Toro ProCore 648 Operator's Manual
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Toro ProCore 648 Operator's Manual

Aerator
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Form No. 3353–518 Rev. A
ProCore 648 Aerator
Model No. 09200–240000001 & Up
Operator's Manual
English (EN, GB)

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Summary of Contents for Toro ProCore 648

  • Page 1 Form No. 3353–518 Rev. A ProCore 648 Aerator Model No. 09200–240000001 & Up Operator’s Manual English (EN, GB)

  • Page 2: Table Of Contents

    Check Hydraulic System Fluid ....The Toro Aerator Commercial Products Warranty Check the Tire Pressure ....

  • Page 3: Introduction

    To reduce the potential for injury, additional information, contact an Authorized Service comply with these safety instructions and always pay Distributor or Toro Customer Service and have the model attention to the safety alert symbol, which means and serial numbers of your product ready.

  • Page 4: Maintenance And Storage

    • Never remove gas cap or add fuel with engine • Do not operate on slopes when grass is wet. Slippery running. Allow engine to cool before refueling. conditions reduce traction and could cause sliding and Do not smoke. loss of control. •...

  • Page 5: Sound Pressure Level

    This unit has a guaranteed sound power level of: 102 dBA/1 pW, based on measurements of identical • Use only Toro-approved attachments. Warranty may machines per Directive 2000/14/EC and amendments. 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...
  • Page 6 107-7534 1. Warning—read the 3. Entanglement hazard, 5. Crushing hazard of hand and 6. Read the instructions before Operator’s Manual. belt—stay away from moving body—engage the service servicing or performing parts. latch when the coring head is maintenance—torque the tine 2.
  • Page 7 106-8853 106-8856 1. Read the Operator’s 2. Coring depth 1. Read the Operator’s Manual. Manual. 93-9084 1. Lift point 2. Tie-down point 107-7555 93-6696 1. Stored energy hazard—read the Operator’s Manual.
  • Page 8 106-8855 1. Move the lever up to drive in 5. Warning—stop the engine 8. Entanglement hazard, belt 9. Tipping hazard—do not turn reverse. and read the instructions and Crushing hazard of hand sharply while traveling fast, before servicing or or foot—stay away from drive slowly when turning, 2.

  • Page 9: Specifications

    Specifications 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 Engine rpm. High Idle–3400 rpm. Low Idle–1400 rpm. Displacement 41 cu–in. (674 cc). Air Filter–Dry, large capacity, replaceable element.

  • Page 10: Accessory Chart

    Accessory Chart ProCore 648 Optional Accessories 48” (1.2 meter) wide Windrower Kit 09220 Model Number 09200 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.

  • Page 11: Setup

    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.

  • Page 12: Install The Rear Wheels

    Note: To raise the coring head, after uncrating the 4. Insert the cable guide around the cables. machine, start the engine and depress the RESET button. 5. Mount the cable guide to the top of the fork with (2) Refer to the Operation section of this manual for more 5/16 x 1/2”...
  • Page 13 Warning Charging the battery produces gasses that can explode. 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.

  • Page 14: Secure Rear Hood

    Secure Rear Hood Secure Belt Cover (Required for CE) (Required for CE) 1. Secure the hood plate to the rear hood with (3) pop 1. Insert a 1/4 x 1 inch capscrew thru the belt cover latch rivets (Fig. 7). lever and secure with a 1/4 locknut (Fig.

  • Page 15: Before Operating

    Before Operating Danger In certain conditions, gasoline is extremely Recommended Gasoline flammable and highly explosive. A fire or explosion from gasoline can burn you and others Use UNLEADED Regular Gasoline suitable for and can damage property. automotive use (85 pump octane minimum). Leaded regular gasoline may be used if unleaded regular is not •...

  • Page 16: Filling The Fuel Tank

    Filling the Fuel Tank Fuel tank capacity is approximately 7.5 gal (28.4 l) 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.

  • Page 17: Check Hydraulic System Fluid

    Donax TD Texaco 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.

  • Page 18: Check The Tire Pressure

    Check the Tire Pressure 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.

  • Page 19: Operation

    Operation Ignition Switch The ignition switch (Fig. 19), which is used to start and Note: Determine the left and right sides of the aerator stop the engine, has three positions: OFF, RUN, and START. Rotate key clockwise to the START position to from the normal operating position (Fig.

  • Page 20: Starting And Stopping The Engine

    Throttle Control Manual Ground Follow Selector Switch The throttle (Fig. 19) is used to operate engine at various Rotate switch to down position to turn off the TrueCoret speeds. Moving throttle forward increases engine feature (Fig. 19) Remove screw to access manual ground speed—FAST;...

  • Page 21: The Safety Interlock System

    Testing the Safety Interlock System Important Do not engage starter for more than 10 seconds at a time. If engine fails to start allow Test the safety interlock system before you use the aerator 30 second cool-down period between attempts. Failure to each time.

  • Page 22: Install Tine Holders, Turf Guards And Tines

    Figure 24 1. Turf guard 2. Turf guard bracket 4. Loosely install a tine clamp to each tine holder with Figure 22 (4) 3/8 x 1–1/2 in. capscrews. (Fig. 26) Do not tighten 1. Service latch in (raised) locked position capscrew.

  • Page 23: Setting The Coring Depth

    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. Figure 27 Figure 28 1. Aeration depth lever 2. Overlay on decal 7.

  • Page 24: Pushing/Pulling The Aerator By Hand

    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). Figure 29 1. Lynch pin 2. Spacers & depth pin 3.

  • Page 25: Transporting Aerator

    To reset the system after engine is started, depress rocker Use a heavy–duty trailer or truck to transport the aerator. switch (Fig. 32) to raise coring head and reset the Ensure that the trailer or truck has all necessary lighting electrical control circuit.

  • Page 26: Loading Aerator

    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.

  • Page 27: Using Line Marker

    Mini Tine (Quad Tine) style tine or any of the mini–tines. The mini–tine head developed by Toro is a very fast way to aerate due to the double row design. This coring head Upon Completion requires the hole spacing to be set at 2.5 inches.

  • Page 28: Adjusting Weight Transfer

    some additional weight transfer may be required. To 3. Hold the rachet or breaker–bar to relieve the tension increase the down pressure of the weight transfer springs, on the spring plate and remove the rear carriage bolt. proceed as follows: 4.
  • Page 29 Output circuits are energized by an appropriate set of 7. If specific output LED is not illuminated and inputs input conditions. The three outputs include SVL, SVR and are in appropriate condition, install new ACM and SVQ. Output LED’s monitor relay condition indicating determine if fault disappears.

  • Page 30: Maintenance

    Maintenance Recommended Maintenance Schedule Maintenance Service Maintenance Procedure Interval • Hydraulic fluid—check level • Hydraulic filter—change After first 8 hours • Pump belt—re–tension • Coring head fasteners–check torque After first 50 Hours • Engine oil & filter—change • Engine oil—check level •...

  • Page 31: Daily Maintenance Checklist

    Daily Maintenance Checklist Duplicate this page for routine use. For the week of: Mon. Tues. Wed. Thurs. Fri. Sat. Sun. Maintenance Check Item 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.

  • Page 32: Lubrication

    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 When changing attachments, tires or performing failure is moisture and contamination working its way past other service, use correct blocks, hoists and jacks.

  • Page 33: Servicing The Air Cleaner

    Figure 41 1. Frame plate 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). Figure 43 1. Knob & O–ring 5.

  • Page 34: Servicing The Engine Oil

    3. Reinstall on paper cartridge. 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. Note: With air cleaner disassembled, check air cleaner components for damage.

  • Page 35: Servicing The Spark Plug

    Note: Dispose of the used oil at a certified recycling center. m–1256 Figure 47 1. Oil filter 3. Adapter 2. Gasket 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.

  • Page 36: Servicing The Fuel Filter

    Servicing the Fuel Filter Replace the fuel filter after every 100 operating hours or yearly, whichever occurs first. Replacing the Fuel Filter Never install a dirty filter if it is removed from the fuel line. 1. Allow the machine to cool down. 2.

  • Page 37: Servicing The Fuel Tank

    Servicing the Fuel Tank Servicing the Hydraulic System Draining The Fuel Tank Warning Danger Hydraulic fluid escaping under pressure can In certain conditions, gasoline is extremely penetrate skin and cause injury. flammable and highly explosive. A fire or explosion from gasoline can burn you and others •...
  • Page 38 Hydraulic System Test Ports The test ports are used to test pressure in the hydraulic circuits. Contact your local Toro distributor for assistance. Test Port G 2 (Fig. 52) is used to assist in trouble shooting the traction charge circuit.

  • Page 39: Re-Setting Ground Following System

    Inspecting Belts If the True Core ground following system requires service The drive belts on the ProCore 648 have been designed to of any kind (with exception of turf guard replacement) or be very durable. However, the normal exposure to UV...

  • Page 40: Side Shield Adjustment

    Figure 55 1. Side shield Figure 57 1. Pump shield Adjusting Pump Belt After the initial, eight (8) hours of use, re–adjust the belt 3. Loosen the pump belt idler bolt just enough to allow tension on the pump drive belt. movement within it’s adjustment slot (Fig.

  • Page 41: Replacing The Turf Guards

    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.

  • Page 42: Check Torque Of Coring Head Fasteners

    Check Torque of Coring Head Servicing the Fuses Fasteners The electrical system is protected by fuses (Fig. 65). It requires no maintenance, however, if a fuse blows check After the initial, eight (8) hours of use, check the coring component/circuit for malfunction or short. head fasteners to ensure proper torque is maintained.

  • Page 43: Storing The Battery

    Maintain the cell level with distilled or demineralized Warning water. Do not fill the cells above the bottom of the split ring inside each cell. Incorrect battery cable routing could damage the Danger tractor and cables causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury.

  • Page 44: Troubleshooting

    Troubleshooting PROBLEM POSSIBLE CAUSES CORRECTIVE ACTION Starter does not crank 1. Battery is dead. 1. Charge the battery. 2. Electrical connections are 2. Check electrical connections corroded or loose. for good contact. 3. Relay or switch is defective. 3. Contact Authorized Service Distributor.
  • Page 45 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. Coring head does not drive. 1. Worn clutch. 1. Replace clutch 2. Worn switch or relay.
  • Page 46 PROBLEM POSSIBLE CAUSES CORRECTIVE ACTION Turf lifting/tearing while aerating 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.

  • Page 47: Wiring Schematic

    Wiring Schematic...

  • Page 48: Hydraulic Schematic

    Hydraulic Schematic “...

  • Page 49: Cleaning And Storage

    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. B. Run engine to distribute conditioned fuel through Remove spark plug wire.
  • Page 50 Notes...
  • Page 51 Notes...

  • Page 52: The Toro Aerator Commercial Products Warranty

    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.

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