Page 2 - This page is intentionally blank.
Page 3 - Table Of Contents; PUMPS SERVICE AND REPAIR MANUAL
Table Of Contents Chapter 1 – Safety Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . 1 – 2 Jacking Instructions . . . . . . . . . . . . . . . . . . . . . . . . . 1 – 4 Safety and Instruction Decals . . . . . . . . . . . . . . . . 1 – 5 Chapter 2 – Product Records and Maintena...
Page 5 - Chapter 1; Table of Contents; Safety
Chapter 1 Safety Table of Contents SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . 2 Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2While Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Maintenance and Service . . . . . . . . . . . . . ...
Page 6 - Safety Instructions; To reduce the potential for injury or death,; Before Operating
Rev. C ProCore 648 Page 1 -- 2 Safety Safety Instructions The ProCore 648 is designed and tested to offer safe service when operated and maintained properly. Al- though hazard control and accident prevention partially are dependent upon the design and configuration of the machine, these factors are ...
Page 7 - Maintenance and Service
7. Anytime the machine is parked (short or long term), 8. Do not park on slopes unless wheels are chocked or install the service latch to secure the coring head in the blocked. raised position. This eliminates the risk of the coring head accidentally lowering to the ground. Maintenance and Service 1...
Page 8 - Figure 1
2 Jacking Instructions CAUTION er jack stands, the machine may move or fall, Frame jacking point Figure 1 1 When changing attachments, tires or perform-ing other service, use correct blocks, hoists and jacks. Make sure machine is parked on a solid level surface such as a concrete floor. Prior to rai...
Page 9 - 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 11 - Chapter 2; Standard Torque for Dry, Zinc Plated and; Product Records and Maintenance
Chapter 2 Product Records and Maintenance Table of Contents PRODUCT RECORDS . . . . . . . . . . . . . . . . . . . . . . . . . 1 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 EQUIVALENTS AND CONVERSIONS . . . . . . . . . . . 2 Decimal and Millimeter Equivalents . . . . . ....
Page 12 - Equivalents and Conversions
Rev. C 0.09375 ProCore 648 Page 2 -- 2 Product Records and Maintenance Equivalents and Conversions
Page 13 - Torque Specifications; reduced by 25% for lubricated fasteners; Fastener Identification
Torque Specifications Recommended fastener torque values are listed in the following tables. For critical applications, as determined by Toro, either the recommended torque or a torque that is unique to the application is clearly identified and spe-cified in this Service Manual. These Torque Specifi...
Page 16 - Other Torque Specifications; Grade 5; Conversion Factors
Other Torque Specifications SAE Grade 8 Steel Set Screws Wheel Bolts and Lug Nuts Thread Size Thread Size Recommended Torque Square Head Hex Socket 1/4 – 20 UNC 140 + 20 in–lb 73 + 12 in–lb 5/16 – 18 UNC 215 + 35 in–lb 145 + 20 in–lb 3/8 – 16 UNC 35 + 10 ft–lb 18 + 3 ft–lb 1/2 – 13 UNC 75 + 15 ft–lb...
Page 17 - Chapter 3; Kohler Engine; ADJUSTMENTS; Kohler
Chapter 3 Kohler Engine Table of Contents INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2SPECIFICATIONS 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 4 Fuel Shutoff Valve . . . . . . . . . . . . . . ...
Page 18 - Introduction
Introduction This Chapter gives information about specifications and repair of the Kohler engine used in the ProCore 648. General engine maintenance procedures are described in your Operator ’s Manual. Information on engine trou-bleshooting, testing, disassembly, and reassembly is identified in the ...
Page 19 - Specifications
Specifications Item Description Make / Designation Kohler, CH23S, 4–stroke, V–Twin Air Cooled, OHV Number of Cylinders 2 Bore x Stroke 3.15” x 2.64” (80 mm x 67 mm) Total Displacement 41.1 Cubic Inches (674 cc) Compression Ratio 8.5:1 Dry Weight (approximate) 90 Pounds (41 Kilograms) Fuel Unleaded, ...
Page 20 - General Information; Fuel Shutoff Valve
General Information Fuel Shutoff Valve The fuel shutoff valve located under the fuel tank (Fig. 1) should be closed when removing the fuel tank or en-gine from the machine. Additionally, close the shutoff valve if the machine is being transported on a trailer or when placing the machine in long term...
Page 21 - Adjustments; Adjust Choke Control; Adjust Engine Speed
Adjustments Adjust Choke Control Proper choke operation is dependent upon proper ad-justment of choke control cable. 1. Park machine on a level surface, fully raise coring head, engage parking brake, stop engine and remove key from the ignition switch. 2. Remove air cleaner cover from engine to view...
Page 23 - Kohler Engine; Service and Repairs; Cooling System; Perform this maintenance procedure at the in-
ProCore 648 Page 3 – 7 Kohler Engine Service and Repairs Cooling System To ensure proper engine cooling, make sure the grassscreen, cooling fins and other external surfaces of theengine are kept clean at all times. NOTE: Perform this maintenance procedure at the in- terval specified in the Operator ...
Page 24 - Fuel System; Figure 5; Anti–seize; DANGER; Check Fuel Lines and Connections
ProCore 648 Page 3 – 8 Kohler Engine Fuel System Figure 5 1. Fuel tank 2. Fuel cap 3. Hose clamp 4. Fuel hose 5. Fuel shut–off valve6. Hose clamp 7. Fuel hose 8. Flat washer (4 used) 9. Clamp10. Cap screw (4 used)11. Flange bushing (4 used)12. Machine frame FRONT RIGHT 2 1 3 9 8 7 6 4 8 10 10 5 6 11...
Page 25 - Apply anti–seize lubricant to fuel tank cap screws and; Connect fuel hose to the fuel filter.
Fuel Tank Removal (Fig. 5) 1. Park machine on a level surface, fully raise coring head, engage parking brake, stop engine and remove key from the ignition switch. Secure coring head with service latch. 2. Close tank fuel shut–off valve. Disconnect fuel hose from the fuel filter (Fig. 6). 3. Use shut...
Page 26 - Exhaust System; Figure 7; FRONT
ProCore 648 Page 3 – 10 Kohler Engine Exhaust System Figure 7 1. Engine2. Exhaust manifold 3. Hex nut (4 used)4. Frame5. Flange nut (2 used) 6. Muffler bracket 7. Flange head screw (3 used)8. Muffler clamp (2 used)9. Exhaust elbow 10. Carriage screw (2 used) 11. Heat shield12. Lock washer (2 used)13...
Page 27 - CAUTION; Make sure exhaust manifold and engine seal-
Removal (Fig. 7) Installation (Fig. 7) CAUTION haust system. The muffler and exhaust pipe may be hot. To avoid possible burns, allow the engine and ex-haust system to cool before working on the ex- 1. Park machine on a level surface, fully raise coring head, engage parking brake, stop engine and rem...
Page 28 - Engine
Rev. C ProCore 648 Page 3 -- 12 Kohler Engine Engine Figure 8 1. Engine 2. Negative battery cable 3. Wire harness ground 4. Flange screw 5. Lock washer 6. Exhaust manifold 7. Hex nut (4 used) 8. Cap screw (4 used) 9. Frame 10. Flange nut (2 used) 11. Muffler bracket 12. Flange head screw (3 used) 13...
Page 29 - Disconnect electrical connections from engine.; Figure 9
ProCore 648 Page 3 – 13 Kohler Engine 7. Disconnect electrical connections from engine. NOTE: Label all electrical connections for reassembly purposes. A. Remove harness red wire and positive batterycable from the starter motor solenoid stud (Fig. 9). B. Disconnect negative battery cable and wire ha...
Page 30 - Reconnect electrical connections to engine:
Installation (Fig. 8) B. Wrap hourmeter wire around spark plug wire and 1. Locate machine on a level surface with key removed from the ignition switch. Chock wheels to keep the ma-chine from moving. 2. Make sure that all parts removed from the engine during maintenance or rebuilding are reinstalled ...
Page 32 - Belt Tensioners
ProCore 648 Page 3 – 16 Kohler Engine Belt Tensioners Figure 12 1. Engine2. Hydraulic pump drive pulley 3. Electric clutch 4. Flange nut 5. Hardened washer 6. Cap screw 7. Flat washer 8. Grommet9. Spacer10. Cap screw11. Clutch strap12. Cap screw 13. Flange nut14. Flat washer15. Idler arm assembly16....
Page 35 - Chapter 4; Hydraulic System; Hydraulic System
Rev. C ProCore 648 Hydraulic System Page 4 -- 1 Chapter 4 Hydraulic System Table of Contents SPECIFICATIONS 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL INFORMATION 4 . . . . . . . . . . . . . . . . . . . . . Hydraulic Hoses 4 . . . . . . . . . . . . . . . . . . . . . . . . . ...
Page 37 - Hydraulic
This page is intentionally blank. Hydraulic System ProCore 648 Page 4 – 3 Hydraulic System
Page 38 - Hydraulic Hoses; WARNING; Hydraulic Fitting Installation; Lubricate the O–ring with a light coating of oil.
General Information Hydraulic Hoses Hydraulic hoses are subject to extreme conditions such as pressure differentials during operation and exposure to weather, sun, chemicals, very warm storage condi-tions, or mishandling during operation and mainte-nance. These conditions can cause damage or prematu...
Page 40 - Pushing/Pulling Machine; tance; Check Hydraulic Fluid; Check level of hydraulic fluid daily.; Relieving Hydraulic System Pressure; Figure 8
Pushing/Pulling Machine IMPORTANT: If push/pull limits are exceeded, se-vere damage to the piston (traction) pump may oc-cur. If it becomes necessary to push/pull the machine, push/ pull at a speed below 1 mph (1.6 kph) , and for a dis- tance less than 100 feet (30.5 meters) . The piston (traction) ...
Page 41 - Hydraulic Schematic
Rev. C ProCore 648 Hydraulic System Page 4 -- 7 Hydraulic Schematic Hydraulic Schematic ProCore 648 All solenoids are shown as de--energized T CHG P PV R1 R2 SVR SVQ SVL ORF1 CYL G1 G2 M2 M3 M1 FORWARD ’B’ PORT (BOTTOM) ’A’ PORT (TOP) ’P’ PORT FRONT WHEEL ’P’ PORT ’P’ PORT P2 P1 2900 -- 40 1000 40 -...
Page 42 - Hydraulic Flow Diagrams
Rev. C ProCore 648 Hydraulic System Page 4 -- 8 Hydraulic Flow Diagrams Working PressureLow Pressure (Charge)Return or SuctionFlow Traction Circuit (Forward Shown) T CHG P PV R1 R2 SVR SVQ SVL ORF1 CYL G1 G2 M2 M3 M1 FORWARD ’B’ PORT (BOTTOM) ’A’ PORT (TOP) ’P’ PORT FRONT WHEEL ’P’ PORT ’P’ PORT P2 ...
Page 43 - Traction Circuit; Forward Direction
ProCore 648 Hydraulic System Page 4 – 9 Traction Circuit The traction (piston) pump (P1) is driven by the engine through the pulleys and pump drive belt. The traction cir- cuit of the hydraulic system acts essentially as a closed loop. Taking its suction directly from the return side of the wheel mo...
Page 44 - Coring Head Raise/Lower Circuits; CORING HEAD
ProCore 648 Hydraulic System Page 4 – 10 Working PressureLow Pressure (Charge)Return or SuctionFlow Coring Head Raise/Lower Circuits T CHG P PV R1 R2 SVR SVQ SVL ORF1 CYL G1 G2 (ENERGIZED) CONTROL MANIFOLD LIFT CYLINDER (ENERGIZED) ENERGIZED) T CHG P PV R1 R2 SVR SVQ SVL ORF1 CYL G1 G2 (NOT ENERGIZE...
Page 45 - Raise Coring Head; Ground Following System
ProCore 648 Hydraulic System Page 4 – 11 Coring Head Raise/Lower Circuits The gear pump (P2) is attached to the traction pump (P1) and is directly coupled to it. The gear pump supplies hydraulic flow for maintaining charge pressure of 40 PSI (2.8 Bar) to the low pressure side of the traction circuit...
Page 46 - Special Tools; Hydraulic Pressure Test Kit
Rev. C ProCore 648 Hydraulic System Page 4 -- 12 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 fitting...
Page 47 - Hydraulic Test Fitting Kit; This kit includes a variety of O–ring Face Seal fittings to; Wheel Hub Puller; The wheel hub puller allows safe removal of the wheel
ProCore 648 Hydraulic System Page 4 – 13 Hydraulic Test Fitting Kit Part Number: 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 48 - Troubleshooting; Problem
ProCore 648 Hydraulic System Page 4 – 14 Troubleshooting The cause of an improperly functioning hydraulic sys- tem is best diagnosed with the use of proper testing equipment and a thorough understanding of the com- plete hydraulic system. A hydraulic system with an excessive increase in heat or nois...
Page 52 - Charge Pressure Test (Using Pressure Gauge)
Rev. C ProCore 648 Hydraulic System Page 4 -- 18 Charge Pressure Test (Using Pressure Gauge) Figure 13 Working PressureLow Pressure (Charge)Return or SuctionFlow Direction T CHG P PV R1 R2 SVR SVQ SVL ORF1 CYL G1 G2 M2 M3 M1 FORWARD ’B’ PORT (BOTTOM) ’A’ PORT (TOP) ’P’ PORT FRONT WHEEL ’P’ PORT ’P’ ...
Page 55 - Operate all hydraulic controls to relieve system
ProCore 648 Hydraulic System Page 4 – 21 Procedure for Coring Head Raise/Lower Relief (R1) Pressure Test: 1. Make sure hydraulic oil is at normal operating tem- perature by operating the machine for approximately 10 minutes. 2. Park machine on a level surface with the coring head fully raised. Make ...
Page 63 - Procedure for Wheel Motor Efficiency Test:; not; forward
Procedure for Wheel Motor Efficiency Test: 1. Make sure hydraulic oil is at normal operating tem-perature by operating the machine for approximately 10 minutes. Make sure the hydraulic reservoir is full. 2. Make sure that traction lever is adjusted to the neu-tral position (see Operator’s Manual). 3...
Page 64 - Check Hydraulic Lines and Hoses
Service and Repairs General Precautions for Removing and Installing Hydraulic System Components Before Repair or Replacement of Components 1. Before removing any parts from the hydraulic sys-tem, park machine on a level surface, fully raise coring head, engage parking brake, stop engine and remove k...
Page 65 - Flush Hydraulic System; The hydraulic reservoir will drain when the hy-
Flush Hydraulic System IMPORTANT: Flush the hydraulic system any time there is a severe component failure or the system is contaminated (oil appears milky or black or con-tains metal particles). IMPORTANT: Flush hydraulic system when chang-Ing from petroleum base hydraulic fluid, such as Mobil 424, ...
Page 67 - Page
10.Start engine and operate the traction system at vary- ing speeds for a 10 minute period. 11. Stop the machine. Check hydraulic reservoir level and fill if necessary. Check hydraulic components for leaks and tighten any loose connections. 1 2 Figure 27 1. Test port 2. Hydraulic manifold ProCore 64...
Page 68 - Hydraulic Pump Drive Belt
ProCore 648 Hydraulic System Page 4 – 34 Hydraulic Pump Drive Belt 1. Flange nut (2 used)2. Hydraulic (traction/charge) pump3. Key4. Engine5. Engine pulley 6. Flange head screw 7. Spring bracket 8. Idler support bracket9. Idler pulley 10. Flange nut11. Tensioning spring12. Set screw 13. Hydraulic pu...
Page 69 - Lift idler pulley and insert pump drive belt under idler.
Drive Belt Removal (Fig. 27) 1. Park machine on a level surface, fully raise coring head, engage parking brake, stop engine and remove key from the ignition switch. Secure coring head with service latch. 2. Remove pump belt cover from machine (see Opera-tor’s Manual). 3. Remove coring head primary d...
Page 70 - Hydraulic Pump Control Assembly
ProCore 648 Hydraulic System Page 4 – 36 Hydraulic Pump Control Assembly 1. Hydraulic pump 2. Cap screw (2 used)3. Flange nut 4. Lock nut 5. Flange nut (2 used)6. Control bracket 7. Washer head screw8. Lock nut 9. Extension spring 10. Speed selector pivot11. Retaining ring12. Swivel13. Cap screw 14....
Page 73 - A. Remove extension spring from the neutral lever.; If hydraulic fittings are to be removed from hy-
ProCore 648 Hydraulic System Page 4 – 39 2. Remove pump belt cover from machine (see Opera-tor’s Manual). 3. Loosen the flange head screw (item 7) and flange nut(item 11) that secure the drive belt idler pulley (item 10).Lift idler pulley to allow removal of drive belt from the hy-draulic pump pulle...
Page 74 - Follow Hydraulic System Start–up procedures.
Installation (Fig. 31) 1. Install hydraulic fittings with new o–rings to the hy-draulic pump. Orientate the fittings as noted during dis-assembly. CAUTION pump support to prevent the pump from falling Support hydraulic pump when installing it to the and causing personal injury. 2. Position hydraulic...
Page 76 - Wheel Motors
ProCore 648 Hydraulic System Page 4 – 42 Wheel Motors 1. Rear wheel motor (LH shown)2. Woodruff key 3. Parking latch support (2 used)4. Stud (4 used per wheel)5. Parking latch disc (2 used)6. Wheel hub 7. Lock nut 8. Bearing plate 9. Lug nut 10. Tire and wheel assembly11. Cap screw (4 used per rear ...
Page 77 - If hydraulic fittings are to be removed from
ProCore 648 Hydraulic System Page 4 – 43 2. Remove wheel from machine (see Wheel Removalin Service and Repairs section of Chapter 6 – Chassis). IMPORTANT: To prevent damage to hydraulic motor,DO NOT hit wheel hub or motor with a hammer dur-ing wheel hub removal or installation. 3. Loosen nut that se...
Page 78 - Wheel Motor Service; The three wheel motors on the ProCore 648 are
ProCore 648 Hydraulic System Page 4 – 44 Wheel Motor Service 1. Dust seal 2. Housing3. O–ring4. Shaft seal 5. Axial needle bearing6. Bearing race 7. Needle bearing 8. Shaft 9. O–ring10. Spring washer11. Balance plate12. Disc valve13. Needle bearing14. Bearing race15. Distributor plate 16. Cardan sha...
Page 80 - Hydraulic Lift Control Manifold
ProCore 648 Hydraulic System Page 4 – 46 Hydraulic Lift Control Manifold 1. Main frame 2. Cap screws (2 used) 3. Hydraulic lift control manifold4. Hydraulic oil filter 5. Flange nut (2 used) Figure 38 FRONT RIGHT 1 3 2 5 4
Page 82 - Hydraulic Lift Control Manifold Service; ft–lb; The ports on the manifold are marked for easy
ProCore 648 Hydraulic System Page 4 – 48 Hydraulic Lift Control Manifold Service 1. Hydraulic lift control manifold2. O–ring3. Quick fitting (2 used)4. Solenoid valve (SVL port)5. Nut 6. Solenoid coil 7. Relief valve (R1 port)8. Solenoid valve (SVQ port)9. Nut10. Solenoid valve (SVR port) 11. Pres. ...
Page 83 - Hydraulic Manifold Service; sure in the General Information section of this
Hydraulic Manifold Service 1. Make sure the manifold is clean before removing any cartridge valve. 2. If solenoid cartridge is being serviced, remove nut securing solenoid to the cartridge valve. Carefully slide solenoid off the valve. CAUTION sure in the General Information section of this Operate ...
Page 84 - Lift Cylinder; upper
ProCore 648 Hydraulic System Page 4 – 50 Lift Cylinder 1. Main frame 2. Shackle (4 used)3. Extension spring (2 used)4. Carriage screw (4 used)5. Spring plate (2 used)6. Flange nut (4 used) 7. Clevis pin (4 used)8. Hair pin (4 used)9. Retaining ring 10. Thrust washer11. Cylinder pin12. Spacer (2 used...
Page 85 - Release hydraulic pressure in lift cylinder:
5. Start engine and allow coring head to fully raise. Turn engine off. Secure coring head with service latch. CAUTION sure in the General Information section of this Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hy-draulic oil. See Relieving Hydraulic Sy...
Page 86 - Lift Cylinder Service; Remove oil from the lift cylinder into a drain pan by; slowly; pumping the cylinder rod. Plug port and clean
ProCore 648 Hydraulic System Page 4 – 52 Lift Cylinder Service 1. Retaining ring 2. Cylinder tube 3. Rod 4. O–ring5. Backup ring 6. Retaining ring 7. Seal8. Head9. Wiper Figure 44 5 1 3 7 8 9 6 4 2 Disassembly (Fig. 44) 1. Remove oil from the lift cylinder into a drain pan by slowly pumping the cyli...
Page 87 - Inspection; Retaining ring
Inspection CAUTION Spanner wrench Retaining ring against left side of barrel groove after installing) Use eye protection such as goggles when using compressed air 1. Wash all parts in solvent. Dry parts with compressed air. 2. Inspect internal surface of tube for deep scratches, out–of–roundness and...
Page 88 - Hydraulic Reservoir
ProCore 648 Hydraulic System Page 4 – 54 Hydraulic Reservoir 1. Hydraulic reservoir 2. Dipstick3. Cap4. Shoulder screw 5. Tank strap 6. Cap screw 7. J clip 8. Flat washer 9. Frame10. O–ring11. Hydraulic adapter12. O–ring13. Hydraulic tube 14. Hydraulic tube15. Suction hose16. Hose clamp17. Hydraulic...
Page 89 - Chapter 5; Electrical System; Electrical
Chapter 5 Electrical System Table of Contents ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . 1 CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 2 OK to Lower Circuit . . . . . . . . . . . . . . . . . . . . . . . . . 2 Lockout Circuit . . . . . . . . . . . . . . . . ...
Page 90 - Circuit Operation; This section provides information concerning; Traction Lever in Neutral or Reverse
Circuit Operation NOTE: This section provides information concerning three sequential, electrical circuits that are used on the ProCore 648. Use these descriptions along with the electrical diagrams and schematics found in Chapter 8 – Electrical Diagrams to better understand circuit opera-tion. OK t...
Page 93 - Figure 2
GROUND CORING HEAD RAISED TO IGNITION TO AERATOR SWITCH CONTROL (NOT PRESSED) (ENERGIZED) TERMINAL ”L” (ENERGIZED) TO ELECTRIC CLUTCH MODULE TO IGNITION SWITCH TERMINAL ”A” GROUND AERATING TO IGNITION TO AERATOR SWITCH CONTROL (ENERGIZED) TERMINAL ”L” (ENERGIZED) MODULE (NOT PRESSED) TO ELECTRIC CLU...
Page 94 - The clutch will continue to be energized until either:; Figure 3
Electric Clutch Circuit (Fig. 3) The electric clutch circuit is used on the ProCore to pro-vide current for the electric clutch which rotates the cor-ing crankshaft. This circuit is composed of the aeration #3 proximity switch, the clutch relay, the electric clutch and diode D3. The electric clutch ...
Page 95 - Multimeter; Toro recommends the use of a DIGITAL Volt–; Battery Terminal Protector; Battery Hydrometer; Figure 6
Special Tools Multimeter The multimeter can test electrical components and cir-cuits for current (amps), resistance (ohms) or voltage. NOTE: Toro recommends the use of a DIGITAL Volt– Ohm–Amp multimeter when testing electrical circuits. The high impedance (internal resistance) of a digital me-ter in...
Page 97 - General Run Problems
Starting Problems (continued) Problem Possible Causes Engine cranks, but does not start. Circuit wiring to engine magneto is grounded (see Chapter 8 – Electrical Diagrams). Circuit wiring to carburetor solenoid is loose, corroded, or damaged (see Chapter 8 – Electrical Diagrams). Engine or fuel syst...
Page 98 - Coring Head Operating Problems
Coring Head Operating Problems Problem Possible Causes Coring head runs (but should not) when raised. Aeration #3 proximity switch is faulty or out of adjustment. Coring head does not lower. Fuse F3 (10 Amp) or F4 (2 Amp) is/are faulty. Raise/lower switch is faulty. SVL valve solenoid is faulty. Aer...
Page 99 - Electrical System Quick Checks; Voltage Measured; Charging System Test; At least 0.50 volt over initial battery voltage.
Electrical System Quick Checks Battery Test (Open Circuit Test) Use a multimeter to measure the voltage between the battery terminals. Set the multimeter to the DC volts setting. The battery should be at a temperature of 60 o to 100 o F (16 o to 38 o C). The ignition key should be in the OFF positio...
Page 100 - Check Operation of Safety Interlock System; operating the machine.
Check Operation of Safety Interlock System CAUTION operating the machine. Do not disconnect interlock switches. They are for the operator’s protection. Check operation of the switches daily to make sure the interlock system is operating correctly. If a switch is not operating properly, adjust or rep...
Page 101 - When testing electrical components for continu-; Ignition Switch; Testing
Component Testing For accurate resistance and/or continuity checks, elec-trically disconnect the component being tested from the circuit (e.g. unplug the ignition switch connector before doing a continuity check). NOTE: Electrical troubleshooting of any 12 Volt power connection can be performed thro...
Page 102 - Engine Oil Pressure Indicator Light; Ground the disconnected wire to the engine block.; If the light comes on, the oil pressure switch is faulty.; Testing Indicator Light; For engine oil pressure switch information, refer; Hour Meter
1 Engine Oil Pressure Indicator Light The engine oil pressure indicator light is located on the handle control panel (Fig. 10). The indicator light should come on when the ignition switch is in the ON position with the engine not running. Also, it should light with the engine running if the engine o...
Page 103 - Relays; Prior to taking small resistance readings with a
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 104 - Manual Raise/Lower Switch
Manual Raise/Lower Switch The manual raise/lower switch is located on the handle control panel (Fig. 16). This rocker switch is one of the components in the ”OK to lower” circuit which is one of the aerator control module inputs. See OK to Lower Cir-cuit in the Circuit Operation section of this chap...
Page 105 - Ground Follow Switch
Ground Follow Switch The ground follow switch is located on the side of the control panel (Fig. 18). This rocker switch allows the True Core TM ground following system to be turned on/ off. The switch is retained in position by a cap screw and nut placed in the switch guard to prevent accidental swi...
Page 106 - Lift Reset Switch
Lift Reset Switch The lift reset switch is located on the control panel (Fig. 21). This momentary rocker switch raises the coring head in instances when the coring head has been stranded in the aerating (lowered) position (e.g. engine runs out of gas, coring head stuck). By depressing the lift reset...
Page 107 - Solenoid Valve Coil; The solenoid does not have to be removed from
Solenoid Valve Coil The hydraulic system on the ProCore 648 uses three (3) solenoid valve coils on the hydraulic lift control manifold (Fig. 23). The aerator control module provides current to the solenoid valve coils based on the position of several inputs. A LED on the aerator control module will ...
Page 108 - Head Low and Head High Limit Switches; ground following system on the Pro-; Head Low and Head High Switch Test; Reconnect the switch electrical connector.
Head Low and Head High Limit Switches The head low and head high limit switches are attached to the coring depth control housing (Fig. 25). These switches are normally open and close when the switch actuator in the housing is rotated past the switch. The head low and head high limit switches provide...
Page 109 - Fuses; UP
Fuses The fuse block is located behind the console cover (Fig. 27). Identification, Function, and Wiring The fuses are held in the fuse block. Use Figure 28 to identify each individual fuse and its correct amperage. Each fuse holder has the following functions: Fuse 1 (20 Amp): Supplies power to ign...
Page 110 - 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 ha...
Page 111 - Before checking switch continuity, clean target
Proximity Switch Test 1. Park machine on a level surface, fully raise coring head, engage parking brake, stop engine and remove key from the ignition switch. Secure coring head with service latch. 2. Locate proximity switch to be tested. Disconnect proximity switch from machine wiring harness. 3. Ch...
Page 112 - Aerator Control Module; Control Module Inputs
Aerator Control Module The ProCore 648 is equipped with an Aerator Control Module to monitor and control electrical components re-quired for safe operation. This Module is located on the inside of the console cover (Fig. 33). Inputs from the start (ignition), head low limit, head high limit, transpo...
Page 114 - Electric Clutch; C) when coil resistance is
Electric Clutch An electric clutch is used to engage the coring head on the ProCore 648. The electric clutch is mounted on the engine crankshaft and engages when current is applied to the clutch. The clutch also incorporates a magnetic brake to stop clutch rotation when the clutch is de–ener-gized. ...
Page 115 - 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 ...
Page 116 - See the Kohler Engine Service Manual for en-; Battery Storage; If the machine will be stored for more than 30 days:; Battery Care; Wear safety goggles and rubber gloves when; Connecting cables to the wrong battery post
Service and Repairs NOTE: See the Kohler Engine Service Manual for en- gine component repair information. Battery Storage If the machine will be stored for more than 30 days: 1. Remove the battery and charge it fully (see Battery Service). 2. Either store battery on a shelf or on the machine. 3. Lea...
Page 117 - Battery Service; When working with batteries, use extreme cau-; Carefully remove battery from machine.; Inspection and Maintenance; between the minimum and maximum fill
Battery Service The battery is the heart of the electrical system. With regular and proper service, battery life can be extended. Additionally, battery and electrical component failure can be prevented. CAUTION When working with batteries, use extreme cau- eyes. Always wear safety goggles and a face...
Page 122 - Removal; Remove the nut from the spool assembly.; Installation; Slide new coil assembly onto the spool assembly.
ProCore 648 Page 5 – 34 Electrical System Solenoid Valve Coil A solenoid valve coil on the hydraulic lift control manifold(Fig. 41) can be replaced without opening the hydraulicsystem. Removal 1. Park machine on a level surface, fully raise coringhead, engage parking brake, stop engine and removekey...
Page 123 - Chapter 6; Chassis
Chapter 6 Chassis Table of Contents SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 4 Wheels . . . . . . . . . . . . . . . . . . . . . . ...
Page 125 - Order special tools from your Toro Distributor.
Rev. C ProCore 648 Page 6 -- 3 Chassis 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 Chassis
Page 126 - Wheels
ProCore 648 Page 6 – 4 Chassis Service and Repairs Wheels 1. Tire and wheel assembly2. Lug nut 3. Front wheel weight4. Wheel weight adapter 5. Weight stud 6. Thrust washer 7. Lock nut 8. Bearing plate 9. Lock nut 10. Wheel hub11. Parking latch disc12. Wheel stud Figure 2 6 7 1 3 2 5 4 FRONT RIGHT 1 ...
Page 127 - B. Carefully slide wheel weight from weight studs.; To prevent personal injury, make sure that; D. Carefully slide wheel weight to wheel.
Wheel Removal (Fig. 2) 1. Park machine on a level surface, fully raise coring head, engage parking brake, stop engine and remove key from the ignition switch. Secure coring head with service latch. 2. Jack machine from ground and support machine with blocking or jack stands (see Operator’s Manual an...
Page 128 - Parking Brake; Figure 4
ProCore 648 Page 6 – 6 Chassis Parking Brake Figure 4 1. Extension spring 2. Bushing3. Retaining ring 4. Parking latch pivot5. Flange nut 6. Shoulder bolt 7. Compression spring 8. Parking latch clevis 9. Hair pin 10. Parking latch link11. Roll pin12. Parking latch bar13. Lock nut14. Tire and wheel a...
Page 129 - Make sure parking brake is disengaged.; If parking latch disc requires removal:; C. Position woodruff key into wheel motor shaft.
Removal (Fig. 4) 1. Park machine on a level surface, fully raise coring head, stop engine and remove key from the ignition switch. Secure coring head with service latch. 2. Make sure parking brake is disengaged. 3. Block front wheel. Jack or hoist rear of machine from ground and support machine with...
Page 130 - Parking Brake Cable
ProCore 648 Page 6 – 8 Chassis Parking Brake Cable 1. Control handle 2. Grommet3. Steering arm 4. Lower handle cover5. Washer head screw (6 used) 6. Flange nut 7. Brake cable 8. Flat washer 9. Cotter pin 10. Brake lever 11. Bushing12. Brake spacer13. Cap screw14. Knob Figure 5 2 5 1 4 3 8 9 12 13 6 ...
Page 132 - Steering Assembly
ProCore 648 Page 6 – 10 Chassis Steering Assembly 1. Grommet2. Stud (3 used)3. Steering arm 4. Cap screw (5 used)5. Slotted hex nut6. Washer7. Bearing cone 8. Bearing cup 9. Frame10. Steering stop11. Cap screw (2 used)12. Cable guide13. Cotter pin 14. Steering spindle15. Lock nut (3 used)16. Lock nu...
Page 134 - Traction Control Cable
Rev. B ProCore 648 Page 6 – 12 Chassis Traction Control Cable Removal 1. Remove traction control cable from hydraulic pumpcontrol (Fig. 10) and traction lever on handle and (Fig.11). 2. Remove traction control cable from machine notingrouting of cable to aid in correct installation. 3. Disassemble t...
Page 135 - Chapter 7; Coring Head
Chapter 7 Coring Head Table of Contents GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 2 Coring Head Operation . . . . . . . . . . . . . . . . . . . . . . . 2 Coring Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Coring Head Service Latch . . . . . . . . . . . . ...
Page 136 - Coring Head Operation; ground following; ground following sys-; Coring Crankshaft
General Information Coring Head Operation The coring head of the Procore 648 consists of a frame that pivots for aerating depth control, a coring crank-shaft, stomper arms with rotolinks to provide vertical tine motion, turf holders, tine holders and aerating tines. Drive for the coring head comes f...
Page 137 - Coring Head Service Latch; Coring Head Adjustments; forming any service to coring head components.
Coring Head Service Latch Whenever service is to be performed on coring head components, fully raise coring head and install service latch (Fig. 3). Before using machine, remove service latch from coring head. 1 Figure 3 1. Service latch (in raised, locked position) Coring Head Adjustments See Opera...
Page 138 - Rotolink Dampers
ProCore 648 Page 7 – 4 Coring Head Service and Repairs Rotolink Dampers 1. Lock nut 2. Hardened D washer3. Flange head screw4. Stud5. Bumper plate 6. Cap screw 7. Lock nut 8. Hardened washer 9. Damper link 10. Bearing11. Stomper arm12. Flange nut 13. Cap screw14. Rubber bumper15. Rotolink damper16. ...
Page 139 - If using longer, solid tines, damper top spacer
Disassembly (Fig. 4) 1. Park machine on a level surface, fully raise coring head, engage parking brake, stop engine and remove key from the ignition switch. Secure coring head with service latch. 2. Remove rotolink components as needed using Fig-ure 4 as a guide. Assembly (Fig. 4) 1. If studs (item ...
Page 140 - Stomper Arms
ProCore 648 Page 7 – 6 Coring Head Stomper Arms 1. Coring frame 2. Cap screw 3. Flat washer 4. Retaining ring 5. Ball bearing 6. Stomper arm 7. Pulley8. Bearing housing 9. Crankarm10. Square key11. Coupling12. Spacer tube Figure 5 FRONT RIGHT 9 10 11 12 1 2 3 4 5 6 7 8 4 5 6 2 2 3 3 150 to 170 ft–lb...
Page 142 - Coring Crankshaft Bearing Housings; STOMPER ARMS SHOWN
ProCore 648 Page 7 – 8 Coring Head Coring Crankshaft Bearing Housings 1. Cap screw 2. Flat washer 3. Spacer tube 4. Stomper arm 5. Ball bearing 6. Retaining ring 7. Crankarm8. Ball bearing 9. Bearing housing 10. Spacer11. Crankarm12. Square key13. Coupling (#5 shown)14. Lock nut15. Coupling plate16....
Page 143 - B. Slide crankarms from bearing housing.
ProCore 648 Page 7 – 9 Coring Head 7. Disassemble bearing housing assembly: A. Remove cap screw (item 1) and flat washer (item2) that fasten crankarms together. Take note of align-ment of identification number on crankarm with tim-ing mark on bearing housing (Fig. 9). B. Slide crankarms from bearing...
Page 144 - Primary Drive Belt
ProCore 648 Page 7 – 10 Coring Head Primary Drive Belt 1. Primary drive belt2. Electric clutch 3. Hardened washer 4. Cap screw 5. Flange nut 6. Flat washer 7. Brake grommet 8. Cap screw 9. Spacer 10. Clutch strap11. Idler mounting bracket12. Lock nut13. Cap screw14. Hardened washer15. Idler pulley16...
Page 145 - Unplug machine wire harness connector from clutch.
Removal (Fig. 11) 1. Park machine on a level surface, fully raise coring head, engage parking brake, stop engine and remove key from the ignition switch. Secure coring head with service latch. 2. Remove belt cover (see Operator’s Manual). 3. Remove exhaust system shield (see Exhaust Sys-tem Removal ...
Page 146 - Secondary Drive Belt
ProCore 648 Page 7 – 12 Coring Head Secondary Drive Belt 1. Secondary drive belt2. Cap screw 3. Secondary pulley 4. Cap screw 5. Flange bushing 6. Idler pulley 7. Idler pivot tube8. Idler arm 9. Lock nut 10. Carriage screw (2 used) 11. Flange nut (2 used)12. Idler spring arm13. Extension spring (2 u...
Page 148 - Coring Head Drive Jackshaft
ProCore 648 Page 7 – 14 Coring Head Coring Head Drive Jackshaft 1. Primary pulley 2. Taper lock bushing3. Lock washer 4. Cap screw 5. Set screw 6. Woodruff key 7. Jackshaft8. Cap screw (2 used per bearing)9. Flange mount bearing10. Plug 11. Set screw12. Lock nut (2 used per bearing)13. Secondary pul...
Page 149 - DIRECTION; LOOSEN; TIGHTEN
NOTE: Jackshaft rotates counterclockwise as viewed from right side of machine (Fig. 18). 7. Loosen set screw that secures each flange mount bearing locking collar to jackshaft. Using the blind hole in bearing collar as a striking point, unlock collar from jackshaft by rotating the collar in the oppo...
Page 151 - Chock wheels to prevent the machine from moving.; flange nut and
ProCore 648 Page 7 – 17 Coring Head Disassembly (Fig. 21) 1. Park machine on a level surface, fully raise coringhead, engage parking brake, stop engine and removekey from the ignition switch. Secure coring head withservice latch. 2. Remove belt cover and rear hood from machine (seeOperator’s Manual)...
Page 152 - C. Rotate lift cylinder toward front of machine.; The coring head assembly weighs approximate-
8. Disconnect upper end of lift cylinder from coring head frame (Figs. 22 and 23): A. Remove retaining ring from one end of cylinder pin that secures lift cylinder to coring head frame. B. Pull cylinder pin from coring head frame and lift cylinder. Locate and retrieve two (2) thrust washers and two ...
Page 153 - Chapter 8; ELECTRICAL SCHEMATIC; Electrical Diagrams
Chapter 8 Electrical Diagrams Table of Contents ELECTRICAL SCHEMATIC Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . 3 ELECTRICAL CIRCUIT DRAWINGS Start Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Lower Coring Head . . . . . . . . . . . . . . . . ....
Page 155 - Electrical Schematic
Page 8 – 3 Electrical Schematic ProCore 648 All relays and solenoids are shown as de–energized. All ground wires are black.
Page 156 - Start Engine
Page 8 – 4 Start Engine Power Current Control Current Indication Current ProCore 648 (ENERGIZED) (NOT ENERGIZED) (NOT ENERGIZED) (NOT ENERGIZED) (NOT ENERGIZED) (NOT ENERGIZED) (NEUTRAL POSITION)
Page 157 - Lower Coring Head
Page 8 – 5 Lower Coring Head Power Current Control Current ProCore 648 (ENERGIZED) (NOT ENERGIZED) (RUN) (NOT ENERGIZED) (NOT IN NEUTRAL) (ENERGIZED) (HEAD BEING LOWERED) (ON) (HEAD BEING LOWERED) (HEAD BEING LOWERED) (HEAD BEING LOWERED) (IN FORWARD) (HEAD BEING LOWERED) (ENERGIZED) (PRESSED TO LOW...
Page 158 - Aerating
Page 8 – 6 Aerating Power Current Control Current ProCore 648 (ENERGIZED) (NOT ENERGIZED) (RUN) (NOT ENERGIZED) (NOT IN NEUTRAL) (ENERGIZED) (ON) (HEAD LOWERED) (HEAD LOWERED) (HEAD LOWERED) (IN FORWARD) (HEAD LOWERED) (ENERGIZED) (NEUTRAL POSITION) (NOT ENERGIZED) (ENERGIZED) (HEAD LOWERED) (ENERGI...
Page 162 - Transport
Page 8 – 10 Transport Power Current Control Current ProCore 648 (ENERGIZED) (NOT ENERGIZED) (RUN) (NOT ENERGIZED) (NOT IN NEUTRAL) (ENERGIZED) (ON) (HEAD RAISED) (NEUTRAL POSITION) (ENERGIZED) (NOT ENERGIZED) Traction Lever Moved to Forward Aerator Control Module ON ON ON SVL SVR SVQ ProCore 648 Aer...
Page 163 - Wire Harness Drawing
Page 8 – 11 ProCore 648 Wire Harness Drawing 5 4 2 3 1 4 3 5 2 1
Page 164 - Wire Harness Diagram
MAGNETO LOW OIL PRESSURE P5 REVERSE P16 SWITCH NEUTRAL SW. RELAY (START) P4 J5 IGNITION SWITCH P1 FUSE BLOCK P27 ACM 1 P9 S M L G B BLUE ORANGE BLACK BLACK VIOLET VIOLET WHITE/BLACK YELLOW YELLOW BLACK PINK/BLACK 1 2 3 4 5 A B A B C D E F 1A 1B 2A 2B 1 2 3 4 5 SP1 1 2 3 4 5 6 7 8 SP7 SP9 1 BLACK PIN...
