ProCore 648 Aerator

ProCore 648 Aerator
Form No. 3353–518 Rev. A
ProCore 648 Aerator
Model No. 09200–240000001 & Up
Operator’s Manual
English (EN, GB)
Warning
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting and Stopping the Engine . . . . . . . . . . . .
The Safety Interlock System . . . . . . . . . . . . . . . .
Service Latches . . . . . . . . . . . . . . . . . . . . . . . . . .
Install Tine Holders, Turf Guards and Tines . . . .
Setting the Coring Depth . . . . . . . . . . . . . . . . . . .
Manual Ground Following . . . . . . . . . . . . . . . . . .
Pushing/Pulling the Aerator by Hand . . . . . . . . .
System Control Circuit Reset . . . . . . . . . . . . . . .
Coring Head Stranded In Lowered Position . . . .
Transporting Aerator . . . . . . . . . . . . . . . . . . . . . .
Loading Aerator . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating Tips . . . . . . . . . . . . . . . . . . . . . . . . . . .
Using Line Marker . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting Weight Transfer . . . . . . . . . . . . . . . . . .
Additional Weight . . . . . . . . . . . . . . . . . . . . . . . .
Aerator Control Module (ACM) . . . . . . . . . . . . .
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recommended Maintenance Schedule . . . . . . . .
Daily Maintenance Checklist . . . . . . . . . . . . . . . .
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Jacking Instructions . . . . . . . . . . . . . . . . . . . . . . .
Servicing the Air Cleaner . . . . . . . . . . . . . . . . . .
Servicing the Engine Oil . . . . . . . . . . . . . . . . . . .
Servicing the Spark Plug . . . . . . . . . . . . . . . . . . .
Servicing the Fuel Filter . . . . . . . . . . . . . . . . . . .
Servicing the Fuel Tank . . . . . . . . . . . . . . . . . . . .
Cleaning the Cooling Systems . . . . . . . . . . . . . . .
Servicing the Hydraulic System . . . . . . . . . . . . .
Re–setting Ground Following System . . . . . . . . .
Inspecting Belts . . . . . . . . . . . . . . . . . . . . . . . . . .
Side Shield Adjustment . . . . . . . . . . . . . . . . . . . .
Adjusting Pump Belt . . . . . . . . . . . . . . . . . . . . . .
Replacing the Turf Guards . . . . . . . . . . . . . . . . . .
Adjusting Hole Spacing . . . . . . . . . . . . . . . . . . . .
Check Torque of Coring Head Fasteners . . . . . . .
Coring Head Timing . . . . . . . . . . . . . . . . . . . . . .
Servicing the Fuses . . . . . . . . . . . . . . . . . . . . . . .
Servicing the Battery . . . . . . . . . . . . . . . . . . . . . .
Storing the Battery . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wiring Schematic . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . .
Cleaning and Storage . . . . . . . . . . . . . . . . . . . . . .
The Toro Aerator Commercial Products Warranty . .
CALIFORNIA
Proposition 65 Warning
The engine exhaust from this product contains
chemicals known to the State of California to
cause cancer, birth defects, or other reproductive
harm.
Important This engine is not equipped with a spark
arrester muffler. It is a violation of California Public
Resource Code Section 4442 to use or operate this engine
on any forest–covered, brush–covered or grass–covered
land. Other states or federal areas may have similar laws.
This spark ignition system complies with Canadian
ICES-002.
Ce système d’allumage par étincelle de véhicule est
conforme à la norme NMB-002 du Canada.
Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safe Operating Practices . . . . . . . . . . . . . . . . . . .
Sound Pressure Level . . . . . . . . . . . . . . . . . . . . . .
Sound Power Level . . . . . . . . . . . . . . . . . . . . . . .
Vibration Level . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety and Instruction Decals . . . . . . . . . . . . . . .
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Accessory Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Loose Parts Chart . . . . . . . . . . . . . . . . . . . . . . . . .
Install the Rear Wheels . . . . . . . . . . . . . . . . . . . .
Install the Handle . . . . . . . . . . . . . . . . . . . . . . . . .
Activate, Charge and Connect the Battery . . . . .
Secure Rear Hood . . . . . . . . . . . . . . . . . . . . . . . .
Secure Belt Cover . . . . . . . . . . . . . . . . . . . . . . . .
Install Tine Holders, Turf Guards and Tines . . . .
Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recommended Gasoline . . . . . . . . . . . . . . . . . . .
Using Stabilizer/Conditioner . . . . . . . . . . . . . . . .
Filling the Fuel Tank . . . . . . . . . . . . . . . . . . . . . .
Check Engine Oil Level . . . . . . . . . . . . . . . . . . . .
Check Hydraulic System Fluid . . . . . . . . . . . . . .
Check the Tire Pressure . . . . . . . . . . . . . . . . . . . .
W 2005 by The Toro Company
8111 Lyndale Avenue South
Bloomington, MN 55420-1196
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Contact us at www.Toro.com
All Rights Reserved
Printed in the USA
Introduction
This manual uses two other words to highlight
information. Important calls attention to special
mechanical information and Note: emphasizes general
information worthy of special attention.
Read this manual carefully to learn how to operate and
maintain your product properly. The information in this
manual can help you and others avoid injury and product
damage. Although Toro designs and produces safe
products, you are responsible for operating the product
properly and safely.
Safety
Improper use or maintenance by the operator or owner
can result in injury. To reduce the potential for injury,
comply with these safety instructions and always pay
attention to the safety alert
symbol, which means
CAUTION, WARNING, or DANGER—“personal
safety instruction.” Failure to comply with the
instruction may result in personal injury or death.
Whenever you need service, genuine Toro parts, or
additional information, contact an Authorized Service
Distributor or Toro Customer Service and have the model
and serial numbers of your product ready. Figure 1
illustrates the location of the model and serial numbers on
the product.
Safe Operating Practices
The following instructions are from ANSI standard
B71.4—1999.
Training
• Read the Operator’s Manual and other training
material. If the operator(s) or mechanic(s) can not read
English it is the owner’s responsibility to explain this
material to them.
1
• Become familiar with the safe operation of the
equipment, operator controls, and safety signs.
Figure 1
1. Location of the model and serial numbers
• All operators and mechanics should be trained. The
owner is responsible for training the users.
Write the product model and serial numbers in the space
below:
• Never let children or untrained people operate or
service the equipment. Local regulations may restrict
the age of the operator.
• The owner/user can prevent and is responsible for
accidents or injuries occurring to himself or herself,
other people or property.
Model No.
Serial No.
Preparation
This manual identifies potential hazards and has special
safety messages that help you and others avoid personal
injury and even death. Danger, Warning, and Caution are
signal words used to identify the level of hazard.
However, regardless of the hazard, be extremely careful.
• Evaluate the terrain to determine what accessories and
attachments are needed to properly and safely perform
the job. Only use accessories and attachments
approved by the manufacturer.
• Wear appropriate clothing including hard hat, safety
glasses and hearing protection. Long hair, loose
clothing or jewelry may get tangled in moving parts.
Danger signals an extreme hazard that will cause serious
injury or death if you do not follow the recommended
precautions.
Warning signals a hazard that may cause serious injury or
death if you do not follow the recommended precautions.
• Inspect the area where the equipment is to be used and
remove all objects such as rocks, toys and wire which
can be contacted by the aerator.
Caution signals a hazard that may cause minor or
moderate injury if you do not follow the recommended
precautions.
• Use extra care when handling gasoline and other fuels.
They are flammable and vapors are explosive.
• Use only an approved container
3
• Never remove gas cap or add fuel with engine
running. Allow engine to cool before refueling.
Do not smoke.
• Do not operate on slopes when grass is wet. Slippery
conditions reduce traction and could cause sliding and
loss of control.
• Never refuel or drain the aerator indoors.
• Do not make sudden turns or rapid speed changes.
• Check that operator’s presence controls, safety
switches and shields are attached and functioning
properly. Do not operate unless they are functioning
properly.
• Reduce speed and use extreme caution on slopes.
Operation
• Watch for ditches, holes, rocks, dips, and rises that
change the operating angle, as rough terrain could
overturn the aerator.
• Remove or mark obstacles such as rocks, tree limbs,
etc. from the operating area. Tall grass can hide
obstacles.
• Never run an engine in an enclosed area.
• Be aware that loss of traction may occur going
downhill. Weight transfer to the front wheel may cause
drive wheels to slip and cause loss of braking and
steering.
• Only operate in good light, keeping away from holes
and hidden hazards.
• Be sure all drives are in neutral and parking brake is
engaged before starting engine. Start the engine only
from the operator’s position.
• Always avoid sudden starting or stopping on a slope. If
tires lose traction, disengage the tines and proceed
slowly off the slope.
• Never operate without the shields, covers or other
guards securely in place. Be sure all interlocks are
functioning properly.
• Follow the manufacturer’s recommendations for wheel
weights or counterweights to improve stability.
• Do not change the engine governor setting or
overspeed the engine.
Maintenance and storage
• Stop on level ground, raise coring head, disengage
drives, engage parking brake, shut off engine before
leaving the operator’s position for any reason.
• Wait for all movement to stop before adjusting,
cleaning or repairing. Disengage tines, raise coring
head, set parking brake, stop engine and remove key.
• Stop equipment and inspect tines after striking objects
or if an abnormal vibration occurs. Make necessary
repairs before resuming operations.
• Clean grass and debris from tines, drives, mufflers, and
engine to help prevent fires. Clean up oil or fuel
spillage.
• Keep hands and feet away from the tine area.
• Let engine cool before storing and do not store near
flame.
• Never carry passengers and keep pets and bystanders
away.
• Shut off fuel while storing or transporting on trailers.
Do not store fuel near flames or drain indoors.
• Be alert, slow down and use caution when making
turns. Look behind and to the side before changing
directions.
• Park aerator on level, hard ground. Never allow
untrained personnel to service aerator.
• Slow down and use caution when crossing roads and
sidewalks.
• Use jack stands or safety latches to support
components when required.
• Do not operate the aerator under the influence of
alcohol or drugs.
• Carefully release pressure from components with
stored energy.
• Use extreme care when loading or unloading the
aerator into a trailer or truck.
• Disconnect battery or remove spark plug wire before
making any repairs. Disconnect the negative terminal
first and the positive last. Reconnect positive first and
negative last.
• Use care when approaching blind corners, shrubs,
trees, or other objects that may obscure vision.
• Keep hands and feet away from moving parts. If
possible, do not make adjustments with the engine
running.
Slope Operation
• Do not operate near drop–offs, ditches, steep banks or
water. Wheels dropping over edges can cause
rollovers, which may result in serious injury or death.
• Charge batteries in an open well ventilated area, away
from spark and flames. Unplug charger before
connecting or disconnecting from battery. Wear
protective clothing and use insulated tools.
4
Sound Power Level
• Keep all parts in good working condition and all
hardware tightened. Replace all worn or damaged
decals.
This unit has a guaranteed sound power level of:
102 dBA/1 pW, based on measurements of identical
machines per Directive 2000/14/EC and amendments.
• Use only Toro-approved attachments. Warranty may
be voided if used with unapproved attachments.
Vibration Level
Sound Pressure Level
This unit does not exceed a vibration level of 2.5 m/s@ at
the hands based on measurements of identical machines
per ISO 5349 procedures.
This unit has an equivalent continuous A–weighted sound
pressure level at the operator ear of 84 dBA, based on
measurements of identical machines per Directive
98/37/EC and amendments.
This unit does not exceed a vibration level of .5 m/s@ at
the posterior based on measurements of identical
machines per ISO 2631 procedures.
Safety and Instruction Decals
Safety decals and instructions are easily visible to the operator and are located near any
area of potential danger. Replace any decal that is damaged or lost.
106-8854
1.
2.
3.
4.
Read the Operator’s Manual.
Engine—stop
Engine—run
Engine—start
5. Read the Operator’s Manual;
move the switch up to turn
ground following on; move
the switch down and install
the spacers to turn ground
following off.
6. Read the Operator’s Manual;
press the switch to test the
safety system.
7. To start the engine, turn the
ignition key and unlock the
parking brake; read the
Operator’s Manual.
5
8. To stop the engine, press the
switch to disengage the PTO,
lock the parking brake, and
turn the ignition key to the
Stop position and remove it;
read the Operator’s Manual.
9. Transport or hole spacing
selection
107-7534
1. Warning—read the
Operator’s Manual.
2. Warning—remove the
ignition key and read the
instructions before servicing
or performing maintenance.
3. Entanglement hazard,
belt—stay away from moving
parts.
4. Crushing hazard of hand or
foot—keep bystanders a safe
distance from the machine.
5. Crushing hazard of hand and
body—engage the service
latch when the coring head is
raised; read the instructions
before servicing or
performing maintenance.
6. Read the instructions before
servicing or performing
maintenance—torque the tine
bolts to 41 N⋅m (30 ft.-lb).
107-7548
1. Read the Operator’s
Manual.
2. Wrench size
3. Bolt size
4. Torque
93-9363
1. Parking brake
2. Locked
3. Unlocked
106-8835
1.
2.
3.
4.
5.
6.
On/off
Output
Solenoid valve lower
Solenoid valve raise
Solenoid valve quick
Input
7.
8.
9.
10.
11.
12.
Head low
Head high
Transport (#1)
Aerate (#4)
Ground following
OK to lower
Battery Symbols
Some or all of these symbols are on your battery.
1. Explosion hazard
2. No fire, open flames, or
smoking.
3. Caustic liquid/chemical
burn hazard
4. Wear eye protection
5. Read the Operator’s
Manual.
6. Keep bystanders a safe
distance from the battery.
6
7. Wear eye protection;
explosive gases can
cause blindness and other
injuries
8. Battery acid can cause
blindness or severe burns.
9. Flush eyes immediately
with water and get medical
help fast.
10. Contains lead; do not
discard.
106-8853
1. Read the Operator’s
Manual.
106-8856
2. Coring depth
1. Read the Operator’s Manual.
93-9084
1. Lift point
2. Tie-down point
107-7555
93-6696
1. Stored energy hazard—read the Operator’s Manual.
7
106-8855
1. Move the lever up to drive in
reverse.
2. Move the lever down to drive
forward.
3. Disengage the PTO and
raise the head.
4. Engage the PTO and lower
the head.
5. Warning—stop the engine
and read the instructions
before servicing or
performing maintenance.
6. Warning—stop the engine
before fueling.
7. Entanglement hazard,
shaft—do not carry
passengers.
8. Entanglement hazard, belt
and Crushing hazard of hand
or foot—stay away from
moving parts and keep
bystanders a safe distance
from the machine.
107-7547
1. Entanglement hazard,
belt—stay away from
moving parts.
2. Warning—Do not touch
the hot surfaces
8
9. Tipping hazard—do not turn
sharply while traveling fast,
drive slowly when turning,
and do not drive the machine
on a slope greater than 15
degrees.
Specifications
Engine
Tires
Kohler, 2 cylinder, air cooled, gasoline engine.19 HP (14.2 kW) @ 3000 rpm.
Torque –32.5 lb–ft. @ 3000 rpm (44.1 N–m) 32.7 lb–ft max (44.3 N–m) @ 2400
rpm. High Idle–3400 rpm. Low Idle–1400 rpm. Displacement 41 cu–in. (674 cc). Air
Filter–Dry, large capacity, replaceable element. Oil Filter–External, spin–on.
Fan–High flow blower.
Front & Rear–20x10–10, 2 ply rated, smooth tread, tubeless, Inflated to 12 psi,
demountable rims.
Controls
Ignition, throttle, choke, parking brake, traction lever, raise/lower, aeration spacing,
manual/ground follow selector switch, system reset and aeration depth.
Electrical
Alternator/Generator–12 Volt, 15 Amp regulated charging
Battery–BCI Group No.: U1, 300 Cold Cranking Amp @ 0_ F
Instrumentation–Hour/tachometer
Controller–Micro–processor logic control
Interlocks–Clutch Latch, traction neutral, coring head raise/lower
Capacities
Brakes
Hydraulic System
Drive Train
Speed & Direction
Aerating Depth Control
Dimensions
Fuel 7.5 gal (28.4 L) Minimum (unleaded gasoline)
Engine Oil w/ Filter 2 Qt. (1.9 L) (Mobil 10W–30)
Hydraulic Oil 3.0 gal (11.3 L)
Service Brake Dynamic through hydrostatic transmission
Parking Brake Hand actuated on handle
Remote Spin–On Filter.
3 wheel drive, Parallel–Series hydrostatic, closed loop
Pump Variable displacement piston type
.97 cu–in (16 cc) full stroke
12 gpm (45.4 lpm) full stroke
2900 psi (200 bar) system relief
Wheel Drive High torque, low speed wheel motors
Rear 12 cu–in (197 cc) displacement
Front 24 cu–in (393 cc) displacement
Hand controlled bail on handle
Operator Presence–Coring head lifts and de–clutches if released
Forward 0–3.5 mph (0–5.6 km/h), variable, 4 aeration speeds
Reverse 0–2.0 mph (0–3.2 km/h), variable
Aerating
Detent 1 1.5” (3.8 cm) spacing
Detent 2 2.0” (5.1 cm) spacing
Detent 3 2.5” (6.4 cm) spacing
Detent 4 3.0” (7.6 cm) spacing
True Core Micro–processor logic control of lift & lower via hydraulic
solenoid/cylinder
Fixed Mechanical stops, operator adjusted for desired depth
Overall Length 104.5 in. (265.4 cm)
Overall Width 50.12 in. (127.3 cm)
Height
Head Raised 45.0 in. (114.3 cm)
Head Lowered 36.5 in. (92.7 cm)
Top of Handle 41.0 in. (104.1 cm)
Wheel Base 44.5 in. (113.0 cm)
Track Width 38.3 in. (97.3 cm)
Coring Width 48 in. (122 cm)
Ground Clearance 4.75 in. (12.1 cm)
Weight (less fuel) 1590 lbs (721 Kg)
9
Accessory Chart
ProCore 648
Optional Accessories
48” (1.2 meter) wide
Model Number 09200
Windrower Kit
09220
Tire Scrapers
09225
Extra Weight
99–6166–01
Tine Heads Required
10 Mini Tine Head
5 Needle Tine Head
1.6” spacing
1.6” spacing
3/8” shank size
Model No. 09222
Model No. 09221
Turf Holders Required
Turf Holders Required
105–1110
qty 2
105–1110
qty 2
105–1111
qty 1
105–1111
qty 1
Tines
Tines
60 Required
30 Required
Classic Tine Options
3/8”
9.5mm
3/16”
4.5mm
1/4”
3/16”
Classic Tine Options
100–3622
3/16”
5mm
Needle Tine
100–3620
Side Eject
94–3417
5/16”
8mm
Needle Tine
100–3621
6.5mm
Side Eject
106–8941
5.0mm
Hollow
100–3625
Solid
3 Tine Head
3 Tine Head
2.6” spacing
2.6” spacing
2.0” spacing
7/8” shank size
3/4” shank size
3/4” shank size
Model No. 09226
Model No. 09223
Model No. 09224
Turf Holders Required
4 Tine Head
Turf Holders Required
Turf Holders Required
105–1106
qty 1
105–1106
qty 1
105–1104
qty 1
105–1107
qty 1
105–1107
qty 1
105–1105
qty 1
Tines
Tines
18 Required
Tines
18 Required
24 Required
Classic Tine Options
7/8”
22mm
Side Eject
104–9877
3/4”
19mm
Side Eject
92–7900
3/8”
9mm
Solid
100–3626
3/4”
19mm
Hollow
86–9720
3/8”
10mm
Solid
100–3627
7/16”
11mm
Solid
100–3628
1/2”
13mm
Solid
100–3629
5/8”
16mm
Solid
100–3630
5/8”
16mm
Side Eject
3/4”
19mm
Side Eject
MAX Quad
1/2”
13mm
Extended Side Eject
106–8947
Extended Side Eject
107–7544
Toro TITAN
and TITAN
Classic Tine Options
MAX tines
A new line of premium and carbide tipped tines
Available in .
104–9876
104–9875
TITAN
& TITAN
TITAN
& TITAN
MAX Hollow
5/8”
16mm
TITAN
& TITAN
MAX Side Eject
3/8”
10mm
Hollow
100–3633
TITAN
& TITAN
MAX Fairway
1/2”
13mm
Hollow
100–3634
TITAN
Solid Round
5/8”
16mm
Hollow
104–0984
TITAN
Cross & TITAN
1/2”
13mm
Extended Hollow
105–1180
5/8”
16mm
Extended Hollow
106–8943
Slicing
See your distributor for more information
10
Setup
Note: Determine the left and right sides of the machine from the normal operating position.
Loose Parts Chart
Note: Use this chart as a checklist to ensure all parts necessary for assembly have been shipped. If any of these parts are
missing, total setup cannot be completed.
Description
Qty.
Locknuts, 1/2–20
3
Cable guide
1
Capscrews, 5/16 x 1/2 in.
2
Hood plate
1
Pop rivet
3
Capscrew, #10–24 x 2 in.
1
Nut, #10–24
1
Locknut, #10–24
1
Capscrew, 1/4–20 x 1 in.
1
Locknut, 1/4–20
1
Carriage bolt, 5/16 x 3/4 in.
2
Flange nut, 5/16
2
Ignition key
2
Carriage screw, 3/8 x 1.25 in.
12
Flat washer, 3/8
12
Flange nut, 3/8
12
Use
Install the handle to the fork
Secure rear hood for CE
Secure jackshaft hood for CE
Secure battery cables to battery posts
Secure turf guards
Declaration of conformity
Operator’s manual
2
Read before operating the machine.
Engine operator’s manual
1
Read before operating the machine.
Parts catalog
1
Operator video
1
Pre–delivery check list
1
Note: Specifications and design subject to change without notice.
11
View before operating the machine
4. Insert the cable guide around the cables.
Note: To raise the coring head, after uncrating the
machine, start the engine and depress the RESET button.
Refer to the Operation section of this manual for more
information.
5. Mount the cable guide to the top of the fork with (2)
5/16 x 1/2” capscrews (Fig. 3).
Install the Rear Wheels
Activate, Charge and Connect
the Battery
1. Remove the (8) lug nuts securing the rear of the
aerator to the packaging.
2. Mount a wheel to each hub with (4) lug nuts (Fig. 2).
Torque the nuts to 45–55 ft.–lb. (61–75 N⋅m).
Warning
Note: Make sure a bearing plate is in position between
each wheel and hub.
CALIFORNIA
Proposition 65 Warning
3. The tires are over inflated for shipping. Make sure the
tire pressure is 12 psi (83 kPa) for front and rear
wheels.
Battery posts, terminals, and related accessories
contain lead and lead compounds, chemicals
known to the State of California to cause cancer
and reproductive harm. Wash hands after
handling.
1
1. Unlatch and open battery compartment cover.
3
2. Remove the battery from the battery compartment.
2
Figure 2
1. Wheel
2. Lug nut
3. Bearing plate
Install the Handle
1. Carefully rotate the handle to the front of the machine.
Use caution not to damage cables.
2. Insert the handle mounting studs into the holes in the
fork (Fig. 3).
1
4
Figure 4
1. Battery compartment
Use only electrolyte (1.265 Specific Gravity) to fill
battery initially.
1
Important Do not add electrolyte while the battery is
in the machine. You could spill it, causing corrosion.
3
2
3. Clean the top of the battery and remove the vent caps.
Figure 3
1. Handle
2. Fork
4. Carefully fill each cell with electrolyte until the plates
are covered with about 1/4 inch (6 mm) of fluid.
3. Locknut
4. Cable guide
5. Allow approximately 20 to 30 minutes for the
electrolyte to soak into the plates. Refill as necessary
to bring the electrolyte to within about 1/4 inch
(6 mm) of the bottom of the fill well.
3. Secure handle studs to fork with (3) 1/2–20 locknuts
(Fig. 3)
12
2
Warning
5
Charging the battery produces gasses that can
explode.
4
Never smoke near the battery and keep sparks
and flames away from battery.
6. Connect a 3 to 4 amp battery charger to the battery
posts. Charge the battery at a rate of 3 to 4 amps until
the specific gravity is 1.250 or higher and the
temperature is at least 60_ F (16_ C) with all cells
gassing freely.
1
7. When the battery is charged, disconnect the charger
from the electrical outlet and battery posts.
Note: After the battery has been activated, add only
distilled water to replace normal loss, although
maintenance–free batteries should not require water under
normal operating conditions.
3
Warning
Battery terminals or metal tools could short
against metal tractor components causing sparks.
Sparks can cause the battery gasses to explode,
resulting in personal injury.
Figure 5
1. Battery tray
2. Battery hold down
3. Hold down rod
• When removing or installing the battery, do not
allow the battery terminals to touch any metal
parts of the tractor.
• Do not allow metal tools to short between the
battery terminals and metal parts of the
tractor.
4. Positive terminal (+)
5. Negative terminal (–)
Important Make sure there is clearance between the
battery cables and the speed selector lever. Verify that the
speed selector lever does not come within 1 inch of either
battery cable when it is moved through its entire range of
motion. Do not wire tie or tape the negative and positive
battery cables together.
8. Insert the battery into the tray in the battery
compartment (Fig. 5) Position the battery so the
terminals are to the outside.
Warning
9. Secure battery to compartment base with a battery rod,
(2) hold down rods, (2) flat washers and (2) wing nuts
(Fig. 5).
Incorrect battery cable routing could damage the
tractor and cables causing sparks. Sparks can
cause the battery gasses to explode, resulting in
personal injury.
10. First, secure the positive cable (red) to the positive (+)
battery terminal with a carriage bolt and nut (Fig. 5),
then the negative cable (black) to the negative (–)
terminal of the battery with a carriage bolt and nut
(Fig. 5). Slide the rubber boot over the positive
terminal to prevent a possible short from occurring.
• Always disconnect the negative (black) battery
cable before disconnecting the positive (red)
cable.
• Always connect the positive (red) battery cable
before connecting the negative (black) cable.
11. Close and latch battery compartment cover.
13
Secure Rear Hood
Secure Belt Cover
(Required for CE)
(Required for CE)
1. Secure the hood plate to the rear hood with (3) pop
rivets (Fig. 7).
1. Insert a 1/4 x 1 inch capscrew thru the belt cover latch
lever and secure with a 1/4 locknut (Fig. 8 & 9).
2. Thread a #10 nut onto a #10 x 2 inch capscrew.
3. Insert the capscrew thru the hood plate (Fig. 7).
1
2
1
Figure 8
1. Belt cover
Figure 6
2. Latch lever
1. Rear hood
2
2
1
1
3
Figure 9
1. Latch lever
Figure 7
1. Hood plate
2. Pop rivet
2. Capscrew & nut
Install Tine Holders, Turf
Guards and Tines
3. Capscrew & nuts
A wide selection of tine holders, turf guards and tines are
available for the aerator. Refer to page 22 for the
installation instructions.
4. Secure the capscrew to the hood plate with a # 10
locknut (Fig. 7).
14
Before Operating
Danger
In certain conditions, gasoline is extremely
flammable and highly explosive. A fire or
explosion from gasoline can burn you and others
and can damage property.
Recommended Gasoline
Use UNLEADED Regular Gasoline suitable for
automotive use (85 pump octane minimum). Leaded
regular gasoline may be used if unleaded regular is not
available.
• Fill the fuel tank outdoors, in an open area,
when the engine is cold. Wipe up any gasoline
that spills.
• Never fill the fuel tank inside an enclosed
trailer.
• Do not fill the fuel tank completely full. Add
gasoline to the fuel tank until the level is 1/4 to
1/2 inch (6 to 13 mm) below the bottom of the
filler neck. This empty space in the tank allows
gasoline to expand.
• Never smoke when handling gasoline, and stay
away from an open flame or where gasoline
fumes may be ignited by a spark.
• Store gasoline in an approved container and
keep it out of the reach of children. Never buy
more than a 30-day supply of gasoline.
• Always place gasoline containers on the ground
away from your vehicle before filling.
• Do not fill gasoline containers inside a vehicle
or on a truck or trailer bed because interior
carpets or plastic truck bed liners may insulate
the container and slow the loss of any static
charge.
• When practical, remove gas–powered
equipment from the truck or trailer and refuel
the equipment with its wheels on the ground.
• If this is not possible, then refuel such
equipment on a truck or trailer from a portable
container, rather than from a gasoline
dispenser nozzle.
• If a gasoline dispenser nozzle must be used,
keep the nozzle in contact with the rim of the
fuel tank or container opening at all times until
fueling is complete.
• Do not operate without entire exhaust system in
place and in proper working condition.
Important Never use methanol, gasoline containing
methanol, or gasohol containing more than 10% ethanol
because the fuel system could be damaged. Do not mix oil
with gasoline.
Warning
Gasoline is harmful or fatal if swallowed.
Long–term exposure to vapors can cause serious
injury and illness.
• Avoid prolonged breathing of vapors.
• Keep face away from nozzle and gas tank or
conditioner opening.
• Keep gas away from eyes and skin.
Using Stabilizer/Conditioner
Use a fuel stabilizer/conditioner in the aerator to provide
the following benefits:
• Keeps gasoline fresh during storage of 90 days or less.
For longer storage it is recommended that the fuel tank
be drained.
• Cleans the engine while it runs
• Eliminates gum-like varnish buildup in the fuel
system, which causes hard starting
Important Do not use fuel additives containing
methanol or ethanol.
Add the correct amount of gas stabilizer/conditioner to the
gas.
Note: A fuel stabilizer/conditioner is most effective when
mixed with fresh gasoline. To minimize the chance of
varnish deposits in the fuel system, use fuel stabilizer at
all times.
15
Filling the Fuel Tank
1
Fuel tank capacity is approximately 7.5 gal (28.4 l)
2
1. Stop the engine, remove the key, and wait for all
moving parts to stop before leaving the operating
position.
2. Clean around each fuel tank cap and remove the cap
(Fig. 10). Add unleaded regular gasoline to fuel tank
until the level is 1/4 to 1/2 inch (6 mm to 13 mm)
below the bottom of the filler neck. This space in the
tank allows gasoline to expand. Do not fill the fuel
tank completely full.
Figure 11
1
1. Oil dipstick
2. Filler tube
3. Pull out the oil dipstick and wipe the metal end clean
(Fig. 12).
4. Slide the oil dipstick fully into the filler tube. Pull the
dipstick out and look at the metal end (Fig. 12). If oil
level is low, slowly pour only enough oil into the filler
tube to raise the level to the full mark.
2
1
Figure 10
1. Fuel tank cap
3. Install fuel tank cap securely. Wipe up any gasoline
that may have spilled.
Figure 12
Check Engine Oil Level
1. Oil dipstick
Note: Check the engine oil daily and when the engine is
cold.
Important Do not overfill the crankcase with oil
because this may cause engine damage. Do not run the
engine with oil below the low mark because the engine
may be damaged as a result.
1. Stop the engine, remove the key, and wait for all
moving parts to stop before leaving the operating
position.
2. Clean around the oil dipstick (Fig. 11) so dirt cannot
fall into the filler hole and damage the engine.
16
2. Metal end
Check Hydraulic System Fluid
Group 3 Hydraulic Fluid (Biodegradable)
ISO VG 32/46 anti-wear hydraulic fluid
The hydraulic system is designed to operate on anti–wear
hydraulic fluid. The machines reservoir is filled at the
factory with approximately 1.75 gallons of high quality
hydraulic fluid. Check level of hydraulic fluid before
engine is first started and daily thereafter. Appropriate
hydraulic fluids are listed below.
Mobil
Note: This synthetic biodegradable hydraulic fluid is not
compatible with the fluids in Group 1.
Note: When changing from standard fluid to the
biodegradable type, be certain to follow approved flushing
procedures as published by Mobil. Contact your local
Toro Distributor for details.
The following list is not assumed to be all–inclusive.
Hydraulic fluids produced by other manufacturers may be
used if they can cross reference to find an equivalent to
the products listed. Toro will not assume responsibility for
damage caused by improper substitutions, so use only
products from reputable manufacturers who will stand
behind their recommendation.
Important Use only types of hydraulic fluids
specified. Other fluids could cause system damage.
Note: A red dye additive for the hydraulic system fluid is
available in 2/3 oz. bottles. One bottle is sufficient for 4–6
gal. of hydraulic fluid. Order Part No. 44–2500 from your
Authorized Toro Distributor.
Important Use only types of hydraulic fluids
specified. Other fluids could cause system damage.
Group 1 Hydraulic Fluid (Moderate climate– average
duty)
1. Position machine on a level surface, stop the engine,
remove the key, and wait for all moving parts to stop
before leaving the operating position.
Note: The fluids within this group are interchangeable.
Universal Tractor Hydraulic Fluid
Mobil
Amoco
Chevron
Conoco
Exxon
Pennzoil
Shell
Texaco
EAL Envirosyn H, ISO Grade 68
2. Unlatch and remove the belt cover (Fig. 13).
Mobil Fluid 424
1000 Fluid
Tractor Hydraulic Fluid
Power-Tran 3
Torque Fluid
Hydra–Tranz
Donax TD
TDH
2
Important For the ProCore 648 the Group 1 fluids are
recommended for use at typical ambient temperatures of
32_ F (0_ C) to 95_ F (35_ C). The Universal Tractor Fluids
offer similar performance for those who prefer them, with
perhaps some slight loss of efficiency at high ambient
temperatures compared to the Type 46/68 fluids.
1
Important For operating conditions where sustained
ambient temperatures are 95_ F (35_ C) or higher Toro
highly recommends the use of Mobil 1 15W–50 synthetic
oil.
Figure 13
1. Belt cover
Note: When changing from one type of hydraulic fluid to
another, be certain to remove all the old fluid from the
system, as some fluids are incompatible with others.
2. Cover latch
3. Clean area around filler neck and cap of hydraulic tank
(Fig. 14). Remove cap from filler neck.
Group 2 Hydraulic Fluids are not recommended for
use in this application
17
Check the Tire Pressure
1
Maintain the air pressure in the front and rear tires as
specified. Uneven tire pressure can cause uneven coring
depth. Check the pressure at the valve stem after every
50 operating hours or monthly, whichever occurs first
(Fig. 16). Check the tires when they are cold to get the
most accurate pressure reading.
Pressure: 12 psi (83 kPa) front and rear wheels.
Figure 14
1. Hydraulic tank cap
2
4. Remove dipstick from filler neck and wipe it with a
clean rag. Insert dipstick into filler neck; then remove
it and check level of fluid. Fluid level should be up to
mark on dipstick (Fig. 15).
1
Figure 16
1. Valve stem
1
Caution
The wheel weight is very heavy, 73 lbs. Use
caution when removing weight from tire assembly.
2
Figure 15
1. Dipstick
2. Wheel weight
2. Full mark
5. If level is low, add appropriate fluid to raise level to
full mark.
6. Install dipstick and cap onto filler neck.
18
Operation
Ignition Switch
The ignition switch (Fig. 19), which is used to start and
stop the engine, has three positions: OFF, RUN, and
START. Rotate key clockwise to the START position to
engage starter motor. When engine starts, release key and
it will move automatically to the ON position. To shut
engine off, rotate key counterclockwise to the OFF
position.
Note: Determine the left and right sides of the aerator
from the normal operating position (Fig. 17).
Left Side
Raise, Lower/Engage Switch
Raise – Press the top of the switch (Fig. 18) to raise the
coring head. The engine must be running to generate lift
pressure. If the coring head is below the transport height,
refer to System Control Circuit Reset, page 24.
Operating
Direction
Lower/Engage – Press the bottom of the switch (Fig. 18)
to lower and engage the coring head. The traction lever
must be in the forward position to activate the switch.
Right Side
Figure 17
Caution
Controls
Keep hands and feet away from the coring head.
Make sure the coring head area is clear of any
obstructions before lowering it.
Become familiar with all the controls before you start the
engine and operate the aerator.
To lower the coring head without engaging the coring
head, turn the ignition key to the RUN position (without
the engine running), move the traction lever to the
forward position and press the bottom of the switch.
Traction Lever
To move forward, move the traction lever forward. To
move rearward, move the traction lever rearward
(Fig. 18).
2
The farther you move the traction control, the faster the
aerator will move.
To stop, release the traction control.
3
Parking Brake
To engage the parking brake, move the lever toward the
engine. To disengage the parking brake, move the lever
forward (Fig. 18).
4
Always set the parking brake when you stop the aerator or
leave it unattended.
1
Jog traction lever forward and reverse to release parking
brake.
Figure 18
Oil Pressure Warning LIght
1. Traction lever
2. Parking brake
The oil pressure warning light (Fig. 18) glows when oil
pressure in engine drops below a safe level. If low oil
pressure ever occurs, stop engine and determine the cause.
Repair the damage before starting the engine again.
3. Raise, lower/engage
switch
4. Oil pressure warning light
Aerator Spacing Lever
Move aerator spacing lever (Fig. 19) to desired hole
spacing or to “T” for transport.
19
Throttle Control
Manual Ground Follow Selector Switch
The throttle (Fig. 19) is used to operate engine at various
speeds. Moving throttle forward increases engine
speed—FAST; backward decreases engine speed—SLOW.
The throttle regulates the speed of the coring head and
controls the ground speed of the traction unit.
Rotate switch to down position to turn off the TrueCoret
feature (Fig. 19) Remove screw to access manual ground
switch.
3
System Reset
Press system reset switch (Fig. 19) to raise coring head if
system becomes disabled (i.e. engine out of fuel, etc.)
4
1
Aeration Depth Lever
Move lever to the desired depth of aeration (Fig. 20)
5
2
1
6
7
Figure 19
1.
2.
3.
4.
Ignition
Aerator spacing lever
Throttle
Choke
5. Hour meter/tachometer
6. Manual ground follow
7. System reset
Figure 20
Hour Meter/Tachometer
1. Aeration depth lever
When the engine is off, the hour meter/tachometer
(Fig. 19) displays the number of hours of operation that
have been logged on the traction unit. When the engine is
running, it displays the speed of the engine in revolutions
per minute (rpm).
Starting and Stopping the
Engine
After the first 50 hours of operation and then after every
100 hours (e.g. 150, 250, 350, etc.) the screen displays
”CHG OIL” to remind you to change the engine oil. After
every 100 hours (e.g. 100, 200, 300, etc.), the screen
displays ”SVC” to remind you to perform the other
maintenance procedures based on a 100, 200, or 500 hour
schedule. These reminders come on starting three hours
prior to the service interval time and flash at regular
intervals for six hours.
Starting the Engine
1. Release the traction lever (bail) and set the parking
brake.
2. Move the choke control to the on position before
starting a cold engine.
Note: A warm or hot engine may not require choking.
After engine starts, move choke control to run position.
Choke
3. Move the throttle control to the fast position before
starting a cold engine.
To start a cold engine, close carburetor choke by moving
choke control (Fig. 19) fully forward. After engine starts,
regulate choke to keep engine running smoothly. As soon
as possible, open the choke by pulling it backward.
4. Turn the ignition key to start. When the engines starts,
release the key.
20
Important Do not engage starter for more than
10 seconds at a time. If engine fails to start allow
30 second cool-down period between attempts. Failure to
follow these instructions can burn out starter motor.
Testing the Safety Interlock System
5. After the engine starts, move the choke to off . If the
engine stalls or hesitates, move the choke back to on
for a few seconds. Then move the throttle lever to
desired setting. Repeat this as required.
• Engine must only crank when the traction lever is in
the neutral position.
Stopping the Engine
If the safety system does not operate as described above,
have an Authorized Service Distributor repair the safety
system immediately.
Test the safety interlock system before you use the aerator
each time.
• If traction lever is released or moved to the neutral
position, the coring head should raise and stop
rotating.
1. Move the throttle lever to the idle position.
2. Let the engine idle for 60 seconds.
Service Latches
3. Turn the ignition key to the off position and remove
the key.
4. Close the fuel shut off valve before transporting or
storing the aerator.
Danger
Important Make sure that the fuel shut off valve is
closed before transporting on a trailer or storing the
aerator, as fuel leakage may occur. Set the parking brake
before transporting. Make sure to remove the key as the
fuel pump may run and cause the battery to lose charge.
Any time the coring head is to be serviced
including changing of tines or turf guards, install
the service latch to secure head in the raised
position.
The service latch should also be installed when the aerator
is to be stored for more than a couple days.
Caution
1. Raise coring head.
Children or bystanders may be injured if they
move or attempt to operate the aerator while it is
unattended.
2. Remove clip ring securing service latch in storage
position (Fig. 21).
Always remove the ignition key and set the
parking brake when leaving the aerator
unattended, even if just for a few minutes.
The Safety Interlock System
Caution
If safety interlock switches are disconnected or
damaged the aerator could operate unexpectedly
causing personal injury.
1
Figure 21
1. Service latch in (lowered) storage position
• Do not tamper with the interlock switches.
• Check the operation of the interlock switches
daily and replace any damaged switches before
operating the aerator.
3. Pivot service latch rearward and insert onto coring
head pin (Fig. 22). Secure with clip ring.
Understanding the Safety Interlock
System
The safety interlock system is designed to prevent the
engine from starting unless the traction bail is in the
neutral position.
21
2
1
Figure 24
1
1. Turf guard
2. Turf guard bracket
4. Loosely install a tine clamp to each tine holder with
(4) 3/8 x 1–1/2 in. capscrews. (Fig. 26) Do not tighten
capscrew.
Figure 22
1. Service latch in (raised) locked position
5. Install tines into the #2 and #5 tine holders (Fig. 25)
Tighten the capscrews.
Install Tine Holders, Turf
Guards and Tines
GRAPHIC #
A wide selection of tine holders, turf guards and tines are
available for the aerator. Choose the required components
per the accessory chart on page 10.
1. Raise coring head and lock in position with service
latch.
2. Mount a tine holder to each tine arm with (3) 1/2 x
1–1/4 in. capscrews (Fig. 23). Torque capscrews to
75 ft.–lbs. (Capscrews provided in tine holder kits)
1
2
Figure 25
1. Number 5 tine holder
1
1. Number 2 tine holder
2
1
Figure 23
1. Tine arm
2. Tine holder
2
3. Loosely install the turf guards to the turf guard
brackets with (12) carriage bolts, flat washers and
flange nuts (Fig. 24). Do not tighten the fasteners.
Carriage bolt heads to be positioned under turf guard
brackets.
Figure 26
1. Tine clamp
22
2. Tine
6. Check that the tines line up with the center of the gaps
in the turf guards (Fig. 27). Adjust turf guards as
required and tighten the nuts.
1
1
2
1
Figure 27
Figure 28
1. Aeration depth lever
7. Install remaining tines into #1, 3, 4 & 6 tine holder.
Torque all tine holder capscrews to 30 ft.–lbs.
2. Overlay on decal
3. Determine which letter setting the other end of the tine
lines up with and set the depth control lever to the
corresponding letter setting.
When replacing all the tines, proceed as follows:
1. Raise the coring head and lock in position with the
service latch.
Note: As the tine wears, you may be able to reset the
depth setting to account for that wear. For instance, if your
new tine depth setting has you in the “G” setting, you can
reset to the “H” setting after 1/4 inch of tine wear.
2. Loosen the tine holder retaining capscrews and remove
the old tines.
3. Insert the new tines into the tine holder.
Manual Ground Following
4. Tighten the capscrews to recommended torque level.
5. Repeat procedure on remaining arms.
Setting the Coring Depth
The only time the manual depth setting spacers are
required is if the TrueCoret ground following system is
not functioning due to damage to the feedback system
(turf guards, tie rod, and actuator assembly).
To set the coring depth of the aerator, proceed as follows
To use the manual depth setting, proceed as follows:
1. Select the preferred tine for your application
1. Remove the lynch pin retaining the spacers and depth
pins (Fig. 29).
2. Lay the tine on the tine depth decal (Fig. 28) with one
end lined up with the desired depth of aeration (see the
tine overlay on the decal).
2. Position the spacers above or below the bracket to
attain the desired coring depth.
• Thick spacers equate to 3/4 inch increments.
• Thin spacer equates to 3/8 inch depth increment.
• With all spacers on the top side, the depth setting is
4–1/4 inches.
23
2. Using a 5/8 in. wrench, rotate the by-pass valve
counterclockwise 1 turn to push/pull. This allows
hydraulic fluid to by-pass the pump enabling the
wheels to turn (Fig. 31).
1
2
2
1
Figure 29
1. Lynch pin
2. Spacers & depth pin
3. Remove locking capscrew and nut from selector
switch (Fig. 30).
Figure 31
1. By–pass valve
Important Do not rotate by-pass valve more than
1 turn. This prevents the valve from coming out of the
body and causing fluid to run out.
1
Important Do not push/pull the aerator more than
100 ft. or faster than 1 mph because hydraulic damage
may occur.
2
3. Disengage the parking brake before pushing/pulling.
Important Do not operate engine with by–pass valve
open for more than 10–15 seconds.
Figure 30
1. Manual ground following
selector switch
Changing to Aerator Operation
2. Capscrew and nut
Rotate the by-pass valve clockwise 1 turn to operate
aerator (Fig. 31).
4. Rotate switch to down position to turn off True Core
feature.
Note: Do not over tighten the by–pass valve.
Note: The aerator will not drive unless the by-pass valve
is turned closed. Do not try to operate traction system with
by–pass open.
5. Re–install locking capscrew and nut to ensure setting
is not accidentally changed.
Pushing/Pulling the Aerator by
Hand
System Control Circuit Reset
If the coring head is ever left in the aerating position (run
out of fuel, forget to install service latch for storage,
mechanical failure of engine/pump, etc.) the electrical
system that controls the hydraulic solenoid coils and the
electric clutch is disabled to prevent unintended
movement of the coring head without the deliberate action
of resetting the system.
Important Never tow the aerator faster than 1 mph
because hydraulic damage may occur.
Pushing/pulling the Aerator
1. Set the parking brake, turn the ignition key to off and
remove the key from the ignition.
24
Use a heavy–duty trailer or truck to transport the aerator.
Ensure that the trailer or truck has all necessary lighting
and marking as required by law. Please carefully read all
the safety instructions. Knowing this information could
help you, your family, pets or bystanders avoid injury.
To reset the system after engine is started, depress rocker
switch (Fig. 32) to raise coring head and reset the
electrical control circuit.
To transport the aerator:
• Set the parking brake and block the wheels.
• Securely fasten the aerator tie downs (Fig. 33–35) to
the trailer or truck with straps, chains, cable, or ropes.
• Secure the trailer to the towing vehicle with safety
chains.
1
Warning
Figure 32
Driving on street or roadway without turn signals,
lights, reflective markings, or a slow moving
vehicle emblem is dangerous and can lead to
accidents causing personal injury.
1. Circuit reset switch
Coring Head Stranded In
Lowered Position
Do not operate aerator on a public street or
roadway.
In the event that the engine fails or cannot be restarted
with the coring head lowered and tines are engaged in the
soil, proceed as follows:
• Remove the tine holders from the stomper arms.
• Open the by–pass valve one turn.
• Pull/push the aerator to a nearby location to continue
service or load onto a trailer.
1
Important Do not pull/push aerator for more than 100
feet and no faster than 1 mph because hydraulic damage
may occur.
Figure 33
Transporting Aerator
1. Tie down
Trailer recommendations
1
Important The Hydroject trailer/tote CAN NOT be
used to trailer this aerator.
Weight
1590 lbs (721 Kg)
1775 lbs (805 Kg) w/ two
optional weights
Width
51 Inches min.
Length
105 Inches min.
Ramp Angle
16 degrees (3.5/12 pitch) max.
Load Direction
Coring head forward (preferred)
Vehicle Tow Capacity
Greater than Gross Trailer Weight
(GTW)
1
Figure 34
1. Tie down
25
Replace broken tines, inspect and correct damage to those
still useable. Repair any other machine damage before
commencing operation.
The ProCore 648 will aerate deeper than most greens
aerators. On native or modified push–up greens & tees,
the deeper depth and longer hollow tines may have
difficulty ejecting the complete core. This is due to harder
native soil that sticks in the end of the tine. Side–eject
greens/tees tines from Toro will stay cleaner and reduce
the time required to clean the tines out. This condition is
eventually eliminated with continued aeration and
top–dressing programs.
1
Hard Ground
If the ground is too firm to obtain the desired coring
depth, the coring head can get into a “bouncing” rhythm.
This is due to the hard pan the tines are attempting to
penetrate. This condition can be corrected by attempting
the following:
Figure 35
1. Tie down
• Do not aerate if ground is too hard or dry, best results
are obtained after a rain or when turf has been watered
the previous day.
Loading Aerator
Use extreme caution when loading the aerator on a trailer
or truck. One full width ramp that is wide enough to
extend beyond the rear tires is required.
• Change to a 3–tine head, if attempting to use the
4–tine head or reduce the number of tines per stomper
arm. Attempt to maintain a symmetrical tine
configuration to evenly load the stomper arms.
The ramp should be long enough so that the angles do not
exceed 16 degrees. A steeper angle may cause aerator
components to get caught as the unit moves from ramp to
trailer or truck. Steeper angles may also cause the unit to
tip backward. If loading on or near a slope, position the
trailer or truck so it is on the down side of the slope and
the ramp extends up the slope. This will minimize the
ramp angle. The trailer or truck should be as level as
possible. Load aerator with the coring head going up the
ramp first.
• Reduce aerator penetration (depth setting), if ground is
hard packed. Clean up cores, water turf, and re–aerate
at a deeper penetration.
Aeration of soil types built on top of hard sub–soils
(i.e. soil/sand placed over rocky soil) can cause undesired
hole quality. This is caused when the aeration depth is
greater than the built up soil and the sub–soil is too hard
to penetrate. When the tines contact this harder sub soil
the aerator may lift and cause the top of the holes to
become elongated. Reduce the aerating depth sufficiently
to avoid penetration into the hard sub–soil.
Important Do Not attempt to turn the unit while on
the ramp; you may lose control and drive off the side.
Avoid sudden acceleration when driving up a ramp and
sudden deceleration when backing down a ramp. Both
maneuvers can cause the unit to tip backward.
Entrance/Exit
If the entrance/exit hole quality is deteriorating, the clutch
may not be engaging soon enough. Check the following:
Operating Tips
• The no. 3 switch location on H–Frame
General
• Clutch wear/slippage
Make very gradual turns when aerating. Never make sharp
turns with the coring head engaged. Plan your aeration
path before lowering the aerator.
If the hole quality upon entrance is slotted (pulled
forward) or the coring head fails to engage before
contacting the turf, the engagement position switch may
require adjustment.
Look behind frequently to ensure the machine is operating
properly and alignment is maintained with previous
passes.
• Verify that the switch assembly along side the
H–Frame is no more than .06 inches from the target
plate
Always clear the area of all damaged machine parts, such
as broken tines, etc., to prevent their being picked up by
mowers or other turf maintenance equipment.
• Verify that the #3 switch is functioning properly
26
• If needed, loosen the switch mounting plate and lift to
its highest position and re–secure the mounting plate.
The higher the switch, the sooner the clutch engages
3. Loosen the capscrews securing the bumper plate.
4. Slide the bumper plate forward and re–secure the
capscrews. This allows the Roto–Link bumpers to
oscillate properly.
If the coring head fails to start before entrance and the
position switch is located as high as permissible, the
electric clutch may have deteriorated sufficiently to cause
a delay in engagement. Contact your Toro distributor or
refer to the ProCore 648 service manual.
Take the aerator to a test area and compare the hole
quality. If improved, complete this procedure with
remaining Roto–Link damper assemblies.
Note: This re–positioning of the Roto–Link damper must
be reversed if the tine type is changed back to a coring
style tine or any of the mini–tines.
Mini Tine (Quad Tine)
The mini–tine head developed by Toro is a very fast way
to aerate due to the double row design. This coring head
requires the hole spacing to be set at 2.5 inches. Ground
speed is critical to maintain the appearance of 1.25 in.
hole spacing. Refer to the hole spacing adjustment section
if your hole spacing requires a small change.
Upon Completion
After daily use, thoroughly wash the machine with a
garden hose without a nozzle so contamination and seal
and bearing damage due to excessive water pressure will
be avoided. A brush may be used to remove caked-on
material. Use mild detergent to clean the covers. Applying
a coat of auto wax periodically will retain the cover’s
glossy finish. After cleaning, inspect for machine damage,
oil leakage, component and tine wear.
With the mini tine head or larger solid tine use, the turf
root structure is important to preventing turf damage due
to tearing of the root zone. If the center two arms begin to
lift the turf or damage to the root zone is excessive,
proceed as follows:
Remove clean and oil the tines. Spray a light oil mist on
coring head bearings (crank & damper links).
• Increase the hole spacing
• Decrease tine size
Secure service latch if the aerator is to be stored for more
than a couple days.
• Remove some of the tines
This damage is caused by the lifting action that solid tines
create when pulled from the turf. This lift can tear the root
zone if the density of tines or diameter of tines is too high.
Using Line Marker
Use the line marker to align aeration rows (Fig. 36).
Front Hole Dimpled or Pushed
(Solid Tines or softer soil conditions)
When aerating with longer solid tines (i.e. 3/8 in. x 4 in.
long) or needle type tines, the front of the holes may
become slotted or tufted. To regain excellent hole quality
for this configuration, slow the engine high idle speed
down to 2800 – 2900 rpm. The hole spacing is not
affected as the traction and coring head speeds are both a
function of engine speed.
2
If slowing the engine speed does not work to the remedy
hole quality for the larger solid tines, the Roto–Link
damper mechanism may require a stiffer setting. A stiffer
Roto–Link setting may help eliminate the front of the hole
from being deformed. However, under most conditions,
the factory setting works best.
1
Figure 36
1. Line marker (storage
position)
2. Line marker (alignment
position)
Note: Alter half of the Roto–Links (3 arms) and test the
difference on a sample plot.
1. Remove the lock nuts securing the Roto–Link damper
assembly to the coring head frame.
Adjusting Weight Transfer
2. Remove the top damper–spacer (1/2 inch thick) and
re–secure the Roto–Link damper assembly to the
coring head frame. Be sure to use the hardened “D”
washer.
The ProCore 648 is designed to transfer weight from the
traction unit to the coring head to help maintain hole
depth in various soil structures. However, if the soil
structure is firm enough to not allow full aeration depth
27
3. Hold the rachet or breaker–bar to relieve the tension
on the spring plate and remove the rear carriage bolt.
some additional weight transfer may be required. To
increase the down pressure of the weight transfer springs,
proceed as follows:
4. Rotate the spring plate until it is aligned with the other
hole, insert the carriage bolt and tighten nuts.
Warning
Note: Rotating spring plates upward will increase weight
transfer.
Sudden release of the spring plates could cause
injury.
Additional Weight
Acquire the help of another person to help adjust
the weight transfer spring.
With the increased weight transfer, it is possible to aerate
firm enough ground that the weight transfer begins to lift
the rear two tires off the ground. This may lead to
irregular hole spacing.
1. Loosen the carriage bolt nuts securing the spring
brackets to the coring head. Do not remove (Fig. 37).
If this occurs, an additional weight plate can be added to
the rear frame axle tube. Each cast weight adds 63 lbs
(28.5 Kg) to the traction unit. Up to two plates can be
added. Refer to parts catalog for these part numbers.
Aerator Control Module (ACM)
2
The Aerator Control Module is a ”potted” electronic
device produced in a ”one size fits all” configuration. The
module uses solid state and mechanical components to
monitor and control electrical features required for safe
product operation.
1
Figure 37
1. Weight transfer springs
2. Spring plate
2. Insert a 1/2 inch rachet or breaker–bar into the square
hole in the spring plate (Fig. 38).
2
1
1
Figure 39
1. Standard control module
The module monitors inputs including head low, head
high, transport, aerate and ground following. The module
is divided into inputs and outputs. Inputs and outputs are
identified by green LED indicators mounted on the printed
circuit board. Power is identified by a red LED indicator.
The start circuit input is energized by 12 VDC. All other
inputs are energized when the circuit is closed to ground.
Each input has a LED that is illuminated when the
specific circuit is energized. Use the input LED’s for
switch and input circuit troubleshooting.
Figure 38
1. Square hole in bracket
2. Rear carriage bolt
28
7. If specific output LED is not illuminated and inputs
are in appropriate condition, install new ACM and
determine if fault disappears.
Output circuits are energized by an appropriate set of
input conditions. The three outputs include SVL, SVR and
SVQ. Output LED’s monitor relay condition indicating
the presence of voltage at one of three specific output
terminals.
Output circuits do not determine output device integrity so
electrical troubleshooting includes output LED inspection
and conventional device and wire harness integrity testing.
Measure disconnected component impedance, impedance
through wire harness (disconnect at ACM), or by
temporarily ”test energizing” the specific component.
The ACM does not connect to an external computer or
hand held device, can not be re–programmed, and does
not record intermittent fault troubleshooting data.
The decal on the ACM only includes symbols. Three LED
output symbols are shown in the output box. All other
LED’s are inputs. The chart below identifies the symbols.
1.
2.
3.
4.
5.
6.
On/off
Output
Solenoid valve lower
Solenoid valve raise
Solenoid valve quick
Input
7.
8.
9.
10.
11.
12.
Head low
Head high
Transport
Aerate
Ground following
OK to lower
Here are the logical troubleshooting steps for the ACM
device.
1. Determine the output fault you are trying to resolve.
2. Move key switch to ”ON” and ensure the red ”power”
LED is illuminated.
3. Move all input switches to ensure all LED’s change
state.
4. Position input devices at appropriate position to
achieve the appropriate output.
5. If specific output LED is illuminated without
appropriate output function, check output harness,
connections, and component. Repair as required.
6. If specific output LED is not illuminated, check both
fuses.
29
Maintenance
Recommended Maintenance Schedule
Maintenance Service
Interval
After first 8 hours
After first 50 Hours
Each Use
Maintenance Procedure
•
•
•
•
Hydraulic fluid—check level
Hydraulic filter—change
Pump belt—re–tension
Coring head fasteners–check torque
• Engine oil & filter—change
•
•
•
•
•
•
•
Engine oil—check level
Safety System—check
Engine air intake—clean1
Belts—check
Hydraulic fluid—check level
Tires—check pressure
Hydraulic lines—check
Every 25 Hours
• Wash and re–oil air precleaner
• Battery—check electrolyte
Every 100 Hours
•
•
•
•
Every 200 Hours
• Hydraulic filter—change
• Spark Plug(s)—check
Every 500 Hours
• Spark Plug(s)—replace
Before Storage Service
1More often
•
•
•
•
Engine oil & filter—change1
Primary air cleaner filter– replace 1
Fuel filter—replace
Engine cooling system—clean1
Battery–charge, Disconnect cables
Gasoline—drain
Chipped Surfaces—paint
Perform all maintenance procedures listed above before storage
in dusty, dirty conditions
Important
Refer to your engine operator’s manual for additional maintenance procedures.
30
Daily Maintenance Checklist
Duplicate this page for routine use.
For the week of:
Maintenance Check Item
Mon.
Tues.
Wed.
Thurs.
Fri.
Sat.
Check safety interlock operation.
Check parking brake operation.
Check fuel level
Check the engine oil level.
Check the air cleaner.
Check the engine for debris.
Check unusual engine noises.
Check unusual operating noises.
Check the hydraulic fluid level.
Check the hydraulic hoses for damage.
Check for fluid leaks.
Check the tire pressure.
Check instrument operation.
Check the condition of the tines.
Touch up damaged paint.
Inspection performed by:
Item
Date
Information
1
2
3
4
5
6
7
8
9
10
Caution
If you leave the key in the ignition switch, someone could accidently start the engine and
seriously injure you or other bystanders.
Remove the key from the ignition and disconnect the wire from the spark plug(s) before you do
any maintenance. Set the wire aside so that it does not accidentally contact the spark plug.
31
Sun.
Lubrication
Jacking Instructions
The aerator has no grease fittings that must be lubricated.
Caution
Important Bearings rarely fail from defects in
materials or workmanship. The most common reason for
failure is moisture and contamination working its way past
the protective seals. Bearings that are greased will rely
upon regular maintenance to purge harmful debris from
the bearing area. Sealed bearings rely on an initial fill of
special grease and a robust integral seal to keep
contaminants and moisture out of the rolling elements.
When changing attachments, tires or performing
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 attachments 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
machine. If the machine is not properly supported
by blocks or jack stands, the machine may move
or fall, which may result in personal injury.
The sealed bearings require no lubrication or short term
maintenance. This minimizes routine service required and
reduces the potential of turf damage due to grease
contamination. These sealed bearing packages will
provide good performance and life under normal use, but
periodic inspections of bearing condition and seal
integrity should be conducted to avoid downtime. These
bearings should be inspected seasonally and replaced if
damaged or worn. Bearings should operate smoothly with
no detrimental characteristics such as high heat, noise,
looseness or rust weeping.
Jacking the Front End
1. Set the parking brake and chock the rear tires to
prevent the machine from moving.
Due to the operating conditions these bearing/seal
packages are subject to (i.e. sand, turf chemicals, water,
impacts, etc.) they are considered normal wear items.
Bearings that fail due to other than defects in materials or
workmanship are typically not covered under warranty.
Important To prevent wheel motor damage, DO NOT
use front wheel motor as a jacking point.
2. Position the jack securely under the front of the frame
(Fig. 40).
Note: Bearing life can be negatively affected by improper
wash down procedures. Do not wash down the unit when
it is still hot and avoid directing high–pressure or high
volume spray at the bearings.
Coring head bearing replacement is suggested at intervals
of 500 hours. A bearing service kit which covers the
complete coring head is available from your distributor.
1
Figure 40
1. Frame
3. Jack the front of the machine off the ground.
32
4. Position the jack stands or hardwood blocks under the
front of the frame to support the machine.
3. Jack (or lift) the rear of the machine off the ground.
4. Position the jack stands or hardwood blocks under the
frame to support the machine.
Jacking the Rear End
Servicing the Air Cleaner
1. Chock the front tire to prevent the machine from
moving.
The foam pre–cleaner must be cleaned and re–oiled after
every 25 hours engine operation if engine is operated in
clean air conditions. However, air cleaner must be cleaned
more frequently if operating conditions are extremely
dusty or sandy.
Important To prevent wheel motor damage, DO NOT
use rear wheel motor as a jacking point.
2. Place the jack securely under the frame plate just
inside of the rear wheel (Fig. 41).
1. Remove knob, O–ring and cover (Fig. 43).
2. Remove foam pre–cleaner by sliding it off the paper
element.
• Wash foam pre–cleaner in detergent and warm
water.
• Wrap foam pre–cleaner in cloth and squeeze dry.
Do not wring precleaner. Allow to air dry.
• Saturate foam pre–cleaner in engine oil. Squeeze to
remove excess oil.
1
1
2
Figure 41
1. Frame plate
3
4
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. 42).
5
6
7
1
8
Figure 43
1.
2.
3.
4.
Figure 42
1. Lifting eyelet
33
Knob & O–ring
Air cleaner cover
Nut
Spacer
5.
6.
7.
8.
Inner cover
Breather seal
Foam pre–cleaner
Paper element
3. Reinstall on paper cartridge.
1
Inspect paper element every 25 hours of operation and
replace if dirty or damaged. Change paper element every
100 hours. Do not wash paper element or do not clean
with compressed air as damage will occur.
2
Note: With air cleaner disassembled, check air cleaner
components for damage. Replace if necessary.
1. Reinstall element with pre–cleaner, breather seal,
spacer, inner cover and nut. Torque nut to 95 in.–lb.
(11 N⋅m).
2. Reinstall air cleaner cover, O–ring and knob.
3. Tighten knob 1/2 to 1 turn after knob contacts cover.
Do not overtighten.
Figure 44
Servicing the Engine Oil
1. Oil dipstick
Change oil:
2. Filler tube
5. Slide the oil dipstick fully into the filler tube. Pull the
dipstick out and look at the metal end (Fig. 45). If oil
level is low, slowly pour only enough oil into the filler
tube to raise the level to the full mark.
• After every 100 operating hours.
Note: Change oil more frequently when operating
conditions are extremely dusty or sandy.
Important Do not overfill the crankcase with oil
because this may cause engine damage. Do not run the
engine with oil below the low mark because the engine
may be damaged as a result.
Oil Type: Detergent oil (API service SH, SJ, SL or higher)
Crankcase Capacity: w/filter, 2 qt. (1.9 l)
Viscosity: See table
2
USE THESE SAE VISCOSITY OILS
10W–30
1
5W–20, 5W–30
–20
°F
0
–30
°C
–20
20
–10
32 40
0
80
60
10
20
100
30
Figure 45
1. Oil dipstick
40
2. Metal end
Note: SAE 30 weight is approved for this application.
Changing the Oil
Checking the Oil Level
1. Start the engine and let it run five minutes. This warms
the oil so it drains better.
Note: Check the oil when the engine is cold.
2. Park the machine so that the drain side is slightly
lower than the opposite side to assure the oil drains
completely. Set the parking brake, and turn the ignition
key to off. Remove the key.
1. and set the parking brake.
2. Stop the engine, remove the key, and wait for all
moving parts to stop before leaving the operating
position.
3. Place a pan below the oil drain. Remove the oil drain
plug to allow oil to drain (Fig. 46).
3. Clean around the oil dipstick (Fig. 44) so dirt cannot
fall into the filler hole and damage the engine.
4. When the oil has drained completely, install the drain
plug.
4. Pull the oil dipstick and wipe the metal end clean.
34
Note: Dispose of the used oil at a certified recycling
center.
3
1
2
m–1256
Figure 47
1. Oil filter
2. Gasket
3. Adapter
5. Install the replacement oil filter to the filter adapter.
Turn the oil filter clockwise until the rubber gasket
contacts the filter adapter, then tighten the filter an
additional 1/2 turn (Fig. 47).
1
Figure 46
1. Oil filter
6. Fill the crankcase with the proper type of new oil;
refer to Changing the Oil, page 34.
5. Slowly pour approximately 80% of the specified oil
into the filler cap (Fig. 44). Refer to Servicing the
Engine Oil, page 34.
Servicing the Spark Plug
Check the spark plug(s) after every 200 operating hours.
Make sure the air gap between the center and side
electrodes is correct before installing the spark plug. Use a
spark plug wrench for removing and installing the spark
plug(s) and a gapping tool/feeler gauge to check and
adjust the air gap. Install a new spark plug(s) if necessary.
6. Check the oil level; refer to Checking the Oil Level,
page 34.
7. Slowly add additional oil to bring it to the full mark.
Change the Oil Filter
Type: Champion RC12YC (or equivalent)
Replace the oil filter every 100 hours or at every oil
change.
Air Gap: 0.030 inch (0.76 mm)
Note: Change the oil filter more frequently when
operating conditions are extremely dusty or sandy.
Removing the Spark Plug(s)
1. Drain the oil from the engine; refer to Changing the
Oil, page 34.
7. Set the parking brake, stop the engine, remove the key,
and wait for all moving parts to stop before leaving the
operating position.
2. Remove the old filter and wipe the filter adapter
(Fig. 47) gasket surface.
8. Pull the wire(s) off the spark plug(s) (Fig. 48). Now
clean around the spark plug(s) to prevent dirt from
falling into the engine and potentially causing damage.
3. Pour new oil of the proper type in through the center
hole. Stop pouring when the oil reaches the bottom of
the threads. Allow a minute or two for the oil to be
absorbed by filter material.
9. Remove the spark plug(s) and metal washer.
4. Apply a thin coat of new oil to the rubber gasket on
the replacement filter (Fig. 47).
35
Servicing the Fuel Filter
Replace the fuel filter after every 100 operating hours or
yearly, whichever occurs first.
Replacing the Fuel Filter
1
Never install a dirty filter if it is removed from the fuel
line.
2
1. Allow the machine to cool down.
2. Set the parking brake, stop the engine, remove the key,
and wait for all moving parts to stop before leaving the
operating position.
m–4811
Figure 48
1. Spark plug wire
2. Spark plug
3. Close the fuel shut–off valve (Fig. 50).
Checking the Spark Plug
1. Look at the center of the spark plug(s) (Fig. 49). If you
see light brown or gray on the insulator, the engine is
operating properly. A black coating on the insulator
usually means the air cleaner is dirty.
2
Important Never clean the spark plug(s). Always
replace the spark plug(s) when it has: a black coating,
worn electrodes, an oily film, or cracks.
1
2. Check the gap between the center and side electrodes
(Fig. 49). Bend the side electrode (Fig. 49) if the gap is
not correct.
2
Figure 50
3
1. Fuel filter
1
2. Fuel shut-off valve
4. Squeeze the ends of the hose clamps together and slide
them away from the filter (Fig. 50).
0.030 inch
(0.76 mm)
5. Remove the filter from the fuel lines.
6. Install a new filter and move the hose clamps close to
the filter (Fig. 50).
m–3215
7. Wipe up any spilled fuel.
Figure 49
1. Center electrode insulator
2. Side electrode
8. Open fuel shut-off valve (Fig. 50).
3. Air gap (not to scale)
Installing the Spark Plug(s)
1. Install the spark plug(s). Make sure the air gap is set
correctly.
2. Tighten the spark plug(s) to 20 ft-lb (27 N⋅m).
3. Push the wire(s) onto the spark plug(s) (Fig. 48).
36
Servicing the Fuel Tank
Servicing the Hydraulic
System
Draining The Fuel Tank
Warning
Danger
Hydraulic fluid escaping under pressure can
penetrate skin and cause injury.
In certain conditions, gasoline is extremely
flammable and highly explosive. A fire or
explosion from gasoline can burn you and others
and can damage property.
• If hydraulic 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 if this is not done.
• Keep body and hands away from pin hole leaks
or nozzles that eject high pressure hydraulic
fluid.
• Use cardboard or paper to find hydraulic leaks.
• Safely relieve all pressure in the hydraulic
system before performing any work on the
hydraulic system.
• Make sure all hydraulic fluid hoses and lines
are in good condition and all hydraulic
connections and fittings are tight before
applying pressure to hydraulic system.
• Drain gasoline from the fuel tank when the
engine is cold. Do this outdoors in an open area.
Wipe up any gasoline that spills.
• Never smoke when draining gasoline, and stay
away from an open flame or where a spark may
ignite the gasoline fumes.
1. Park the machine on a level surface, to ensure the fuel
tank drains completely. Then, set the parking brake,
and turn the ignition key to off. Remove the key.
2. Close the fuel shut–off valve (Fig. 50).
3. Loosen the hose clamp at the fuel filter and slide it up
the fuel line away from the fuel filter (Fig. 50).
Replacing the Hydraulic Filter
4. Pull the fuel line off fuel filter (Fig. 50). Open fuel
shut-off valve and allow gasoline to drain into a gas
can or drain pan.
Change the hydraulic filter:
• After the first 8 operating hours.
Note: Now is the best time to install a new fuel filter
because the fuel tank is empty.
• After every 200 operating hours.
5. Install the fuel line onto the fuel filter. Slide the hose
clamp close to the fuel filter to secure the fuel line
(Fig. 50).
1. Set the parking brake, stop the engine, remove the key,
and wait for all moving parts to stop before leaving the
operating position.
Cleaning the Cooling Systems
Important Do not substitute automotive oil filter or
severe hydraulic system damage may result.
Cleaning the Engine Screen
2. Place a drain pan under filter, remove the old filter and
wipe the filter adapter gasket surface clean (Fig. 51).
Before each use, check and clean engine screen. Remove
any build–up of grass, dirt or other debris from the engine
air intake screen.
1
Figure 51
1. Hydraulic filter
37
Adjusting the Traction Drive for Neutral
3. Apply a thin coat of hydro fluid to the rubber gasket
on the replacement filter.
The machine must not creep when traction lever is
released. If it does creep, an adjustment is required.
4. Install the replacement hydraulic filter onto the filter
adapter. Turn the hydraulic oil filter clockwise until
the rubber gasket contacts the filter adapter, then
tighten the filter an additional 1/2 turn
1. Park the aerator on a level surface shut the engine off,
and engage the parking brake.
2. Jack up the machine so the front wheel and one rear
wheel is just off the ground. Place jack stands under
machine. Refer to Jacking Instructions.
5. Add fluid to the FULL mark on the dipstick, refer to
Checking the Hydraulic Fluid.
6. Start the engine and let it run for about two minutes to
purge air from the system. Stop the engine and check
for leaks.
3. Loosen the locknut on the traction adjustment cam
(Fig. 53).
7. Recheck level while fluid is warm. Add fluid to raise
level to top of the baffle, if required. Do not overfill.
Hydraulic System Test Ports
The test ports are used to test pressure in the hydraulic
circuits. Contact your local Toro distributor for assistance.
1
Test Port G 2 (Fig. 52) is used to assist in trouble shooting
the traction charge circuit.
Test Port G 1 (Fig. 52) is used to assist in trouble shooting
the lift circuit pressure.
1
Figure 53
1. Traction adjustment cam
Warning
The engine must be running so the final
adjustment of the traction adjustment cam can be
performed. This could cause personal injury.
2
Keep hands, feet, face, and other body parts away
from the muffler, other hot parts of the engine,
and any rotating parts.
Figure 52
1. Test port G2
2. Test port G1
4. Start engine and release the parking brake.
5. Rotate cam hex in either direction until the wheels do
not rotate.
6. Tighten locknut securing adjustment.
7. Stop the engine.
8. Remove the jack stands and lower the machine to the
ground.
9. Test the machine to make sure it does not creep.
38
Checking the Hydraulic Lines
6. Rotate the tie rod until the ball switch just closes or
makes contact.
Before each use, check the hydraulic lines and hoses for
leaks, loose fittings, kinked lines, loose mounting
supports, wear, weather and chemical deterioration. Make
necessary repairs before operating.
2
Note: Keep areas around hydraulic system clean from
debris build up.
Warning
3
Hydraulic fluid escaping under pressure can
penetrate skin and cause injury.
4
• If hydraulic 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 if this is not done.
• Keep body and hands away from pin hole leaks
or nozzles that eject high pressure hydraulic
fluid.
• Use cardboard or paper to find hydraulic leaks.
• Safely relieve all pressure in the hydraulic
system before performing any work on the
hydraulic system.
• Make sure all hydraulic fluid hoses and lines
are in good condition and all hydraulic
connections and fittings are tight before
applying pressure to hydraulic system.
5
1
Figure 54
1. Turf guard mounting
bracket
2. Ground following lever
3. Out board ball switch
4. Depth adjustment tie rod
5. Locking pin
7. Secure the LH & RH jam nuts on the tie rod.
8. Re–connect the ball switch to the wire harness.
9. Remove the“pin” from the turf guard bracket and
depth setting tube.
Re–setting Ground Following
System
Inspecting Belts
If the True Core ground following system requires service
of any kind (with exception of turf guard replacement) or
if the tine holders are contacting the turf guards when set
in the deepest setting, the depth adjustment tie rod may
need to be re–set.
The drive belts on the ProCore 648 have been designed to
be very durable. However, the normal exposure to UV
radiation, ozone or incidental exposure to chemicals can
deteriorate the rubber compounding over time and lead to
premature wear or material loss (i.e. chunking).
1. Rotate the LH turf guard mounting bracket (Fig. 54)
up until a locking pin (5/16 drill rod or capscrew) can
be inserted between the bracket and the depth setting
tube welded to the frame.
Annual belt inspection is highly recommended for signs of
wear, excessive cushion cracks, or large embedded debris
with replacement when needed.
A complete belt service kit is available from your
Authorized Toro Distributor.
2. Move the ground following lever (Fig. 54) to the “H”
setting (deepest).
3. Disconnect the out–board ball switch (Fig. 54) from
the wire harness (Head–Low switch).
Side Shield Adjustment
4. Loosen the jam nuts (LH & RH) on the depth
adjustment tie rod (Fig. 54) .
The coring head side shields should be adjusted so the
bottom rides between 1 to 1.5 inches from the turf while
aerating.
5. Use a multi–meter to determine electrical closure of
the ball switch.
1. Loosen the bolts and nuts securing the side shield to
frame (Fig. 55).
2. Adjust shield up or down and tighten nuts.
39
1
1
Figure 55
1. Side shield
Figure 57
Adjusting Pump Belt
1. Pump shield
After the initial, eight (8) hours of use, re–adjust the belt
tension on the pump drive belt.
3. Loosen the pump belt idler bolt just enough to allow
movement within it’s adjustment slot (Fig. 58).
1. Unlatch and remove the belt cover (Fig. 56).
1
1
Figure 58
1. Idler bolt
2. Idler pulley
4. Tap the top of the idler pulley and allow its tensioning
spring to adjust the belt tension.
Figure 56
Note: Do not apply more belt tension than the tensioning
spring allows as damage to the components may result.
1. belt cover
5. Secure the belt idler bolt.
2. Remove the (2) pump shield mounting nuts and
remove shield (Fig. 57).
6. Re–install pump shield and belt cover.
40
Replacing the Turf Guards
Example: Nominal Hole Spacing Setting of 2 inches
21.2 divided by 10 is 2.12, hole spacing is long by .12
inch from nominal (Fig. 60).
All turf guards should be replaced if broken or worn to
less than 1/4 inch thickness. Broken turf guards can catch
and tear turf creating undesirable damage.
21.2 inches (10 holes)
Figure 60
18.8 divided by 10 is 1.88, hole spacing is short by .12
inch from nominal (Fig. 61).
18.8 inches (10 holes)
1
Figure 61
Figure 59
1. Turf guard
5. If an adjustment is needed, turn the pump stop bolt
(Fig. 62) closer to the stop plate to decrease hole
spacing or turn stop bolt away from stop plate to
increase hole spacing.
Thin turf guards can cause the True Core ground
following system to be off from the desired depth setting
due to both wear and the loss of stiffness.
Adjusting Hole Spacing
The hole spacing of the ProCore 648 is determined by the
ground speed the traction system is set to maintain. The
hole spacing is set to within 1/8” of the nominal setting at
the factory.
1
In the event the hole spacing is off from the nominal
setting more than desired, proceed as follows:.
1. Unlatch and remove the belt cover (Fig. 56).
2. Remove the (2) pump shield mounting nuts and
remove shield (Fig. 57).
3. In an open space that is free to aerate (i.e. sample
plot), set hole spacing lever to desired hole spacing
and make an aeration pass of at least 15 feet.
Figure 62
1. Pump stop bolt
4. Measure the distance between several holes and divide
by the number of holes measured to get your average
hole spacing.
6. Repeat steps 3–5 until spacing is at the nominal
setting.
Note: One complete turn of the stop bolt, adjusts the hole
spacing approximately 5/8 inch.
41
Check Torque of Coring Head
Fasteners
Servicing the Fuses
The electrical system is protected by fuses (Fig. 65). It
requires no maintenance, however, if a fuse blows check
component/circuit for malfunction or short.
After the initial, eight (8) hours of use, check the coring
head fasteners to ensure proper torque is maintained.
Fastener torque requirements are listed on the reference
service decal located on the coring head.
1. To replace fuses pull out on the fuse to remove it.
2. Install a new fuse.
1
Figure 63
Figure 65
Coring Head Timing
1. Fuses
The coring head timing marks are easily identified by the
marks in the casting.
Servicing the Battery
Warning
1
CALIFORNIA
Proposition 65 Warning
Battery posts, terminals, and related accessories
contain lead and lead compounds, chemicals
known to the State of California to cause cancer
and reproductive harm. Wash hands after
handling.
1
The battery electrolyte level must be properly maintained
and the top of the battery kept clean. lf the machine is
stored in a location where temperatures are extremely
high, the battery will run down more rapidly than if the
machine is stored in a location where temperatures are
cool.
Figure 64
1. Timing marks
Check the electrolyte level every 25 operating hours or, if
the machine is in storage, every 30 days.
42
Maintain the cell level with distilled or demineralized
water. Do not fill the cells above the bottom of the split
ring inside each cell.
Warning
Incorrect battery cable routing could damage the
tractor and cables causing sparks. Sparks can
cause the battery gasses to explode, resulting in
personal injury.
Danger
Battery electrolyte contains sulfuric acid which is
a deadly poison and causes severe burns.
• Always disconnect the negative (black) battery
cable before disconnecting the positive (red)
cable.
• Always connect the positive (red) battery cable
before connecting the negative (black) cable.
• Do not drink electrolyte and avoid contact with
skin, eyes or clothing. Wear safety glasses to
shield your eyes and rubber gloves to protect
your hands.
• Fill the battery where clean water is always
available for flushing the skin.
Storing the Battery
Keep the top of the battery clean by washing it
periodically with a brush dipped in ammonia or
bicarbonate of soda solution. Flush the top surface with
water after cleaning it. Do not remove the fill caps while
cleaning the battery.
If the machine will be stored more than 30 days, remove
the battery and charge it fully. Either store it on the shelf
or on the machine. Leave the cables disconnected if it is
stored on the machine. Store the battery in a cool
atmosphere to avoid quick deterioration of the charge in
the battery. To prevent the battery from freezing, make
sure it is fully charged. The specific gravity of a fully
charged battery is 1.265–1.299.
The battery cables must be tight on the terminals to
provide good electrical contact.
If corrosion occurs at the terminals, disconnect the cables,
negative (–) cable first, and scrape the clamps and
terminals separately. Reconnect the cables, positive (+)
cable first, and coat the terminals with petroleum jelly.
Warning
Battery terminals or metal tools could short
against metal tractor components causing sparks.
Sparks can cause the battery gasses to explode,
resulting in personal injury.
• When removing or installing the battery, do not
allow the battery terminals to touch any metal
parts of the tractor.
• Do not allow metal tools to short between the
battery terminals and metal parts of the
tractor.
43
Troubleshooting
PROBLEM
Starter does not crank
Engine
g
will not start,, starts hard,, or
f il to
fails
t keep
k
running.
i
Engine
g
loses power.
p
Engine
g
overheats.
POSSIBLE CAUSES
CORRECTIVE ACTION
1. Battery is dead.
1. Charge the battery.
2. Electrical connections are
corroded or loose.
2. Check electrical connections
for good contact.
3. Relay or switch is defective.
3. Contact Authorized Service
Distributor.
4. Traction lever not in neutral
position.
4. Move traction lever to neutral
position
5. Neutral switch incorrectly
adjusted.
5. Adjust neutral switch
1. Fuel tank is empty.
1. Fill fuel tank with gasoline.
2. Choke is not on.
2. Move choke lever fully forward.
3. Air cleaner is dirty.
3. Clean or replace air cleaner
element.
4. Spark plug wires are loose or
disconnected.
4. Install wires on spark plugs.
5. Spark plugs are pitted, fouled,
or gap is incorrect.
5. Install new, correctly gapped
spark plugs.
6. Dirt in fuel filter.
6. Replace fuel filter.
7. Dirt, water, or stale fuel is in
fuel system.
7. Contact Authorized Service
Distributor.
1. Engine load is excessive.
1. Reduce ground speed.
2. Air cleaner is dirty.
2. Clean air cleaner element.
3. Oil level in crankcase is low.
3. Add oil to crankcase.
4. Cooling fins and air passages
under engine blower housing
are plugged.
4. Remove obstruction from
cooling fins and air passages.
5. Spark plugs are pitted, fouled,
or gap is incorrect.
5. Install new, correctly gapped
spark plugs.
6. Dirt in fuel filter.
6. Replace fuel filter.
7. Dirt, water, or stale fuel is in
fuel system.
7. Contact Authorized Service
Distributor.
1. Engine load is excessive.
1. Reduce ground speed.
2. Oil level in crankcase is low.
2. Add oil to crankcase.
3. Cooling fins and air passages
under engine blower housing
are plugged.
3. Remove obstruction from
cooling fins and air passages.
44
PROBLEM
Abnormal vibration.
POSSIBLE CAUSES
CORRECTIVE ACTION
1. Engine mounting bolts are
loose.
1. Tighten engine mounting bolts.
2. Jackshaft or coring head
bearings worn.
2. Replace bearings.
3. Jackshaft or coring head
components loose or worn
3. Tighten or replace components.
1. The parking brake is on.
1. Release the parking brake.
2. Hydraulic fluid level low.
2. Add hydraulic fluid.
3. The tow valve is open.
3. Close the tow valve.
4. Hydraulic system is damaged.
4. Contact your Toro Distributor.
1. Worn clutch.
1. Replace clutch
2. Worn switch or relay.
2. Replace switch or relay.
3. Worn or loose belts.
3. Adjust or replace belts.
4. Hydraulic fluid level low.
4. Add hydraulic fluid.
5. The tow valve is open.
5. Close the tow valve
6. Hydraulic system is damaged.
6. Contact your Toro Distributor.
1. Ground is too hard.
1. Refer to the operating tips on
page 26.
2. Relief setting/Restriction orifice.
2. Dynamic response of lift
system. Adjust the system
pressures. Refer to the Service
Manual.
1. Mis–adjusted switch bundle.
1. Adjust the #3 switch. Refer to
the operating tips on page 26.
2. Clutch wear/slippage
2. Contact your Toro Distributor
for testing.
1. Mis–adjusted switch bundle.
1. Adjust the switch. Refer to the
Service Manual.
2. Head lowers too slowly.
2. Check the function of the SVQ
solenoid.
Quad (or mini) tine hole spacing.
1. Holes not evenly spaced.
1. Check the spacing. Refer to the
operating tips on page 26.
Hole tufting with side eject tines.
1. Ejection window catching on
exit.
1. Rotate the tine 45–90_ so it
ejects out the side.
Aerator does not drive.
Coring head does not drive.
Head bounces while aerating.
Turf tufting/tearing on entrance
and exit.
Turf tufting/tearing on entrance.
2. Try a hollow tine.
45
PROBLEM
Turf lifting/tearing while aerating
Front of the hole is dimpled or
pushed.
POSSIBLE CAUSES
CORRECTIVE ACTION
1. Check coring head attitude
1. Refer to the Service Manual for
specification.
2. Improper tine selection.
2. Reduce the tine diameter,
reduce the tine diameter,
reduce the number of tines per
head or increase the hole
spacing.
3. Excessive depth.
3. Reduce the depth.
4. Hole spacing too close.
4. Increase the hole spacing.
5. Turf conditions (i.e. root
structure insufficient to resist
damage.
5. Alter the aeration methods or
timing.
1. Roto–Link in the “soft” position.
1. See operating tips on page 27.
46
47
83–0020
M
L
A
S
W
VIO
T
BK
4
T
W
VIO
3
2
S
L
M
2 A FUSE 94–6710
10 A FUSE 218–578
20 A FUSE 109101
IGN. CONN. FRONT
OR
5
1
G
AB
STOP –––– G+M+A
RUN –––– B+L+A
START ––– B+L+S
BK G
OR B
IGN. SWITCH
OFFRUNSTART
20 A
F1
VIO
85
F 2 10 A
BK
PK
W/BK
LOW OIL
PRESSURE
Y
86
W
BK
BK
R/VIO 2
3
BN
AERATION
100–1270
#3
85
BN
BK
86
CLUTCH RELAY
87a
30
87
TRANSPORT100–1270
LIMIT
#2
Y
BU
GY
+
GY
BU/W
85
H
STARTER
D1–A A
BK
CARBURETOR
SPARK PLUG
85
86
86
G
D1–B B
F
85
D1–C C
86
OR
LOCKOUT LATCHOR
87a
30
BK
87
OR
PK
LATCHING RELAY OR
87a
30
T
87
NEUTRAL SW. RELAY (LATCH)
87a
85
86
VIO
PK
30
87
99–7430
–
OIL
SWITCH
AC
AC
IGNITION
MODULES
SPARK PLUG
CLUTCH INTERLOCK RELAY
87a
30
87
GY
OR
PK
B+
MAG
START
OIL
REG
T
TRANSPORT100–1270
LIMIT
#1
AERATION
100–1270
#4
GN
72–4320
HEAD LOW
LIMIT
6
4
3
2
OR
1
LIFT RESET
106–8920
5
T
1
5
4
2
5
GY
6
106–8921
MANUAL RAISE/LOWER
3
100–1270
REVERSE
(NO)
(IN NEUTRAL+REVERSE)
T
2
HEAD HIGH72–4320
LIMIT
#1
OR
1
3
4
5
6
GROUND FOLLOW
107–0255
BK
R
W
BU
GN
VIO
ENGINE CONN. FRONT
GN
BU
1
NEUTRAL SW 100–1270
(START)
(IN NEUTRAL)
2
BU
BK
NEUTRAL SW. RELAY (START)
87a
30
87
F 3 10 A
F4 2A
GN
4
5
W
PK
HOUR
METERHR
PK/BK
GN
GY
OR
OR
W/BK
BU/W
BU
NOT USED
1–E
GROUND
1–F
PK/BK
OR
85
GY
86
LOCKOUT
87a
30
87
CLUTCH
D D1–D E BK
PK/BK
2–G HEAD LOW {Type}
T
{RefDes}
AERATOR
CONTROL MODULE
2–H +12 V / SVR
106–8831
2–F AERATE
TRANSPORT
1–D
SVL1–C
SVQ1–B
+12 V / SVQ,
1–A
SVL
2–E OK LOWER
2–D HEAD HIGH
2–C IGN. SW. ”I”
2–B FLOAT
2–A SVR
BK
R/BK
BN
BU
SVLLOWER SOLENOID
SVQFAST RAISE SOLENOID
SVRRAISE SOLENOID
BK
Wiring Schematic
Hydraulic Schematic
PSI
“
48
Cleaning and Storage
Note: A fuel stabilizer/conditioner is most effective when
mixed with fresh gasoline and used at all times.
1. Set the parking brake and turn the ignition key to off.
Remove spark plug wire. Remove the key.
B. Run engine to distribute conditioned fuel through
the fuel system (5 minutes).
2. Remove grass, dirt, and grime from the external parts
of the entire machine, especially the engine and
hydraulic system. Clean dirt and chaff from the outside
of the engine’s cylinder head fins and blower housing.
C. Stop engine, allow to cool and drain the fuel tank;
refer to Servicing the Fuel Tank.
D. Restart engine and run it until it stops.
Important You can wash the machine with mild
detergent and water. Do not pressure wash the machine.
Avoid excessive use of water, especially near the control
panel, engine, hydraulic pumps and motors.
E. Choke the engine. Start and run engine until it will
not start.
F. Dispose of fuel properly. Recycle as per local
codes.
3. Service the air cleaner; refer to Servicing the Air
Cleaner.
Important Do not store stabilizer/conditioned gasoline
over 90 days.
4. Change the crankcase oil; refer to Servicing the
Engine Oil.
10. Remove the spark plugs and check the condition; refer
to Servicing the Spark Plugs. With the spark plugs
removed from the engine, pour two tablespoons of
engine oil into each spark plug hole. Now use the
starter to crank the engine and distribute the oil inside
the cylinders. Install the spark plugs. Do not install the
wires on the spark plugs.
5. Change the hydraulic filter; refer to Servicing the
Hydraulic System.
6. Check the tire pressure; refer to Checking the Tire
Pressure.
7. Charge the battery; refer to Servicing the Battery.
11. Check and tighten all bolts, nuts, and screws. Repair or
replace any part that is damaged or defective.
Note: Run the machine with the engine at high idle for 2
to 5 minutes after washing.
8. Check the condition of the tines. Refer to Servicing the
Tines.
12. Wash and dry entire unit. Remove tines, clean and oil.
Spray light oil mist on coring head bearings (crank &
damper links).
9. Prepare the machine for storage when non–use occurs
over 30 days. Prepare machine for storage as follows.
13. Paint all scratched or bare metal surfaces. Paint is
available from your Authorized Service Distributor.
14. Store the machine in a clean, dry garage or storage
area. Remove the key from the ignition switch and
keep it out of reach of children or other unauthorized
users.
A. Add a petroleum based stabilizer/conditioner to
fuel in the tank. Follow mixing instructions from
stabilizer manufacture. Do not use an alcohol
based stabilizer (ethanol or methanol).
15. Secure service latch if the aerator is to be stored for
more than a couple days.
16. Cover the machine to protect it and keep it clean.
49
Notes
50
Notes
51
The Toro Aerator Commercial Products Warranty
A Two-Year Limited Warranty
Conditions and Products Covered
The Toro Company and its affiliate, Toro Warranty Company,
pursuant to an agreement between them, jointly warrant your Toro
Hydrojectr 3000, Hydrojectr 4000, Greens, Fairway Aerator or
ProCoret Aerator (“Product”) to be free from defects in materials
or workmanship for two years or 500 operational hours*, whichever occurs first. Where a warrantable condition exists, we will repair
the Product at no cost to you including diagnosis, labor, parts, and
transportation. This warranty begins on the date the Product is
delivered to the original retail purchaser.
* Product equipped with hour meter
Instructions for Obtaining Warranty Service
You are responsible for notifying the Commercial Products
Distributor or Authorized Commercial Products Dealer from whom
you purchased the Product as soon as you believe a warrantable
condition exists.
If you need help locating a Commercial Products Distributor or
Authorized Dealer, or if you have questions regarding your
warranty rights or responsibilities, you may contact us at:
Toro Commercial Products Service Department
Toro Warranty Company
8111 Lyndale Avenue South
Bloomington, MN 55420-1196
952-888-8801 or 800-982-2740
E-mail: commercial.service@toro.com
Owner Responsibilities
As the Product owner, you are responsible for required maintenance and adjustments stated in your operator’s manual. Failure
to perform required maintenance and adjustments can be grounds
for disallowing a warranty claim.
Items and Conditions Not Covered
Not all product failures or malfunctions that occur during the
warranty period are defects in materials or workmanship. This
express warranty does not cover the following:
• Product failures which result from the use of non-Toro
replacement parts, or from installation and use of add-on,
modified, or unapproved accessories
• Product failures which result from failure to perform required
maintenance and/or adjustments
• Product failures which result from operating the Product in an
abusive, negligent or reckless manner
• Parts subject to consumption through use unless found to be
defective. Examples of parts which are consumed, or used up,
during normal Product operation include, but are not limited to,
blades, reels, bedknives, tines, spark plugs, castor wheels,
tires, filters, belts, etc.
•
•
Failures caused by outside influence. Items considered to be
outside influence include, but are not limited to, weather,
storage practices, contamination, use of unapproved coolants,
lubricants, additives, or chemicals, etc.
Normal “wear and tear” items. Normal “wear and tear” includes,
but is not limited to, damage to seats due to wear or abrasion,
worn painted surfaces, scratched decals or windows, etc.
Parts
Parts scheduled for replacement as required maintenance are
warranted for the period of time up to the scheduled replacement
time for that part.
Parts replaced under this warranty become the property of Toro.
Toro will make the final decision whether to repair any existing part
or assembly or replace it. Toro may use factory remanufactured
parts rather than new parts for some warranty repairs.
General Conditions
Repair by an Authorized Toro Distributor or Dealer is your sole
remedy under this warranty.
Neither The Toro Company nor Toro Warranty Company is
liable for indirect, incidental or consequential damages in
connection with the use of the Toro Products covered by this
warranty, including any cost or expense of providing substitute equipment or service during reasonable periods of
malfunction or non-use pending completion of repairs under
this warranty. Except for the Emissions warranty referenced
below, if applicable, there is no other express warranty. All
implied warranties of merchantability and fitness for use are
limited to the duration of this express warranty.
Some states do not allow exclusions of incidental or consequential
damages, or limitations on how long an implied warranty lasts, so
the above exclusions and limitations may not apply to you.
This warranty gives you specific legal rights, and you may also
have other rights which vary from state to state.
Note regarding engine warranty: The Emissions Control System
on your Product may be covered by a separate warranty meeting
requirements established by the U.S. Environmental Protection
Agency (EPA) and/or the California Air Resources Board (CARB).
The hour limitations set forth above do not apply to the Emissions
Control System Warranty. Refer to the Engine Emission Control
Warranty Statement printed in your operator’s manual or contained in the engine manufacturer’s documentation for details.
Countries Other than the United States or Canada
Customers who have purchased Toro products exported from the United States or Canada should contact their Toro Distributor (Dealer)
to obtain guarantee policies for your country, province, or state. If for any reason you are dissatisfied with your Distributor’s service or
have difficulty obtaining guarantee information, contact the Toro importer. If all other remedies fail, you may contact us at Toro Warranty
Company.
Part No. 374-0032 Rev. A
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