch operation Information on this Control Module is described in the Operator s Manual and in the Compo nent Testing section of this Chapter Testing of individual interlock switches is included in the Component Testing section of this Chapter Electrical System Page 5 12 The Safety Interlock System of the ProCore 648 ensur es the following operations 1 The engine should crank only when the traction lever is in the neutral position 2 When aerating if the traction lever is released from the forward position moved to the neutral or reverse position the coring head should automatically ra
172. urn or Suction RELIEF PRESSURE TEST IS SHOWN Flow Direction Figure 20 Hydraulic System Page 4 24 Rev C ProCore 648 Procedure for Traction Circuit Relief Pressure Test 1 Make sure hydraulic oil is at normal operating tem perature by operating the machine for approximately 10 minutes Make sure that traction lever is adjusted to the neutral position see Operator s Manual 2 Park machine on a level surface with the coring head fully raised Make sure engine is off and parking brake is engaged Secure coring head with service latch 3 Read Precautions For Hydraulic Testing in this sec tion 4 Set the aerator spacing lever to the transport posi tion 5 Make sure that hydraulic pump drive belt is adjusted properly see Operator s Manual 6 Lift or jack front of machine so front wheel is off the floor Support front of machine with jackstands or block ing Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hy draulic oil 7 Clean hose fitting and disconnect appropriate hy draulic hose from fitting on the rear side of the traction pump Fig 21 A For forward direction relief pressure test discon nect hose from lower 45 fitting NOTE forward relief pressure can also be measured with hydraulic tester installed as described in TEST NO 3 Traction Pis ton Pump Flow Make sure flow control valve on the tester is fully open NOTE An alternate testing
173. w through the circuit is reversed When the traction le ver is moved to the reverse position the linkage from the lever positions the swash plate in the traction motor so oil flows out the upper port of the pump Oil flow from the pump goes to the wheel motors rear motors first and then front motor and turns them in the reverse direction Maximum reverse traction pressure is limited by a 2900 PSI 200 Bar relief valve located in the top of the pump assembly flowing from the wheel motors returns to the bottom port of the traction pump and is continuously pumped out the top port as long as the traction lever is held in the reverse direction Hydraulic System E 52 ORF1 CYLINDER EXTENDING CYL SVL ENERGIZED LB ENERGIZED CORING HEAD GtX e SVQ S or ENERGIZED RAISE CONTROL cR RAE MANIFOLD T FROM TO GEAR TRACTION PUMP PUMP ORF1 LIFT B iid ENERGIZED P NEMUS RI NOT ENERGIZED COBINGEAD GLK um SVQ LOWER A ENERGIZED re amp R2 n T m 1 d G2 T 1 A Coring Head Raise Lower Circuits t Working Pressure GEAR TRACTION Low Pressure Charge PUMP PUMP Hydraulic System Page 4 10 Return or Suction Flow ProCore 648 Coring Head Raise Lowe
174. wer switch the latching relay and diode D1 allow a latch circuit to keep the latching relay energized The manual raise lower switch in the middle aerate position along with the energized latching relay provide a closed path for the OK to lower input to the aerator control module The OK to lower LED on the aerator control module will continue to be illuminated while aerating The OK to lower input to the aerator control module will remain closed until either the operator presses the manual raise lower switch to the raise position or the traction lever is moved to the neutral or reverse position ProCore 648 CONTROL MODULE OK TO LOWER LED TRACTION LEVER IN NEUTRAL OR REVERSE pas IS NOT ILLUMINATED TERMINAL L GROUND TO AERATOR CONTROL MODULE OK TO LOWER MANUAL RAISE LOWER IN RAISE POSITION OR REVERSE ENERGIZED OR GROUND To LOCKOUT AERATION 3 CIRCUIT PROX SWITCH CONTROL MODULE TO IGNITION TO LOWER LED BEGIN AERATING TRACTION LEVER IN FORWARD ey KTO owen TE TERMINAL 71 OR GROUND TO AERATOR CONTROL MODULE OK TO LOWER 85 6 E ZR e ENERGIZED MANUAL RAISE LOWER PRESSED TO LOWER 2 AND 3 CLOSED 5 AND 6 CLOSED NOT ENERGIZED OR GROUND TO LOCKOUT AERATION 3 CIRCUIT PROX SWITCH TO IGNITION CONTROL MODULE AERATING TRACTION LEVER IN FORWARD CONTHOL MODULE SWITCH IS ILLUMINATED
175. when placing the machine in long term storage Figure 1 1 Fuel shutoff valve under the fuel tank Kohler Engine Page3 4 ProCore 648 Adjustments Adjust Choke Control Proper choke operation is dependent upon proper ad justment of choke control cable 1 Park machine on a level surface fully raise coring head engage parking brake stop engine and remove key from the ignition switch 2 Remove air cleaner cover from engine to view choke plate in carburetor 3 Move choke control lever to RUN position Check that choke plate in carburetor is fully open 4 Move choke control lever to CHOKE position Check that choke plate in carburetor is fully closed Figure 2 5 If needed choke cable can be adjusted by loosening 1 Choke cable 2 Cable clamp cable clamp screw and repositioning control cable until choke plate operates correctly 6 Install air cleaner cover to engine Adjust Engine Speed 1 Allow engine to reach operating temperature before checking or adjusting engine speed Park machine on a level surface fully raise coring head and apply parking brake 2 With engine running move throttle control lever to FAST high idle position 3 Using a tachometer check that engine is operating at 3400 50 RPM 4 If high idle speed is incorrect adjust high speed Screw on governor assembly until high idle is 3400 50 Fi 3 RPM Fig 3 MR 1 High speed screw 5 Move throttle control lever to
176. ximity switch aeration 4 proximity switch and ground follow switches are moni tored by the Module The condition open or closed of the OK to lower circuit is also monitored by the Module Output to the three hydraulic solenoid valves lower SVL raise SVR and quick raise SVQ are controlled based on the inputs received by the Module The Aerator Control Module does not connect to an ex ternal computer or hand held device can not be grammed and does not record intermittent fault data The Aerator Control Module can be used to check op eration of machine switches by monitoring the LED s of the module If a module LED does not illuminate e g the ground follow LED does not illuminate when the ground follow switch is in the ON position testing of the switch and circuit wiring would be required Control Module Inputs The power input LED should be illuminated when the ignition switch is in the ON position The head low input LED should be illuminated when the head low limit switch is closed The head high input LED should be illuminated when the head high limit switch is closed The transport 1 input LED should be illuminated when the transport limit 41 proximity switch is closed coring head raised The aerate 4 input LED should be illuminated when the aeration 4 proximity switch is closed coring head low ered The ground follow ON LED should be illuminated when the ground follow switch is in the ON
177. y Removal Fig 31 1 Park machine on a level surface fully raise coring head engage parking brake stop engine and remove key from the ignition switch Secure coring head with Operate all hydraulic controls to relieve system service latch pressure and avoid injury from pressurized hy draulic oil See Relieving Hydraulic System Pres sure in the General Information section of this chapter Hydraulic System Page 4 38 ProCore 648 2 Remove pump belt cover from machine see Opera tor s Manual 3 Loosen the flange head screw item 7 and flange nut item 11 that secure the drive belt idler pulley item 10 Lift idler pulley to allow removal of drive belt from the hy draulic pump pulley IMPORTANT Before loosening pump pulley mark position of the pulley on the hydraulic pump shaft Pulley position is critical for proper alignment of the hydraulic pump drive belt 4 Loosen two 2 set screws that secure pump pulley to the hydraulic pump shaft Slide pulley from the pump shaft Locate and remove key from pump shaft 5 Remove two 2 lock nuts that secure pump shield to pump Fig 32 Remove shield from pump Locate and retrieve two 2 flat washers from tops of studs on pump control assembly 6 Disconnect hydraulic pump controls Fig 32 and 33 from the pump as follows The extension spring is under tension and may cause personal injury during removal Use cau tion when removing spring from neutral lever
178. ydraulic fitting 13 O ring 2 used 7 O ring Hydraulic System 2 5 gt Hydraulic Lift Control Manifold Service 20 ft lb 27 1 N m C uiN m 25 ft Ib 33 9 20 ft lb 120 in Ib 13 6 N m 12 20 ft Ib 27 1 Figure 40 1 Hydraulic lift control manifold 6 Solenoid coil 11 Pres compensating valve PV port 2 O ring 7 Relief valve R1 port 12 4 plug zero leak 3 Quick fitting 2 used 8 Solenoid valve SVQ port 13 Orifice plug 4 Solenoid valve SVL port 9 Nut 14 Check valve 5 Nut 10 Solenoid valve SVR port 15 Plug NOTE The ports on the manifold are marked for easy identification of components Example P is the pump connection port and R1 is the location for the relief valve See Hydraulic Schematics to identify the function of the hydraulic lines and cartridge valves at each port Hydraulic System Page 4 48 NOTE The ProCore 648 hydraulic lift control manifold uses two zero leak plugs item 12 These plugs have a tapered sealing surface on the plug head that is de signed to resist vibration induced plug loosening The zero leak plugs also have an o ring not shown as a secondary seal If zero leak plug removal is necessary lightly rap the plug head using a punch and hammer be fore using an allen wrench to remove the plug the im pact will allow plug removal with less chance of damage to the socket head of the plug When installing pl
179. zed hy draulic oil 4 Remove hydraulic tube that connects the gear pump P2 outlet to port P of hydraulic manifold Fig 23 IMPORTANT Make sure oil flow indicator arrow on the flow meter is showing that oil will flow from the gear pump through the tester and into hydraulic manifold port P 5 Install elbows to fittings on pump and manifold to al low connection of hydraulic tester with flow meter and pressure gauges to fittings Install hydraulic tester in place of the removed hydraulic tube between the gear pump P2 outlet and port P in the hydraulic manifold Make sure flow control valve on the tester is fully open 6 Make sure that traction lever is in neutral and the parking brake is engaged ProCore 648 4 27 7 Start and operate engine at full speed 3400 50 RPM 8 Watch flow and pressure gauges carefully while slowly closing the flow control valve until pressure gauge reads 500 PSI 9 Flow gauge reading should be approximately 4 GPM 10 flow control valve on tester and turn off engine Record results of hydraulic pressure test 11 If specification is not met repair or replace gear pump 12 Disconnect tester from the pump and control man ifold Reconnect hydraulic tube to the pump and man ifold Figure 23 2 Manifold port P 1 Gear pump outlet Hydraulic System 2 5 5 gt Wheel Motor Efficiency Test Using Tester With Flow Meter and Pressure

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