Instruction/ maintenance manual of the product 648 Toro
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Part No. 04129S L (Rev . C) Service Manual ProCore R 648 Preface The pur pose of this public ation is to pr ovide t he service technic ian with inf orm ation f or t roubles hooting, test ing and repair of maj or syst ems and co mponents on the ProCor e 648.
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T able Of Contents Chapter 1 – Safety Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . 1 – 2 Jacking Instructions . . . . . . . . . . . . . . . . . . . . . . . . . 1 – 4 Safety and Instruction Decals . . . . . . . . . . . .
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Chapter 1 Safety T able of Contents SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . 2 Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 While Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Maintenance and Service .
Rev . C ProCor e 648 Page 1 - - 2 Safety Safety Instructions The P roCore 648 is designed and t est ed t o offer s afe serv ice when operated and maintained proper ly .
7. Anytime the machine is parked (short or long term), 8. D o not park on slopes unless wheels are chocked or install the service latch to secure the coring head in the blocked. raised position. This eliminates the risk of the coring head accidentally lowering to the ground.
2 Jacking Instructions CAUTION er jack stands, the machine may move or fall, Frame jacking point Figure 1 1 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 .
Safety and Instruction Decals Numerous safety and instruction decals are affixed to th e 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 T oro Distributor .
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Chapter 2 Product Records and Maintenance T able of Contents PRODUCT RECORDS . . . . . . . . . . . . . . . . . . . . . . . . . 1 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 EQUIV ALENTS AND CONVERSIONS . . . . . . . . . .
Rev . C 0.09375 ProCore 648 Page 2 - - 2 Product Records and Maintenance Equivalents and Conversions.
T orque Specifications Recommended fastener torque values are listed in the following tables. For critical applications, as determined by T oro, either the recommended torque or a torque that is unique to the application is clearly identified and spe- cified in this Service Manual.
Standard T orque for Dry , Zinc Plated and Steel Fasteners (Inch Series) Grade 1, 5 & SAE Grade 1 Bolts, Screws, Studs & SAE Grade 5 Bolts, Screws, Studs & SAE Grade 8 Bolts, Screws, Studs.
Standard T orque for Dry , Zinc Plated and Steel Fasteners (Metric Fasteners) Thread Size Thread Size Class 8.8 Bolts, Screws and Studs with Regular Height Nuts Regular Height Nuts (Class 8 or Stronger Nuts) Class 10.9 Bolts, Screws and Studs with Regular Height Nuts Regular Height Nuts (Class 10 or Stronger Nuts) M5 X 0.
Other T orque Specifications SAE Grade 8 Steel Set Screws Wheel Bolts and Lug Nuts Thread Size Thread Size Recommended T orque Square Head Hex Socket 1/4 – 20 UNC 140 + 20 in–lb 73 + 12 in–lb 5/.
Chapter 3 Kohler Engine T able of Contents INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 SPECIFICATIONS 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL INFORMA TION . . . . . . . . . . . . . . . . . . . .
Introduction This Chapter gives information about specifications a nd repair of the Kohler engine used in the ProCore 648. General engine maintenance procedures are described in your Operator ’s Manual.
Specifications Item Description Make / Designation Kohler , CH23S, 4–stroke, V–T win Air Cooled, OHV Number of Cylinders 2 Bore x Stroke 3.15” x 2.
General Information Fuel Shutoff V alve The fuel shutof f 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 shutof f valve if the machine is being transported on a trailer or when placing the machine in long term storage.
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.
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ProCore 648 Page 3 – 7 Kohler Engine Service and Repairs Cooling System T o 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.
ProCore 648 Page 3 – 8 Kohler Engine Fuel System Figure 5 1. Fuel tank 2. Fuel cap 3. Hose clamp 4. Fuel hose 5. Fuel shut–off valve 6. Hose clamp 7. Fuel hose 8. Flat washer (4 used) 9. Clamp 10. Cap screw (4 used) 1 1. Flange bushing (4 used) 12.
Fuel T ank 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.
ProCore 648 Page 3 – 10 Kohler Engine Exhaust System Figure 7 1. Engine 2. Exhaust manifold 3. Hex nut (4 used) 4. Frame 5. Flange nut (2 used) 6. Muffler bracket 7. Flange head screw (3 used) 8. Muffler clamp (2 used) 9. Exhaust elbow 10. Carriage screw (2 used) 1 1.
Removal (Fig. 7) Installation (Fig. 7) CAUTION haust system. The muffler and exhaust pipe may be hot. T o avoid possible burns, allow the engine and ex- haust system to cool before working on the ex - 1. Park machine on a level surface, fully raise coring head, engage parking brake, stop engine and remove key from the ignition switch.
Rev . C ProCore 648 Page 3 - - 12 Kohle r Engine Engi ne Figur e 8 1. Engine 2. Negat ive batt ery cable 3. Wire harness ground 4. Flange scr ew 5. Lock w asher 6. Exhaus t manifold 7. Hex nut ( 4 used) 8. Cap scr ew ( 4 used) 9. Frame 10. Flange nut (2 used) 1 1.
ProCore 648 Page 3 – 13 Kohler Engine 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).
Installation (Fig. 8) B. Wrap hourmeter wire around spark plug wire and 1. Locate m achine 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.
Kohler Engine This page is intentionally blank. ProCore 648 Page 3 – 15 Kohler Engine.
ProCore 648 Page 3 – 16 Kohler Engine Belt T ensioners Figure 12 1. Engine 2. Hydraulic pump drive pulley 3. Electric clutch 4. Flange nut 5. Hardened washer 6. Cap screw 7. Flat washer 8. Grommet 9. Spacer 10. Cap screw 1 1. Clutch strap 12. Cap screw 13.
Removal (Fig. 12) 1. Release tension on idler torsion spring (item 19): CAUTION 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.
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Rev . C ProCore 648 Hydraulic System Page 4 - - 1 Chapter 4 Hydraulic System T able of Contents SPECIFICA TIONS 2 ............................. GENERAL INFORMA TION 4 ..................... Hydraulic Hoses 4 ............................ Hydraulic Fitting Installation 4 .
Specifications Item Description T raction Pump (P1) V ariable displacement piston pump Displacement at full stroke (per revolution) .976 Cubic Inches (16 cc) Forward relief pressure 2900 PSI (200 Bar) Reverse relief pressure 2900 PSI (200 Bar) Charge/Lift Pump (P2) Gear pump Displacement (per revolution) .
This page is intentionally blank. Hydraulic System ProCore 648 Page 4 – 3 Hydraulic System.
General Information Hydraulic Hoses Hydraulic hoses are subject to extreme conditions such as pressure differentials du ring operation and exposure to weather , sun, chemicals, very warm storage condi- tions, or mishandling during operation and mainte- nance.
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 r eplace the O–ring seal when this type of fit- ting shows signs of leakage.
Pushing/Pulling Machine IMPORT ANT : 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.
Rev . C ProCore 648 Hydraulic System Page 4 - - 7 Hydraulic Schematic Hydraulic Schematic ProCore 648 All solenoids are shown as de - - energized T CHG P PV R1 R2 SVR SVQ SVL ORF1 CYL G1 G2 M2 M3 M1 F.
Rev . C ProCore 648 Hydraulic System Page 4 - - 8 Hydraulic Flow Diagrams Working Pressure Low Pressure (Charge) Return or Suction Flow T raction Circuit (Forward Shown) T CHG P PV R1 R2 SVR SVQ SVL O.
ProCore 648 Hydraulic System Page 4 – 9 T raction Circuit The traction (piston) pump (P1) is driven by the engine through the pulleys and pump drive belt.
ProCore 648 Hydraulic System Page 4 – 10 Working Pressure Low Pressure (Charge) Return or Suction Flow Coring Head Raise/Lower Circuits T CHG P PV R1 R2 SVR SVQ SVL ORF1 CYL G1 G2 (ENERGIZED) CONTRO.
ProCore 648 Hydraulic System Page 4 – 1 1 Coring Head Raise/Lower 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.
Rev . C ProCore 648 Hydraulic System Page 4 - - 12 Special T ools Order these special tools from your T oro Distributor . Hydraulic Pressure T est Kit T oro Part Number: TOR47009 Use to take various pressure readings for diagnostic tests. Quick disconnect fittings provided attach directly to mating fittings on machine test ports without tools.
ProCore 648 Hydraulic System Page 4 – 13 Hydraulic T est Fitting Kit Part Number: TOR4079 This kit includes a variety of O–ring Face Seal fittings t o 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.
ProCore 648 Hydraulic System Page 4 – 14 T roubleshooting 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.
ProCore 648 Hydraulic System Page 4 – 15 Problem Possible Cause No traction in either direction Parking brake is engaged. Oil level in reservoir is low . T raction pump by–pass valve is open. Pump drive belt is loose, worn or broken. T raction cable broken or damaged.
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ProCore 648 Hydraulic System Page 4 – 17 T esting The most effective method for isolating problems 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 T ools section in this Chapter).
Rev . C ProCore 648 Hydraulic System Page 4 - - 18 Charge Pressure T est (Using Pressure Gauge) Figure 13 Working Pressure Low Pressure (Charge) Return or Suction Flow Direction T CHG P PV R1 R2 SVR S.
ProCore 648 Hydraulic System Page 4 – 19 Procedure for Charge Pressure T est: 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.
Rev . C ProCore 648 Hydraulic System Page 4 - - 20 Coring Head Raise/Lower Relief (R1) Pressure T est (Using Pressure Gauge) Figure 15 Working Pressure Low Pressure (Charge) Return or Suction Flow Dir.
ProCore 648 Hydraulic System Page 4 – 21 Procedure for Coring Head Raise/Lower Relief (R1) Pressure T est: 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.
Rev . C ProCore 648 Hydraulic System Page 4 - - 22 T raction (Piston) Pump (P1) Flow T est (Using T ester With Flow Meter and Pressure Gauge) Figure 18 Working Pressure Low Pressure (Charge) Return or.
Rev . B ProCore 648 Hydraulic System Page 4 – 23 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 something immovable in the shop to prevent the machine from moving during testing.
Rev . C ProCore 648 Hydraulic System Page 4 - - 24 T raction Circuit Relief Pressure T est (Using T ester With Flow Meter and Pressure Gauge) Figure 20 Working Pressure Low Pressure (Charge) Return or.
ProCore 648 Hydraulic System Page 4 – 25 Procedure for T raction Circuit Relief Pressure T est: 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).
Rev . C ProCore 648 Hydraulic System Page 4 - - 26 Gear Pump (P2) Flow T est (Using T ester With Flow Meter and Pressure Gauge) Figure 22 Working Pressure Low Pressure (Charge) Return or Suction Flow .
ProCore 648 Hydraulic System Page 4 – 27 Procedure for Gear Pump (P2) Flow T est: 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.
Rev . C ProCore 648 Hydraulic System Page 4 - - 28 Wheel Motor Efficiency T est (Using T ester With Flow Meter and Pressure Gauge) Figure 24 Working Pressure Low Pressure (Charge) Return or Suction Fl.
Procedure for Wheel Motor Efficiency T est: 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).
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.
Flush Hydraulic System IMPORT ANT : 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).
Hydraulic System Start - - up NOTE: When initially starting the hydraulic system with new or rebuilt components such as the hydraulic pump, wheel motors or lift cylinder , it is important that this start - - up procedure be used.
10. Start engine and operate the traction system at vary- ing speeds for a 10 minute period. 1 1. Stop the machine. Check hydraulic reservoir level and fill if necessary . Check hydraulic components for leaks and tighten any loose connections. 1 2 Figure 27 1.
ProCore 648 Hydraulic System Page 4 – 34 Hydraulic Pump Drive Belt 1. Flange nut (2 used) 2. Hydraulic (traction/charge) pump 3. Key 4. Engine 5. Engine pulley 6. Flange head screw 7. Spring bracket 8. Idler support bracket 9. Idler pulley 10. Flange nut 1 1.
Drive Belt Removal (Fig. 27) 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. R emo ve pump belt cover from machine (see Opera- tor ’s Manual).
ProCore 648 Hydraulic System Page 4 – 36 Hydraulic Pump Control Assembly 1. Hydraulic pump 2. Cap screw (2 used) 3. Flange nut 4. Lock nut 5. Flange nut (2 used) 6. Control bracket 7. Washer head screw 8. Lock nut 9. Extension spring 10. Speed selector pivot 1 1.
ProCore 648 Hydraulic System Page 4 – 37 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. R emo ve pump belt cover from machine (see Opera- tor ’s Manual).
ProCore 648 Hydraulic System Page 4 – 38 Hydraulic (T raction/Charge) Pump 1. Hydraulic (traction/charge) pump 2. O–ring 3. O–ring 4. 90 o hydraulic fitting 5. Engine 6. Engine pulley 7. Flange head screw 8. Spring bracket 9. Idler support bracket 10.
ProCore 648 Hydraulic System Page 4 – 39 2. R emo ve pump belt cover from machine (see Opera- tor ’s Manual). 3. Loosen the flange head screw (item 7) and flange nut (item 1 1) that secure the drive belt idler pulley (item 10). Lift id ler pu lle y t o al low r emoval of drive belt from the hy- draulic pump pulley .
Installation (Fig. 31) 1. Install hydraulic fittings with new o–rings to the hy- draulic pump. Orientate the fittings as noted during dis- assembly . CAUTION pump support to prevent the pump from falling Support hydraulic pump when installing it to the and causing personal injury .
ProCore 648 Hydraulic System Page 4 – 41 Hydraulic (T raction/Charge) Pump Service 1. Retaining ring 2. Seal 3. Spacer 4. Pump shaft kit 5. Pump housing 6. Thrust washer 7. Spring block 8. Nut (4 used) 9. Trunnion seal kit 10. Pin (2 used) 1 1. O–ring 12.
ProCore 648 Hydraulic System Page 4 – 42 Wheel Motors 1. Rear wheel motor (LH shown) 2. Woodruff key 3. Parking latch support (2 used) 4. Stud (4 used per wheel) 5. Parking latch disc (2 used) 6. Wheel hub 7. Lock nut 8. Bearing plate 9. Lug nut 10.
ProCore 648 Hydraulic System Page 4 – 43 2. Remove wheel from machine (see Wheel Removal in Service and Repairs section of Chapter 6 – Chassis). IMPORT ANT : T o prevent damage to hydraulic motor , DO NOT hit wheel hub or motor with a hammer dur- ing wheel hub removal or installation.
ProCore 648 Hydraulic System Page 4 – 44 Wheel Motor Service 1. Dust seal 2. Housing 3. O–ring 4. Shaft seal 5. Axial needle bearing 6. Bearing race 7. Needle bearing 8. Shaft 9. O–ring 10. Spring washer 1 1. Balance plate 12. Disc valve 13. Needle bearing 14.
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ProCore 648 Hydraulic System Page 4 – 46 Hydraulic Lift Control Manifold 1. Main frame 2. Cap screws (2 used) 3. Hydraulic lift control manifold 4. Hydraulic oil filter 5.
ProCore 648 Hydraulic System Page 4 – 47 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.
ProCore 648 Hydraulic System Page 4 – 48 Hydraulic Lift Control Manifold Service 1. Hydraulic lift control manifold 2. O–ring 3. Quick fitting (2 used) 4. Solenoid valve (SVL port) 5. Nut 6. Solenoid coil 7. Relief valve (R1 port) 8. Solenoid valve (SVQ port) 9.
Hydraulic Manifold Service 1. Ma k e 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.
ProCore 648 Hydraulic System Page 4 – 50 Lift Cylinder 1. Main frame 2. Shackle (4 used) 3. Extension spring (2 used) 4. Carriage screw (4 used) 5. Spring plate (2 used) 6. Flange nut (4 used) 7. Clevis pin (4 used) 8. Hair pin (4 used) 9. Retaining ring 10.
5. Start engine and allow coring head to fully raise. T u r n engine off. Secure coring head with service latch. CAUTION sure in the General Information section of this Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hy- draulic oil.
ProCore 648 Hydraulic System Page 4 – 52 Lift Cylinder Service 1. Retaining ring 2. Cylinder tube 3. Rod 4. O–ring 5. Backup ring 6. Retaining ring 7. Seal 8. Head 9. Wiper Figure 44 5 1 3 7 8 9 6 4 2 Disassembly (Fig. 44) 1. Remove oil from the lift cylinder into a drain pan by slowly pumping the cylinder rod.
Inspection CAUTION Spanner wrench Retaining ring against left side of barrel groove after installing) Us e 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.
ProCore 648 Hydraulic System Page 4 – 54 Hydraulic Reservoir 1. Hydraulic reservoir 2. Dipstick 3. Cap 4. Shoulder screw 5. T ank strap 6. Cap screw 7. J clip 8. Flat washer 9. Frame 10. O–ring 1 1. Hydraulic adapter 12. O–ring 13. Hydraulic tube 14.
Chapter 5 Electrical System T able of Contents ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . 1 CIRCUIT OPERA TION . . . . . . . . . . . . . . . . . . . . . . . . . 2 OK to Lower Circuit . . . . . . . . . . . . . . . . . . . . . . . . .
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.
GROUND TO GROUND TO SWITCH PROX. SWITCH LOCKOUT CIRCUIT GROUND TO GROUND TO SWITCH PROX. SWITCH LOCKOUT CIRCUIT GROUND TO GROUND TO SWITCH PROX. SWITCH LOCKOUT CIRCUIT (ENERGIZED) (ENERGIZED) (ENERGIZ.
Lockout Circuit (Fig. 2) Th e 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.
GROUND CORING HEAD RAISED TO IGNITION T O AERA TOR SWITCH CONTROL (NOT PRESSED) (ENERGIZED) TERMINAL ”L” (ENERGIZED) TO ELECTRIC CLUTCH MODULE TO IGNITION SWITCH TERMINAL ”A” GROUND AERA TING .
Electric Clutch Circuit (Fig. 3) The electric clutch circuit is used on the ProCore to pro- vide current for the electric clutch which rot ates the cor- ing crankshaft. This circuit is composed of the aeration #3 proximity switch, the clutch relay , the electric clutch an d diode D3.
Special T ools Multimeter The multimeter can test electrical components and cir- cuits for current (amps), resistance (ohms) or voltage. NOTE: T oro recommends the use of a DIGIT AL V olt– Ohm–Amp multimeter when testing electrical circuits.
T roubleshooting CAUTION Remove all especially rings and watches, before doing any electrical trouble- cables unless the test requires battery voltage.
Starting Problems (continued) Problem Possible Causes Engine cranks, but does not start. 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).
Coring Head Operating Problems Problem Possible Causes Coring head runs (but should not) when raised. Aeration #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 .
Electrical System Quick Checks Battery T est (Open Circuit T est) Use a multimeter to measure the voltage between the battery terminals. Set the multimeter to the DC volts setting. The battery should be at a temperature of 60 o to 100 o F (16 o to 38 o C).
Check Operation of Safety Interlock System CAUTION operating the machine. 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 .
Component T esting 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).
1 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.
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 rela y , clutch relay , neutral switch (start) relay and lockout latch relay . The remain- in g two (2) relays are attached under the handle console (Fig.
Manual Raise/Lower Switch The manual raise/lower switch is located on the handle control panel (Fig. 16). This rocker switch is one of the components in the ”OK to lower” circuit which is one of the aerator control m odule inputs.
Ground Follow Switch The ground follow switch is located on the side of the control panel (Fig. 18). This rocker switch allows the T rue Core TM 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.
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).
Solenoid V alve Coil Th e 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.
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.
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.
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.
Proximity Switch T est 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.
Aerator Control Module The ProCore 648 is equipped with an Aerator Control Module to monitor and control electrical components re - quired for safe operation.
Control Module Outputs 3. Th e SVR output LED will be illuminated in two situa- 1. Th e 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.
Electric Clutch An electric clutch is used to engage the coring head on the ProCore 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.
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 8 – Electrical Diagrams).
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.
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. CAUTION When working with batteries, use extreme cau- eyes.
T esting 1. T o 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.
Charging T o 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.
ProCore 648 Page 5 – 32 Electrical System Electric Clutch 1. Drive belt 2. Electric clutch 3. Hardened washer 4. Cap screw 5. Flange nut 6. Flat washer 7. Brake grommet 8. Cap screw 9. Spacer 10. Clutch strap 1 1. Idler mounting bracket 12. Lock nut 13.
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. R emo ve pump belt cover from machine (see Opera- tor ’s Manual).
ProCore 648 Page 5 – 34 Electrical System Solenoid V alve 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.
Chapter 6 Chassis T able of Contents SPECIFICA TIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 SPECIAL T OOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SERVICE AND REP AIRS . . . . . . . . . . . . . . . . . . . . . . 4 Wheels .
Specifications Item Description Front and Rear T ires Size 19 x 10.5 – 8, 2 Ply , Tubeless Pressure 12 PSI (.83 Bar) Wheel lug nut torque 45 to 55 ft–lb (61 to 75 N–m) Wheel hub nut torque 190 t.
Rev . C ProCore 648 Page 6 - - 3 Chassis Special T ools Order special tools from your T oro Distributor . Wheel Hub Puller Part Number: TOR4097 The wheel hub puller allows safe removal of the wheel hub from the shaft of wheel motors.
ProCore 648 Page 6 – 4 Chassis Service and Repairs Wheels 1. Tire and wheel assembly 2. Lug nut 3. Front wheel weight 4. Wheel weight adapter 5. Weight stud 6. Thrust washer 7. Lock nut 8. Bearing plate 9. Lock nut 10. Wheel hub 1 1. Parking latch disc 12.
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).
ProCore 648 Page 6 – 6 Chassis Parking Brake Figure 4 1. Extension spring 2. Bushing 3. Retaining ring 4. Parking latch pivot 5. Flange nut 6. Shoulder bolt 7. Compression spring 8. Parking latch clevis 9. Hair pin 10. Parking latch link 1 1. Roll pin 12.
Removal (Fig. 4) 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.
ProCore 648 Page 6 – 8 Chassis Parking Brake Cable 1. Control handle 2. Grommet 3. Steering arm 4. Lower handle cover 5. Washer head screw (6 used) 6. Flange nut 7. Brake cable 8. Flat washer 9. Cotter pin 10. Brake lever 1 1. Bushing 12. Brake spacer 13.
ProCore 648 Page 6 – 9 Chassis 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. Re m o v e six (6) washer head screws that secure low- er handle cover to control handle.
ProCore 648 Page 6 – 10 Chassis Steering Assembly 1. Grommet 2. Stud (3 used) 3. Steering arm 4. Cap screw (5 used) 5. Slotted hex nut 6. W asher 7. Bearing cone 8. Bearing cup 9. Frame 10. Steering stop 1 1. Cap screw (2 used) 12. Cable guide 13. Cotter pin 14.
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.
Rev . B ProCore 648 Page 6 – 12 Chassis T raction Control Cable Removal 1. Remove traction control cable from hydraulic pump control (Fig. 10) and traction lever on handle and (Fig. 1 1). 2. Remove traction control cable from machine noting routing of cable to aid in correct installation.
Chapter 7 Coring Head T able of Contents GENERAL INFORMA TION . . . . . . . . . . . . . . . . . . . . . 2 Coring Head Operation . . . . . . . . . . . . . . . . . . . . . . . 2 Coring Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Coring Head Service Latch .
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.
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 us ing machine, remove service latch from coring head.
ProCore 648 Page 7 – 4 Coring Head Service and Repairs Rotolink Dampers 1. Lock nut 2. Hardened D washer 3. Flange head screw 4. Stud 5. Bumper plate 6. Ca p screw 7. Lock nut 8. Hardened washer 9. Damper link 10. Bearing 1 1. Stomper arm 12. Flan g e nut 13.
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 – 6 Coring Head Stomper Arms 1. Coring frame 2. Cap screw 3. Flat washer 4. Retaining ring 5. Ball bearing 6. Stomper arm 7. Pulley 8.
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.
ProCore 648 Page 7 – 8 Coring Head Coring Crankshaft Bearing Housings 1. Cap screw 2. Flat washer 3. Spacer tube 4. Stomper arm 5. Ball bearing 6. Retaining ring 7. Crankarm 8. Ball bearing 9. Bearing housing 10. Spacer 1 1. Crankarm 12. Square key 13.
ProCore 648 Page 7 – 9 Coring Head 7. Disassemble bearing housing assembly: A. Re mo ve cap screw (item 1) and flat washer (item 2) that fasten crankarms together . T ake note of align- ment of identification number on crankarm with tim- ing mark on bearing housing (Fig.
ProCore 648 Page 7 – 10 Coring Head Primary Drive Belt 1. Primary drive belt 2. Electric clutch 3. Hardened washer 4. Cap screw 5. Flange nut 6. Flat washer 7. Brake grommet 8. Cap screw 9. Spacer 10. Clutch strap 1 1. Idler mounting bracket 12. Lock nut 13.
Removal (Fig. 1 1) 1. Park machine on a level surface, fully raise coring head, engage parking brake, stop engine and remove key from the ignition switch.
ProCore 648 Page 7 – 12 Coring Head Secondary Drive Belt 1. Secondary drive belt 2. Cap screw 3. Secondary pulley 4. Cap screw 5. Flange bushing 6. Idler pulley 7. Idler pivot tube 8. Idler arm 9. Lock nut 10. Carriage screw (2 used) 1 1. Flange nut (2 used) 12.
NOTE: If desired, extension spring tension can be re- 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.
ProCore 648 Page 7 – 14 Coring Head Coring Head Drive Jackshaft 1. Primary pulley 2. T aper lock bushing 3. Lock washer 4. Cap screw 5. Set screw 6. Woodruff key 7. Jackshaft 8. Cap screw (2 used per bearing) 9. Flange mount bearing 10. Plug 1 1. Set screw 12.
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.
ProCore 648 Page 7 – 16 Coring Head Coring Head Pivot (H–Frame) 1. Coring frame 2. H–frame 3. Hex nut 4. Lock washer 5. Rod end (LH thread) 6. Jam nut (LH thread) 7. Upper link 8. Jam nut 9. Rod end 10. Flange bushing (4 used) 1 1. Main frame 12.
ProCore 648 Page 7 – 17 Coring Head 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. Re m o ve belt cover and rear hood from machine (see Operator ’s Manual).
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.
Chapter 8 Electrical Diagrams T able of Contents ELECTRICAL SCHEMA TIC Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . 3 ELECTRICAL CIRCUIT DRA WINGS Start Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Lower Coring Head .
This page is intentionally blank. Electrical Diagrams Page 8 – 2 ProCore 648.
Page 8 – 3 Electrical Schematic ProCore 648 All relays and solenoids are shown as de–energized. All ground wires are black..
Page 8 – 4 Start Engine Power Current Control Current Indication Current ProCore 648 (ENERGIZED) (NOT ENERGIZED) (NOT ENERGIZED) (NOT ENERGIZED) (NOT ENERGIZED) (NOT ENERGIZED) (NEUTRAL POSITION).
Page 8 – 5 Lower Coring Head Power Current Control Current ProCore 648 (ENERGIZED) (NOT ENERGIZED) (RUN) (NOT ENERGIZED) (NOT IN NEUTRAL) (ENERGIZED) (HEAD BEING LOWERED) (ON) (HEAD BEING LOWERED) (.
Page 8 – 6 Aerating Power Current Control Current ProCore 648 (ENERGIZED) (NOT ENERGIZED) (RUN) (NOT ENERGIZED) (NOT IN NEUTRAL) (ENERGIZED) (ON) (HEAD LOWERED) (HEAD LOWERED) (HEAD LOWERED) (IN FOR.
Page 8 – 7 Aerating Power Current Control Current ProCore 648 (ENERGIZED) (NOT ENERGIZED) (RUN) (NOT ENERGIZED) (NOT IN NEUTRAL) (ENERGIZED) (ON) (HEAD LOWERED) (CLOSED BY TURF GUARD) (HEAD LOWERED).
Page 8 – 8 Aerating Power Current Control Current ProCore 648 (ENERGIZED) (NOT ENERGIZED) (RUN) (NOT ENERGIZED) (NOT IN NEUTRAL) (ENERGIZED) (ON) (CLOSED BY TURF GUARD) (HEAD LOWERED) (HEAD LOWERED).
Page 8 – 9 Raise Coring Head Power Current Control Current ProCore 648 (ENERGIZED) (NOT ENERGIZED) (RUN) (NOT ENERGIZED) (NOT IN NEUTRAL) (ENERGIZED) (HEAD LOWERED) (ON) (HEAD LOWERED) (HEAD LOWERED.
Page 8 – 10 T ransport Power Current Control Current ProCore 648 (ENERGIZED) (NOT ENERGIZED) (RUN) (NOT ENERGIZED) (NOT IN NEUTRAL) (ENERGIZED) (ON) (HEAD RAISED) (NEUTRAL POSITION) (ENERGIZED) (NOT.
Page 8 – 1 1 ProCore 648 Wire Harness Drawing 5 4 2 3 1 4 3 5 2 1.
MAGNETO LOW OIL PRESSURE P5 REVERSE P16 SWITCH NEUTRAL SW . RELA Y (ST ART) P4 J5 IGNITION SWITCH P1 FUSE BLOCK P27 ACM 1 P9 S M L G B BLUE ORANGE BLACK BLACK VIOLET VIOLET WHITE/BLACK YELLOW YELLOW B.
An important point after buying a device Toro 648 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Toro 648 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Toro 648 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Toro 648 you will learn all the available features of the product, as well as information on its operation. The information that you get Toro 648 will certainly help you make a decision on the purchase.
If you already are a holder of Toro 648, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Toro 648.
However, one of the most important roles played by the user manual is to help in solving problems with Toro 648. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Toro 648 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
