Toro ProCore 648 Service Manual
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Toro ProCore 648 Service Manual

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Form No. 04129SL Rev D
®
ProCore
648
Original Instructions (EN)

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Summary of Contents for Toro ProCore 648

  • Page 1 Form No. 04129SL Rev D ® ProCore Original Instructions (EN)
  • Page 2 THE TORO COMPANY 2018 This document and all information contained herein is the sole property of The Toro Company (and/or its affiliated companies). No intellectual property rights are granted by the delivery of this document or the disclosure of its content. This document shall not be...
  • Page 3 Reader Comments The Toro Company Technical Assistance Center maintains a continuous effort to improve the quality and usefulness of its publications. To do this effectively, we encourage user feedback. Please comment on the completeness, accuracy, organization, usability, and readability of this manual by an e-mail to servicemanuals@toro.com...
  • Page 4 NOTES...
  • Page 5 IMPORTANT: The IMPORTANT notice will give im- portant instructions which must be followed to pre- vent damage to systems or components on the machine. E The Toro Company - - 2004, 2006, 2009, 2018...
  • Page 6 This page is intentionally blank. ProCore 648...

  • Page 7: Table Of Contents

    Service and Repairs ..... . . 4 – 30 HYDRO–GEAR BDP–10A/16A/21L HYDROSTATIC PUMPS SERVICE AND REPAIR MANUAL DANFOSS GROUP 2 GEAR PUMPS AND MOTORS SERVICE MANUAL DANFOSS OMEW HYDRAULIC MOTOR SERVICE MANUAL ProCore 648...
  • Page 8 This page is intentionally blank. ProCore 648...
  • Page 9 JACKING INSTRUCTIONS ..... 4 SAFETY AND INSTRUCTION DECALS ..5 ProCore 648 Safety...

  • Page 10: Safety Instructions

    Safety Instructions The ProCore 648 is designed and tested to offer safe service when operated and maintained properly. Al- WARNING though hazard control and accident prevention partially are dependent upon the design and configuration of the To reduce the potential for injury or death, machine, these factors are also dependent upon the comply with the following safety instructions.

  • Page 11: Maintenance And Service

    Toro replacement parts and ac- may result. cessories. Replacement parts and accessories made 6.

  • Page 12: Jacking Instructions

    (Fig. 2). NOTE: If available, a hoist can be used to lift the rear of the ProCore 648. Use eyelets in coring head bearing housings as hoist attachment points (Fig. 3). 3. Jack (or lift) rear of machine off the ground.

  • Page 13: Safety And Instruction Decals

    Safety and Instruction Decals Numerous safety and instruction decals are affixed to the ProCore 648. If any decal becomes illegible or dam- aged, install a new decal. Part numbers for replacement decals are listed in your Parts Catalog. Order replace- ment decals from your Authorized Toro Distributor.
  • Page 14 This page is intentionally blank. Safety ProCore 648 Page 1 – 6...

  • Page 15: Product Records

    Fastener Identification ..... . . 3 Product Records Insert Operator’s Manual and Parts Catalog for your ProCore 648 at the end of this chapter. Additionally, if any optional equipment or accessories have been installed to your ProCore, insert the Installation Instruc - tions, Operator’s Manuals and Parts Catalogs for those...

  • Page 16: Equivalents And Conversions

    Equivalents and Conversions 0.09375 Product Records and Maintenance ProCore 648 Rev. C Page 2 - - 2...

  • Page 17: Torque Specifications

    For critical applications, as determined reduced by 25% for lubricated fasteners to achieve by Toro, either the recommended torque or a torque that the similar stress as a dry fastener. Torque values may is unique to the application is clearly identified and spe - also have to be reduced when the fastener is threaded cified in this Service Manual.

  • Page 18: Standard Torque For Dry, Zinc Plated And Steel Fasteners (Inch Series)

    The specific torque value should be determined based on the fastener size, the aluminum or base material strength, length of thread engagement, etc. Product Records and Maintenance ProCore 648 Page 2 – 4...

  • Page 19: Standard Torque For Dry, Zinc Plated And

    The specific torque value should be determined based on the fastener size, the aluminum or base material strength, length of thread engagement, etc. ProCore 648 Product Records and Maintenance Page 2 – 5...

  • Page 20: Other Torque Specifications

    All torque values are based on non–lubricated fasteners. Conversion Factors in–lb X 11.2985 = N–cm N–cm X 0.08851 = in–lb ft–lb X 1.3558 = N–m N–m X 0.7376 = ft–lb Product Records and Maintenance ProCore 648 Page 2 – 6...
  • Page 21 Adjust Engine Speed ......5 KOHLER ENGINE SERVICE MANUAL ProCore 648 Page 3 – 1 Kohler Engine...

  • Page 22: Introduction

    This Chapter gives information about specifications and Most repairs and adjustments require tools which are repair of the Kohler engine used in the ProCore 648. commonly available in many service shops. Special tools are described in the Kohler Engine Service Manu - General engine maintenance procedures are described al.

  • Page 23: Specifications

    High Idle (no load) 3400 + 50 RPM Engine Oil See Operator’s Manual Oil Pump Gear driven trochoid type Crankcase Oil Capacity 2 U.S. Quart (1.9 Liters) with filter Starter 12 VDC ProCore 648 Page 3 – 3 Kohler Engine...

  • Page 24: General Information

    Additionally, close the shutoff valve if the machine is being transported on a trailer or when placing the machine in long term storage. Figure 1 1. Fuel shutoff valve (under the fuel tank) Kohler Engine ProCore 648 Page 3 – 4...

  • Page 25: Adjustments

    6. Using a tachometer, check that engine is operating at 1400 + 50 RPM. 7. For additional information, refer to the Kohler Engine Service Manual that is included at the end of this Chap- ter. ProCore 648 Page 3 – 5 Kohler Engine...
  • Page 26 This page is intentionally blank. Kohler Engine ProCore 648 Page 3 – 6...

  • Page 27: Service And Repairs

    IMPORTANT: Never operate engine without the blower housing installed. Overheating and engine damage will result. 5. Make sure grass screen and blower housing are re- installed to the engine if removed. ProCore 648 Page 3 – 7 Kohler Engine...

  • Page 28: Fuel System

    To clean fuel tank, flush tank out with clean solvent. Make sure tank is free of contaminates and debris. Kohler Engine ProCore 648 Page 3 – 8...
  • Page 29 30 to 60 in–lb (3.4 to 6.8 N–m). 2. Connect fuel hose to the fuel filter. 3. Fill fuel tank (see Operator’s Manual). Open fuel shut–off valve. 4. Return coring head service latch to stored position before using machine. ProCore 648 Page 3 – 9 Kohler Engine...

  • Page 30: Exhaust System

    8. Muffler clamp (2 used) 13. Cap screw (2 used) 4. Frame 9. Exhaust elbow 14. Flange nut (2 used) 5. Flange nut (2 used) 10. Carriage screw (2 used) 15. Muffler Kohler Engine ProCore 648 Page 3 – 10...
  • Page 31 (4) hex nuts from the exhaust manifold studs on engine. washers. Separate the exhaust manifold from the engine. 7. Return coring head service latch to stored position 6. Remove exhaust gaskets. before using machine. ProCore 648 Page 3 – 11 Kohler Engine...

  • Page 32: Engine

    2. Disconnect negative (--) and then positive (+) battery cables at the battery. 3. Remove pump belt cover from machine (see Opera- tor’s Manual). Kohler Engine ProCore 648 Rev. C Page 3 - - 12...
  • Page 33 System) and hydraulic pump drive pulley from en- 2. Pump pulley 5. Cap screw 3. Electric clutch gine (Fig. 11). 12.If needed, remove belt tensioning components from engine (see Belt Tensioners in this section). ProCore 648 Page 3 – 13 Kohler Engine...
  • Page 34 The rear two (2) cap screws should be up 18.Return coring head service latch to stored position through frame and engine. before using machine. 6. Reconnect electrical connections to engine: A. Plug engine wire harness connector into machine harness connector. Kohler Engine ProCore 648 Page 3 – 14...
  • Page 35 This page is intentionally blank. ProCore 648 Page 3 – 15 Kohler Engine...

  • Page 36: Belt Tensioners

    9. Spacer 21. Hardened washer 32. Flange head screw 10. Cap screw 22. Cap screw 33. Idler pulley 11. Clutch strap 23. Cap screw 34. Bracket (fastens to machine frame) 12. Cap screw Kohler Engine ProCore 648 Page 3 – 16...
  • Page 37 Manual) and primary drive belt (coring head) (see Pri- mary Drive Belt in the Service and Repairs section of 2. Remove belt tensioner components from engine as Chapter 7 – Coring Head). needed using Figure 12 as a guide. ProCore 648 Page 3 – 17 Kohler Engine...
  • Page 38 This page is intentionally blank. Kohler Engine ProCore 648 Page 3 – 18...

  • Page 39: Specifications

    ....Wheel Motor Efficiency Test ....Rev. C ProCore 648 Page 4 - - 1 Hydraulic System...

  • Page 40: Specifications

    12 Cubic Inches (197 cc) Hydraulic Filter Spin–on cartridge type Hydraulic Oil See Operator’s Manual Hydraulic Reservoir Capacity 1.75 U.S. Gal. (6.6 L) Total Hydraulic System Capacity 3 U.S. Gal. (11.4 L) (Approximate) Hydraulic System Page 4 – 2 ProCore 648...
  • Page 41 This page is intentionally blank. ProCore 648 Page 4 – 3 Hydraulic System...

  • Page 42: Hydraulic Hoses

    6 (3/8 in.) 0.75 + 0.25 8 (1/2 in.) 0.75 + 0.25 10 (5/8 in.) 1.00 + 0.25 Figure 2 12 (3/4 in.) 0.75 + 0.25 16 (1 in.) 0.75 + 0.25 Hydraulic System Page 4 – 4 ProCore 648...
  • Page 43 6 (3/8 in.) 1.50 + 0.25 8 (1/2 in.) 1.50 + 0.25 10 (5/8 in.) 1.50 + 0.25 12 (3/4 in.) 1.50 + 0.25 Figure 6 16 (1 in.) 1.50 + 0.25 ProCore 648 Page 4 – 5 Hydraulic System...

  • Page 44: Pushing/Pulling Machine

    Figure 7 1. By–pass valve location Check Hydraulic Fluid The ProCore 648 hydraulic system is designed to oper - ate on anti–wear hydraulic fluid. The reservoir (Fig. 8) holds about 1.75 gallons (6.6 liters) of hydraulic fluid. Check level of hydraulic fluid daily.

  • Page 45: Hydraulic Schematic

    ’P’ PORT ’P’ PORT ’P’ PORT ’A’ PORT (TOP) COMPONENT 10.5 2900 1000 23.8 12.1 12.1 ProCore 648 ORF1 .050 Hydraulic Schematic All solenoids are shown as de- -energized Rev. C ProCore 648 Page 4 - - 7 Hydraulic System...
  • Page 46 MANIFOLD FRONT WHEEL ’B’ PORT FORWARD (BOTTOM) ’P’ PORT ’P’ PORT ’P’ PORT ’A’ PORT (TOP) Traction Circuit (Forward Shown) Working Pressure Low Pressure (Charge) Return or Suction Flow Rev. C Hydraulic System Page 4 - - 8 ProCore 648...

  • Page 47: Traction Circuit

    Oil flowing from the rear wheel motors returns to the top port of the traction pump and is continuously pumped out the bottom port as long as the traction lever is held in the forward direction. ProCore 648 Page 4 – 9 Hydraulic System...

  • Page 48: Coring Head Raise/Lower Circuits

    PUMP LIFT ORF1 CYLINDER (RETRACTING) (ENERGIZED) (NOT ENERGIZED) CORING HEAD LOWER (ENERGIZED) CONTROL MANIFOLD Coring Head Raise/Lower Circuits Working Pressure FROM Low Pressure (Charge) TRACTION GEAR PUMP PUMP Return or Suction Flow Hydraulic System Page 4 – 10 ProCore 648...
  • Page 49 The weight of the coring head and tension of the weight transfer springs cause the lift cylin- der to retract and the coring head to lower. Oil flowing from the retracting lift cylinder returns to the reservoir. ProCore 648 Page 4 – 11 Hydraulic System...

  • Page 50: Special Tools

    Special Tools Order these special tools from your Toro Distributor. Hydraulic Pressure Test Kit Toro Part Number: TOR47009 Use to take various pressure readings for diagnostic tests. Quick disconnect fittings provided attach directly to mating fittings on machine test ports without tools. A high pressure hose is provided for remote readings.

  • Page 51: Hydraulic Test Fitting Kit

    Part Number: TOR4079 TORO TEST FITTING KIT (NO. TOR4079) This kit includes a variety of O–ring Face Seal fittings to enable connection of test gauges to the ProCore 648 hy- draulic system. The kit includes: tee’s, unions, reducers, plugs, caps, and male test fittings.

  • Page 52: Troubleshooting

    Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Hydraulic System Page 4 – 14 ProCore 648...
  • Page 53 Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á ProCore 648 Page 4 – 15...
  • Page 54 This page is intentionally blank. Hydraulic System Page 4 – 16 ProCore 648...

  • Page 55: Testing

    11. All hydraulic tests should be made with the hydraulic within a few hours by a doctor familiar with this oil at normal operating temperature. type of injury. Gangrene may result from such an injury. ProCore 648 Page 4 – 17 Hydraulic System...

  • Page 56: Charge Pressure Test

    PRESSURE GAUGE FRONT WHEEL ’B’ PORT FORWARD (BOTTOM) ’P’ PORT ’P’ PORT ’P’ PORT ’A’ PORT (TOP) Working Pressure Low Pressure (Charge) Return or Suction Flow Direction Figure 13 Rev. C Hydraulic System Page 4 - - 18 ProCore 648...
  • Page 57 A. Leave pressure gauge connected to hydraulic control manifold G2 port. B. Disengage parking brake. Start engine and oper- ate at full speed (3400 + 50 RPM). Move the traction lever fully forward. ProCore 648 Page 4 – 19 Hydraulic System...
  • Page 58 CONTROL MANIFOLD FRONT WHEEL ’B’ PORT FORWARD (BOTTOM) ’P’ PORT ’P’ PORT ’P’ PORT ’A’ PORT (TOP) Working Pressure Low Pressure (Charge) Return or Suction Flow Direction Figure 15 Rev. C Hydraulic System Page 4 - - 20 ProCore 648...

  • Page 59: Pressure Test

    B. If measured relief pressure is too high, decrease relief valve pressure setting by using an allen wrench to turn adjustment socket counterclockwise. A 1/8 turn on the socket will make a measurable change in relief pressure. ProCore 648 Page 4 – 21 Hydraulic System...

  • Page 60: Traction (Piston) Pump (P1) Flow Test (Using Tester With Flow Meter And Pressure

    Make sure engine is off and parking brake 5. Make sure that hydraulic pump drive belt is adjusted is disengaged. Secure coring head with service latch. properly (see Operator’s Manual). Rev. C Hydraulic System Page 4 - - 22 ProCore 648...
  • Page 61 IMPORTANT: Do not rotate the traction pump trun- nion shaft clockwise (reverse) during testing. 13.Using a wrench, slowly rotate traction pump trunnion shaft counter–clockwise to the fully forward position. ProCore 648 Page 4 – 23 Rev. B Hydraulic System...

  • Page 62: Traction Circuit Relief Pressure Test

    ’P’ PORT ’P’ PORT ’P’ PORT ’A’ PORT (TOP) Working Pressure Low Pressure (Charge) Return or Suction NOTE: FORWARD TRACTION CIRCUIT RELIEF PRESSURE TEST IS SHOWN Flow Direction Figure 20 Rev. C Hydraulic System Page 4 - - 24 ProCore 648...
  • Page 63 8. Install Tee–fitting with pressure gauge between the traction pump and the disconnected hose. 9. Check and adjust the oil level in the reservoir after connecting pressure gauge. Figure 21 1. Lower 45 fitting 2. Upper 90 fitting ProCore 648 Page 4 – 25 Hydraulic System...
  • Page 64 MANIFOLD TESTER FRONT WHEEL ’B’ PORT FORWARD (BOTTOM) ’P’ PORT ’P’ PORT ’P’ PORT ’A’ PORT (TOP) Working Pressure Low Pressure (Charge) Return or Suction Flow Direction Figure 22 Rev. C Hydraulic System Page 4 - - 26 ProCore 648...
  • Page 65 Make sure flow control valve on the tester is fully 1. Gear pump outlet 2. Manifold port P open. 6. Make sure that traction lever is in neutral and the parking brake is engaged. ProCore 648 Page 4 – 27 Hydraulic System...
  • Page 66 Continued operation with a worn, inefficient motor can generate excessive heat, cause damage to seals and other components in the hydraulic system and affect overall machine performance. Rev. C Hydraulic System Page 4 - - 28 ProCore 648...
  • Page 67 C. Make sure parking brake is engaged to prevent rear wheel rotation. 8. Clean hose fitting and disconnect hose from upper fitting on traction pump (Fig. 25). Figure 25 1. Upper 90 fitting 2. Lower 45 fitting ProCore 648 Page 4 – 29 Hydraulic System...

  • Page 68: Service And Repairs

    If fluid is in- jected into the skin, it must be surgically re- moved within a few hours by a doctor familiar with this type of injury. Gangrene may result from such an injury. Hydraulic System Page 4 – 30 ProCore 648...

  • Page 69: Flush Hydraulic System

    7. Disconnect and ground both spark plug wires to pre - vent engine from starting. 8. Turn ignition key switch to start position; engage starter for ten (10) seconds to prime hydraulic pumps. Repeat this step again. ProCore 648 Page 4 – 31 Hydraulic System...
  • Page 70 10 minutes. with jack stands or blocking to allow wheels to turn freely. L. Lower machine to ground. Remove chain from rear of machine. Hydraulic System Page 4 - - 32 Rev. A ProCore 648...
  • Page 71 11. Stop the machine. Check hydraulic reservoir level and fill if necessary. Check hydraulic components for leaks and tighten any loose connections. Figure 27 1. Test port 2. Hydraulic manifold ProCore 648 Page 4 - - 33 Rev. A Hydraulic System...

  • Page 72: Hydraulic System Start--Up

    9. Idler pulley 15. L bracket 4. Engine 10. Flange nut 16. Flange head screw 5. Engine pulley 11. Tensioning spring 17. Flange head screw (2 used) 6. Flange head screw 12. Set screw Hydraulic System Page 4 – 34 ProCore 648...
  • Page 73 4. Loosen the flange head screw (item 6) and flange nut Manual). (item 10) that secure the drive belt idler pulley (item 11). Lift idler pulley to allow removal of drive belt from the pul- leys and the machine. ProCore 648 Page 4 – 35 Hydraulic System...

  • Page 74: Hydraulic Pump Control Assembly

    10. Speed selector pivot 23. Stroke control cable 35. Washer head screw 11. Retaining ring 24. Traction stud 36. Cable clamp 12. Swivel 25. Lock washer 37. Spacing control cable 13. Cap screw Hydraulic System Page 4 – 36 ProCore 648...
  • Page 75 3. Install pump belt cover to machine (see Operator’s Manual). 4. Check traction drive for neutral and adjust if needed (see Operator’s Manual). 5. Operate machine and verify hole spacing accuracy. Adjust if needed (see Operator’s Manual). ProCore 648 Page 4 – 37 Hydraulic System...

  • Page 76: Hydraulic (Traction/Charge) Pump

    Operate all hydraulic controls to relieve system service latch. pressure and avoid injury from pressurized hy- draulic oil. See Relieving Hydraulic System Pres- sure in the General Information section of this chapter. Hydraulic System Page 4 – 38 ProCore 648...
  • Page 77 Support hydraulic pump when removing it from the pump support to prevent the pump from fal- 1. Extension spring 3. Flange nut/cap screw 2. Socket head screw 4. Washer head screw ling and causing personal injury. ProCore 648 Page 4 – 39 Hydraulic System...
  • Page 78 CAUTION The extension spring is under tension and may cause personal injury during installation. Use caution when installing the spring to the neutral lever. D. Install extension spring to the neutral lever. Hydraulic System Page 4 – 40 ProCore 648...
  • Page 79 HYDRO–GEAR BDP–10A/16A/21L HY- DROSTATIC PUMPS SERVICE AND REPAIR MANU- AL (hydrostat) and the SAUER DANFOSS GROUP 2 GEAR PUMPS AND MOTORS SERVICE MANUAL (gear pump) at the end of this chapter. ProCore 648 Page 4 – 41 Hydraulic System...

  • Page 80: Wheel Motors

    Operate all hydraulic controls to relieve system service latch. pressure and avoid injury from pressurized hy- draulic oil. See Relieving Hydraulic System Pres- sure in the General Information section of this chapter. Hydraulic System Page 4 – 42 ProCore 648...
  • Page 81 B. On rear wheel motor, insert four (4) cap screws through holes in parking latch support (with parking latch bar installed) and then through motor flange and frame. Secure motor to frame with lock nuts. ProCore 648 Page 4 – 43 Hydraulic System...

  • Page 82: Wheel Motor Service

    15. Distributor plate 22. Cap screws (7 used) 8. Shaft NOTE: The three wheel motors on the ProCore 648 are NOTE: For repair of the wheel motors, see the SAUER similar in construction but are different from each other. DANFOSS OMEW HYDRAULIC MOTOR SERVICE The front wheel motor (24 c.i.
  • Page 83 This page is intentionally blank. ProCore 648 Page 4 – 45 Hydraulic System...

  • Page 84: Hydraulic Lift Control Manifold

    Hydraulic Lift Control Manifold RIGHT FRONT Figure 38 1. Main frame 3. Hydraulic lift control manifold 5. Flange nut (2 used) 2. Cap screws (2 used) 4. Hydraulic oil filter Hydraulic System Page 4 – 46 ProCore 648...
  • Page 85 1. Position hydraulic manifold to the frame mounting bracket. Install two (2) cap screws and flange nuts but do not tighten. 2. Make sure all hydraulic connections, ports and fit- tings are clean. ProCore 648 Page 4 – 47 Hydraulic System...

  • Page 86: Hydraulic Lift Control Manifold Service

    10. Solenoid valve (SVR port) 15. Plug NOTE: The ports on the manifold are marked for easy NOTE: The ProCore 648 hydraulic lift control manifold identification of components. Example: P is the pump uses two zero leak plugs (item 12). These plugs have a...
  • Page 87 9. After assembly, if problems still exist, remove valve there may be water in the system. and clean again or replace valve. CAUTION Use eye protection such as goggles when using compressed air for cartridge valve cleaning. ProCore 648 Page 4 – 49 Hydraulic System...

  • Page 88: Lift Cylinder

    E. Remove hair pin (item 8) and clevis pin (item 7) that secure spring shackle (item 2) to frame. Hydraulic System Page 4 – 50 ProCore 648...
  • Page 89 Install cylinder pin making sure that a spacer is on each side of the cylinder pivot and a thrust washer is positioned between coring head frame and re - taining ring (Fig. 43). Secure with retaining ring. ProCore 648 Page 4 – 51 Hydraulic System...

  • Page 90: Lift Cylinder Service

    4. Grasp end of rod; extract rod and head by carefully twisting and pulling on the rod. Figure 45 IMPORTANT: Do not clamp vise jaws against rod surface. Protect rod surface before mounting in vise. Hydraulic System Page 4 – 52 ProCore 648...
  • Page 91 Rotate head clockwise as far as the retaining ring will allow. The offset end of the retaining ring will be against the left side of the tube groove as shown in Fig- ure 46. ProCore 648 Page 4 – 53 Hydraulic System...

  • Page 92: Hydraulic Reservoir

    3. Replace any hydraulic hose, tube or fitting if dam- aged or leaking. 1. Clean hydraulic reservoir with solvent. 4. Make sure cap screw (item 6) that secures tank strap 2. Inspect reservoir for leaks, cracks or other damage. is tight. Hydraulic System Page 4 – 54 ProCore 648...

  • Page 93: Electrical Diagrams

    Hour Meter ....... . 14 Electrical Diagrams The electrical schematic, electrical circuit drawings and wire harness drawings for the ProCore 648 are located in Chapter 8 – Electrical Diagrams. ProCore 648 Electrical System Page 5 –...

  • Page 94: Circuit Operation

    Circuit Operation NOTE: This section provides information concerning three sequential, electrical circuits that are used on the ProCore 648. Use these descriptions along with the electrical diagrams and schematics found in Chapter 8 – Electrical Diagrams to better understand circuit opera- tion.
  • Page 95 GROUND TO AERATOR CONTROL MODULE OK TO LOWER (ENERGIZED) (IN MIDDLE/AERATE POSITION) (2 AND 3 CLOSED) (NOT ENERGIZED) GROUND LOCKOUT AERATION #3 CIRCUIT PROX. SWITCH CONTROL CURRENT OK TO LOWER Figure 1 ProCore 648 Electrical System Page 5 – 3...
  • Page 96 Once the lockout circuit has initially been closed by transport limit #2 proximity switch, the lockout latch relay and diode D2 allow a latch circuit to keep the lockout relay energized and hydraulic solenoid valve operation to continue while aerating. Electrical System ProCore 648 Page 5 – 4...
  • Page 97 TERMINAL ”A” CORING HEAD STRANDED TO AERATOR TO IGNITION GROUND CONTROL SWITCH MODULE TERMINAL ”L” (ENERGIZED) (ENERGIZED) (PRESSED) TO ELECTRIC CLUTCH TO IGNITION SWITCH TERMINAL ”A” CONTROL CURRENT POWER CURRENT Figure 2 ProCore 648 Electrical System Page 5 – 5...

  • Page 98: Ok To Lower Circuit

    OK TO LOWER TERMINAL ”L” CIRCUIT (NOT ENERGIZED) (NOT ENERGIZED) (ENERGIZED) AERATING (CLUTCH ENGAGED) TO IGNITION SWITCH GROUND OK TO LOWER TERMINAL ”L” CIRCUIT (ENERGIZED) (ENERGIZED) (HEAD LOWERED) CONTROL CURRENT CLUTCH CURRENT Figure 3 Electrical System ProCore 648 Page 5 – 6...

  • Page 99: Special Tools

    The multimeter can test electrical components and cir- cuits for current (amps), resistance (ohms) or voltage. NOTE: Toro recommends the use of a DIGITAL Volt– Ohm–Amp multimeter when testing electrical circuits. The high impedance (internal resistance) of a digital me- ter in the voltage mode will make sure that excess cur - rent is not allowed through the meter.

  • Page 100: Troubleshooting

    Neutral proximity switch is out of adjustment or faulty. Sensing plate on traction lever is loose. Neutral switch relay is faulty. Ignition switch is faulty. Fuse block is faulty. Starter solenoid is faulty. Electrical System ProCore 648 Page 5 – 8...

  • Page 101: General Run Problems

    Chapter 8 – Electrical Diagrams). Circuit wiring to carburetor solenoid is loose, corroded, or damaged (see Chapter 8 – Electrical Diagrams). Engine or fuel system is malfunctioning (see Chapter 3 – Kohler Engine). ProCore 648 Electrical System Page 5 – 9...

  • Page 102: Coring Head Operating Problems

    Clutch is loose on engine crankshaft. Clutch strap is loose or damaged. Broken leaf spring(s) on clutch. Failed clutch bearing(s). Clutch is slipping. Lubricant has contaminated clutch lining material. Gap between clutch rotor and armature is excessive. Electrical System ProCore 648 Page 5 – 10...

  • Page 103: Electrical System Quick Checks

    NOTE: Depending upon the condition of the battery charge and battery temperature, the charging system voltage will increase at different rates as the battery charges. ProCore 648 Electrical System Page 5 – 11...
  • Page 104 Check Operation of Safety Interlock System The Safety Interlock System of the ProCore 648 ensur - es the following operations: CAUTION 1. The engine should crank only when the traction lever is in the neutral position. Do not disconnect interlock switches. They are for the operator’s protection.

  • Page 105: Component Testing

    Module power input LED should be illuminated. If the ignition switch is in the START position, the Module HEX NUT start output LED should also be illuminated. SWITCH LOCK WASHER Figure 9 ProCore 648 Electrical System Page 5 – 13...

  • Page 106: Engine Oil Pressure Indicator Light

    Kohler Engine Service Manual at the end of Chap- ter 3 – Engine. Hour Meter The hour meter used on the ProCore 648 uses an induc- tive pickup wire connected to the rear spark plug wire to sense when the engine is running. The hour meter should increase 1/10 of an hour every six (6) minutes of engine running time.

  • Page 107: Relays

    Relays Six (6) relays are used on the ProCore 648. Four (4) of these relays are attached under the control panel next to the battery (Fig. 13): lockout relay, clutch relay, neutral switch (start) relay and lockout latch relay. The remain- ing two (2) relays are attached under the handle console (Fig.

  • Page 108: Manual Raise/Lower Switch

    Figure 16 SWITCH NORMAL OTHER POSITION CIRCUITS CIRCUITS 1. Manual raise/lower switch RAISE NONE NONE MIDDLE/ AERATE 2 + 3 NONE LOWER (MOMENTARY) 2 + 3 5 + 6 Figure 17 Electrical System ProCore 648 Page 5 – 16...

  • Page 109: Ground Follow Switch

    ON (Fig. 20). If the ground follow switch is in the OFF (lower) position, the Module ground follow output LED should not be illuminated. Figure 19 Figure 20 1. Control module 2. Ground follow LED ProCore 648 Electrical System Page 5 – 17...

  • Page 110: Lift Reset Switch

    Verify continuity between switch termi- nals. Figure 21 1. Lift reset switch SWITCH NORMAL OTHER POSITION CIRCUITS CIRCUITS NORMAL 2 + 3 5 + 6 MOMENTARY 1 + 2 4 + 5 ON (RESET) Figure 22 Electrical System ProCore 648 Page 5 – 18...

  • Page 111: Solenoid Valve Coil

    Solenoid Valve Coil The hydraulic system on the ProCore 648 uses three (3) solenoid valve coils on the hydraulic lift control manifold (Fig. 23). The aerator control module provides current to the solenoid valve coils based on the position of several inputs.

  • Page 112: Head Low And Head High Limit Switches

    4. Reconnect the switch electrical connector. 5. If switch replacement is necessary, apply small amount of grease onto the switch ball before installing switch in depth control housing. Electrical System ProCore 648 Page 5 – 20...

  • Page 113: Fuses

    Fuse 4 (2 Amp): Supplies power to aerator control 1. Fuse block module. Testing Remove fuses from the fuse block for testing. Fuse should have continuity between fuse terminals. Fuse 1 Fuse 2 Fuse 3 Fuse 4 Figure 28 ProCore 648 Electrical System Page 5 – 21...

  • Page 114: Proximity Switches

    Proximity Switches The ProCore 648 uses six (6) identical proximity switches. These switches are normally open switches that close when a sensing plate is positioned near the target end of the switch (Fig. 32). The reverse and neutral proximity switches are mounted on the control handle under the handle con- sole (Fig.
  • Page 115 (Fig. 30) should be mounted to allow from .030” to .090” (.8 to 2.3 mm) clear - ance between the switch targets and sensing plate on the coring head H–frame. ProCore 648 Electrical System Page 5 – 23...

  • Page 116: Aerator Control Module

    Aerator Control Module The ProCore 648 is equipped with an Aerator Control Module to monitor and control electrical components re - quired for safe operation. This Module is located on the inside of the console cover (Fig. 33). Inputs from the start (ignition), head low limit, head high...
  • Page 117 B. Both ”OK to lower” and ground follow LED’s are illuminated and aerate #4 LED is not illuminated. C. ”OK to lower”, ground follow, aerate #4 and head high limit LED’s are all illuminated. ProCore 648 Electrical System Page 5 – 25...

  • Page 118: Electric Clutch

    An electric clutch is used to engage the coring head on 8. As an additional test, apply 12 volts to the terminals the ProCore 648. The electric clutch is mounted on the of the clutch. The clutch should engage. If clutch does engine crankshaft and engages when current is applied not engage when voltage is applied, replace clutch.

  • Page 119: Diode Assemblies

    Diode Assemblies Diodes D1, D2 and D3 provide logic for the latch relays used in the ProCore 648. Diode D4 is used for circuit protection from voltage spikes when the electric clutch is de–energized. The diodes plug into the wiring har- ness at various locations (see Wire Harness Drawings in Chapter 8 –...

  • Page 120: Service And Repairs

    A. Clean battery by washing entire case with a solu- tion of baking soda and water. Rinse with clear water. B. Spray battery terminals with Battery Terminal Protector (Toro Part No. 107–0392) to prevent cable and terminal corrosion. Petroleum jelly can be used as well.

  • Page 121: Battery Service

    1 inch (25.4 mm) of either battery cable when moved through its entire range of motion. Also check that bat - tery cables do not contact rotating screen on engine. ProCore 648 Electrical System Page 5 – 29...
  • Page 122 –6.7 –12.2 –17.8 I. If the test voltage is below the minimum, replace the battery. If the test voltage is at or above the mini - mum, return the battery to service. Electrical System ProCore 648 Page 5 – 30...
  • Page 123 5.8 hrs 11.5 hrs 17.3 hrs 23 hrs 6 amps 6 amps 6 amps 6 amps above 6 hrs 12 hrs 18 hrs 24 hrs 10 amps 10 amps 10 amps 10 amps ProCore 648 Electrical System Page 5 – 31...

  • Page 124: Electric Clutch

    14. Hardened washer 22. Idler arm 6. Flat washer 15. Idler pulley 23. Flat washer 7. Brake grommet 16. Torsion spring 24. Cap screw 8. Cap screw 17. Spacer 25. Flange nut 9. Spacer Electrical System ProCore 648 Page 5 – 32...
  • Page 125 5. Install muffler heat shield (see Exhaust System in the Service and Repairs section of Chapter 3 – Kohler En - gine). 6. Install pump belt cover to machine (see Operator’s Manual). ProCore 648 Electrical System Page 5 – 33...

  • Page 126: Solenoid Valve Coil

    Figure 41 3. Connect the solenoid coil to the machine wiring har- 1. Solenoid valve coil (SVL) 4. Nut 2. Solenoid valve coil (SVQ) 5. Nut ness. 3. Solenoid valve coil (SVR) Electrical System ProCore 648 Page 5 – 34...
  • Page 127 Steering Assembly ......10 Traction Control Cable ..... . 12 ProCore 648 Page 6 – 1...

  • Page 128: Specifications

    19 x 10.5 – 8, 2 Ply, Tubeless Pressure 12 PSI (.83 Bar) Wheel lug nut torque 45 to 55 ft–lb (61 to 75 N–m) Wheel hub nut torque 190 to 230 ft–lb (258 to 312 N–m) Chassis Page 6 – 2 ProCore 648...

  • Page 129: Special Tools

    Special Tools Order special tools from your Toro Distributor. Wheel Hub Puller Part Number: TOR4097 The wheel hub puller allows safe removal of the wheel hub from the shaft of wheel motors. Figure 1 Rev. C ProCore 648 Page 6 - - 3...

  • Page 130: Service And Repairs

    9. Lock nut 2. Lug nut 6. Thrust washer 10. Wheel hub 3. Front wheel weight 7. Lock nut 11. Parking latch disc 4. Wheel weight adapter 8. Bearing plate 12. Wheel stud Chassis Page 6 – 4 ProCore 648...
  • Page 131 1. If rear wheel was removed: A. Position rear wheel to wheel hub. Figure 3 B. Secure wheel to machine with four (4) lug nuts. Torque lug nuts from 45 to 55 ft–lb (61 to 75 N–m). ProCore 648 Page 6 – 5 Chassis...

  • Page 132: Parking Brake

    13. Lock nut 20. Woodruff key 6. Shoulder bolt 14. Tire and wheel assembly 21. Parking brake cable 7. Compression spring 15. Lug nut (4 used per wheel) 22. Clevis pin 8. Parking latch clevis Chassis Page 6 – 6 ProCore 648...
  • Page 133 C. Remove wheel studs to allow separation of park- ing latch disc, wheel hub and bearing plate. 7. Clean all parts. Inspect parking latch bar and parking latch disc for excessive wear or damage. Replace any damaged parts. ProCore 648 Page 6 – 7 Chassis...

  • Page 134: Parking Brake Cable

    7. Brake cable 12. Brake spacer 3. Steering arm 8. Flat washer 13. Cap screw 4. Lower handle cover 9. Cotter pin 14. Knob 5. Washer head screw (6 used) 10. Brake lever Chassis Page 6 – 8 ProCore 648...
  • Page 135 5. Position lower handle cover to control handle and se- cure with six (6) washer head screws. 6. Make sure that steering components do not contact cables or wire harness. 7. Remove service latch from coring head before ma- chine use. ProCore 648 Page 6 – 9 Chassis...

  • Page 136: Steering Assembly

    10. Steering stop 23. Spring retainer 35. Low oil pressure light 11. Cap screw (2 used) 24. Compression spring 36. Raise/lower switch 12. Cable guide 25. Override rod 37. Handle control cover 13. Cotter pin Chassis Page 6 – 10 ProCore 648...
  • Page 137 D. Disconnect parking brake cable from brake lever (see Parking Brake Cable Removal in this section). Figure 8 1. Relay 3. Neutral prox switch 2. Reverse prox switch ProCore 648 Page 6 – 11 Chassis...

  • Page 138: Traction Control Cable

    4. Check and adjust traction drive for neutral (see Op- erator’s Manual). Figure 10 1. Pump control 3. Cable ball joint 2. Traction control cable Figure 11 1. Traction lever 2. Cable ball joint Rev. B Chassis Page 6 – 12 ProCore 648...
  • Page 139 Coring Head Drive Jackshaft ....14 Coring Head Pivot (H–Frame) ....16 ProCore 648 Page 7 – 1...

  • Page 140: General Information

    General Information Coring Head Operation The coring head of the Procore 648 consists of a frame that pivots for aerating depth control, a coring crank- shaft, stomper arms with rotolinks to provide vertical tine motion, turf holders, tine holders and aerating tines.

  • Page 141: Coring Head Service Latch

    1. Service latch (in raised, locked position) Coring Head Adjustments See Operator’s Manual for adjustment procedures for the coring head on the ProCore 648. CAUTION Never work on the coring head with the engine running. Always fully raise coring head, stop en -...

  • Page 142: Service And Repairs

    16. Damper standoff Bumper plate 11. Stomper arm 17. Damper top spacer Cap screw 12. Flange nut NOTE: The rotolink damper assemblies for all stomper arms used on the ProCore 648 are identical. Coring Head Page 7 – 4 ProCore 648...
  • Page 143 (item 16) should contact bumper plates (item 5). If only damper standoff (item 16) is used, rubber bumpers should contact frame (bumper plates moved forward). 6. Remove service latch from coring head before using machine. ProCore 648 Page 7 – 5 Coring Head...

  • Page 144: Stomper Arms

    648 are identical. Coring crankshaft positions are identi- fied as #1 through #6. The #1 position is on the right (pulley) side of the coring crankshaft (Fig. 6). Figure 6 1. #1 position 2. #6 position Coring Head Page 7 – 6 ProCore 648...
  • Page 145 5. Coupling plate 2. Iso mount (2 used) 6. Cap screw (4 used) 3. Coupling (#2 shown) 7. Lock nut (2 used) 4. Cap screw (2 used) 8. Flat washer (2 used) ProCore 648 Page 7 – 7 Coring Head...

  • Page 146: Coring Crankshaft Bearing Housings

    6. Support bearing housing assembly to prevent it from 2. Remove rear hood (see Operator’s Manual). falling. Remove fasteners that secure bearing housing assembly to coring head frame. Remove bearing hous- ing assembly. Coring Head Page 7 – 8 ProCore 648...
  • Page 147 8. Flat washer (2 used) A. Cap screws that fasten crankarms. B. Cap screws that secure top and bottom of stomp- er arms. C. Cap screws that secure coupling plates (Fig. 10). ProCore 648 Page 7 – 9 Coring Head...

  • Page 148: Primary Drive Belt

    14. Hardened washer 22. Idler arm 6. Flat washer 15. Idler pulley 23. Flat washer 7. Brake grommet 16. Torsion spring 24. Cap screw 8. Cap screw 17. Spacer 25. Flange nut 9. Spacer Coring Head Page 7 – 10 ProCore 648...
  • Page 149 (item 10) to clutch. Position clutch strap away from 7. Remove service latch from coring head before using clutch. machine. 7. Unplug machine wire harness connector from clutch. 8. Remove primary drive belt from pulleys and ma- chine. ProCore 648 Page 7 – 11 Coring Head...

  • Page 150: Secondary Drive Belt

    Be careful when lifting the idler pulley. The idler 1. Extension springs 3. Upper flange nut pulley is spring loaded and may cause personal 2. Spring arm 4. 1/2” drive hole injury. Coring Head Page 7 – 12 ProCore 648...
  • Page 151 5. Install belt cover and rear hood to machine (see Op- erator’s Manual). 6. Remove service latch from coring head before using machine. Figure 16 1. Secondary drive belt 2. #1 rotolink damper ProCore 648 Page 7 – 13 Coring Head...

  • Page 152: Coring Head Drive Jackshaft

    Remove bushings and pulleys sembly, remove loosened cap screws and lock nuts and from the jackshaft. Locate and retrieve woodruff keys remove jackshaft assembly from machine. (item 6) that locate bushings on jackshaft. Coring Head Page 7 – 14 ProCore 648...
  • Page 153 180 to 200 in–lb (20.3 to 22.6 N–m) in three equal steps and in a circular pattern to se - Figure 20 cure secondary pulley and taper lock bushing. 1. Flange mount bearing 3. Set screw 2. Jackshaft ProCore 648 Page 7 – 15 Coring Head...

  • Page 154: Coring Head Pivot (H-Frame)

    H–frame Upper link 12. Thrust washer Hex nut Jam nut 13. Carriage screw Lock washer Rod end 14. Pivot shaft Rod end (LH thread) 10. Flange bushing (4 used) 15. Flange nut Coring Head Page 7 – 16 ProCore 648...
  • Page 155 Return key Figure 24 switch to OFF and remove key from the ignition switch. 1. Proximity switch bracket 2. Machine frame ProCore 648 Page 7 – 17 Coring Head...
  • Page 156 45.2 cm) long (rod center to rod center) (Fig. 26). IMPORTANT: When installing pivot shaft to H– frame, make sure that both sides of H–frame are aligned with holes in machine frame before instal - ling pivot shaft. Coring Head Page 7 – 18 ProCore 648...
  • Page 157 Wire Harness Drawing ..... . . 11 Wire Harness Diagram ..... . 12 ProCore 648 Page 8 – 1...
  • Page 158 This page is intentionally blank. Electrical Diagrams Page 8 – 2 ProCore 648...

  • Page 159: Electrical Schematic

    ProCore 648 Electrical Schematic All relays and solenoids are shown as de–energized. All ground wires are black. Page 8 – 3...

  • Page 160: Start Engine

    (ENERGIZED) (NOT ENERGIZED) (NEUTRAL POSITION) (NOT ENERGIZED) (NOT ENERGIZED) ProCore 648 (NOT ENERGIZED) Start Engine Power Current Control Current Indication Current (NOT ENERGIZED) Page 8 – 4...

  • Page 161: Lower Coring Head

    ProCore 648 Aerator Aerator Control Module (RUN) (NOT ENERGIZED) (NOT IN NEUTRAL) (NOT ENERGIZED) (ENERGIZED) (ON) (HEAD BEING LOWERED) (ENERGIZED) (ENERGIZED) (PRESSED TO LOWER) (NOT ENERGIZED) (IN FORWARD) (HEAD BEING LOWERED) (HEAD BEING LOWERED) (HEAD BEING LOWERED) (HEAD BEING LOWERED)

  • Page 162: Aerating (Level Ground Surface)

    ProCore 648 Aerator Aerator Control Module (RUN) (NOT ENERGIZED) (NOT IN NEUTRAL) (NOT ENERGIZED) (NOT ENERGIZED) (ON) (HEAD LOWERED) (NOT ENERGIZED) (ENERGIZED) (NEUTRAL POSITION) (NOT ENERGIZED) (IN FORWARD) (HEAD LOWERED) (HEAD LOWERED) (HEAD LOWERED) (HEAD LOWERED) ProCore 648 (ENERGIZED) Aerating...

  • Page 163: Aerating (High Spot In Turf Encountered)

    ProCore 648 Aerator Aerator Control Module (RUN) (NOT ENERGIZED) (NOT IN NEUTRAL) (NOT ENERGIZED) (NOT ENERGIZED) (ON) (CLOSED BY TURF GUARD) (ENERGIZED) (ENERGIZED) (NEUTRAL POSITION) (NOT ENERGIZED) (IN FORWARD) (HEAD LOWERED) (HEAD LOWERED) (HEAD LOWERED) (HEAD LOWERED) ProCore 648 (ENERGIZED)
  • Page 164 ProCore 648 Aerator Aerator Control Module (RUN) (NOT ENERGIZED) (NOT IN NEUTRAL) (ENERGIZED) (NOT ENERGIZED) (ON) (HEAD LOWERED) (NOT ENERGIZED) (ENERGIZED) (NEUTRAL POSITION) (NOT ENERGIZED) (IN FORWARD) (HEAD LOWERED) (CLOSED BY TURF GUARD) (HEAD LOWERED) (HEAD LOWERED) ProCore 648 (ENERGIZED)

  • Page 165: Raise Coring Head

    ProCore 648 Aerator Aerator Control Module (RUN) (NOT ENERGIZED) (NOT IN NEUTRAL) (ENERGIZED) (ENERGIZED) (ON) (HEAD LOWERED) (NOT ENERGIZED) (NOT ENERGIZED) (NEUTRAL POSITION) (ENERGIZED) (HEAD LOWERED) (HEAD LOWERED) (HEAD LOWERED) (HEAD LOWERED) (ENERGIZED) ProCore 648 (ENERGIZED) Raise Coring Head Traction Lever Moved from Forward...

  • Page 166: Transport

    ProCore 648 Aerator Aerator Control Module (RUN) (NOT ENERGIZED) (NOT IN NEUTRAL) (NOT ENERGIZED) (NOT ENERGIZED) (ON) (HEAD RAISED) (NOT ENERGIZED) (NOT ENERGIZED) (NEUTRAL POSITION) (NOT ENERGIZED) (IN FORWARD) (HEAD RAISED) (HEAD RAISED) (HEAD RAISED) (HEAD RAISED) ProCore 648 (ENERGIZED)

  • Page 167: Wire Harness Drawing

    ProCore 648 Wire Harness Drawing Page 8 – 11...

  • Page 168: Wire Harness Diagram

    GREEN PINK BLACK YELLOW YELLOW DIODE D1 YELLOW BLUE DIODE D2 BLACK BLACK DIODE D3 YELLOW ProCore 648 Wire Harness Diagram TRANSPORT AERATION #3 CLUTCH DIODE CLUTCH RELAY LIFT RESET ENGINE CONNECTOR GROUND RAISE LOWER FAST RAISE TRANSPORT LIMIT #1...

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