Form No. 3360-821 Rev B ProCore® 648 Aerator Model No. 09200—Serial No. 280000001 and Up To register your product or download an Operator's Manual or Parts Catalog at no charge, go to www.Toro.com.
Warning Model No. CALIFORNIA Proposition 65 Warning The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. Serial No. This manual identifies potential hazards and has safety messages identified by the safety alert symbol (Figure 2), which signals a hazard that may cause serious injury or death if you do not follow the recommended precautions. This spark ignition system complies with Canadian ICES-002.
Contents Changing the Engine Oil and Filter ..................... 37 Servicing the Spark Plugs.................................... 38 Fuel System Maintenance ....................................... 39 Replacing the Fuel Filter ..................................... 39 Draining the Fuel Tank....................................... 39 Electrical System Maintenance................................ 40 Servicing the Battery........................................... 40 Fuses........................................
Safety – Never refuel or drain the aerator indoors. • Check that the operator presence controls, safety switches, and shields are attached and functioning properly. Do not operate unless they are functioning properly. Improper use or maintenance by the operator or owner can result in injury. To reduce the potential for injury, comply with these safety instructions and always pay attention to the safety alert symbol, which means Caution, Warning, or Danger—personal safety instruction.
• Do not operate on slopes when grass is wet. Slippery conditions reduce traction and could cause sliding and loss of control. • Keep all parts in good working condition and all hardware tightened. Replace all worn or damaged decals. • Do not make sudden turns or rapid speed changes. • Use only Toro-approved attachments. The warranty may be voided if the machine is used with unapproved attachments. • Reduce speed and use extreme caution on slopes.
Safety and Instructional Decals Safety decals and instructions are easily visible to the operator and are located near any area of potential danger. Replace any decal that is damaged or lost. 93- 6696 93–6696 1. Stored energy hazard—read the Operator’s Manual. 106-8835 1. 2. 3. 4. 5. 6. 93-9084 1. Lift point 2. Tie-down point On/off Output Solenoid valve lower Solenoid valve raise Solenoid valve quick Input 7. 8. 9. 10. 11. 12.
110-4664 1. Read the Operator’s Manual. 2. Wrench size 3. Bolt size 4. Torque Battery Symbols Some or all of these symbols are on your battery 1. Explosion hazard 2. No fire, open flame, or smoking. 106-8856 3. Caustic liquid/chemical burn hazard 4. Wear eye protection 1. Read the Operator’s Manual. 5. Read the Operator’s Manual. 107-7547 1. Entanglement hazard, belt—stay away from moving parts. 2. Warning—Do not touch the hot surfaces 107-7555 7 6.
106-8854 1. Read the Operator’s Manual. 2. Engine—stop 3. Engine—run 4. Engine—start 7. To start the engine, turn the ignition key and unlock the parking brake; read the Operator’s Manual. 5. Read the Operator’s Manual; move the 8. To stop the engine, press the switch to disengage the PTO, lock the parking switch up to turn ground following on; brake, and turn the ignition key to the move the switch down and install the Stop position and remove it; read the spacers to turn ground following off.
106-8855 1. Move the lever up to drive in reverse. 4. Engage the PTO and lower the head. 2. Move the lever down to drive forward. 5. Warning—stop the engine and read the instructions before servicing or performing maintenance. 3. Disengage the PTO and raise the head. 6. Warning—stop the engine before fueling. 7. Entanglement hazard, shaft—do not carry passengers. 8.
Setup Loose Parts Use the chart below to verify that all parts have been shipped. Procedure Description 1 Wheel assembly 2 3 4 5 6 Use Qty. Install the rear wheels. Locknut (1/2 inch) Cable guide Bolt (5/16 x 1/2 inch) Bolt (1/4 x 1 inch) Flange nut (5/16 inch) Hood plate Pop rivet Nut (#10) Bolt (#10 x 2 inch) Locknut (#10) Bolt (1/4 x 1 inch) Locknut (1/4 inch) 3 1 2 2 2 1 3 1 1 1 1 1 No parts required – Install the handle. Activate and charge the battery. Securing the rear hood (CE only).
4 1 Installing the Rear Wheels 1 Parts needed for this procedure: Wheel assembly 2 3 G00XXXX Figure 4 Procedure 1. Handle 2. Fork 1. Remove the 8 lug nuts securing the rear of the aerator to the packaging. 2. Mount a wheel assembly onto each rear wheel hub (Figure 3). 3. Locknut 4. Cable guide 3. Secure handle studs to fork with 3 locknuts (1/2 inch) (Figure 4) 1 4. Insert the cable guide around the cables. 5. Mount the cable guide to the top of the fork with 2 bolts (5/16 x 1/2 inch) (Figure 4).
Charging the battery produces gasses that can explode. Never smoke near the battery and keep sparks and flames away from it. 7. When the battery is charged, disconnect the charger from the electrical outlet and battery posts. Note: After the battery has been activated, add only distilled water to replace normal loss, although maintenance-free batteries should not require water under normal operating conditions. 1 Figure 5 1. Battery compartment 8.
2 5 Incorrect battery cable routing could damage the machine and cables causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury. • Always disconnect the negative (black) battery cable before disconnecting the positive (red) cable. 4 • Always connect the positive (red) battery cable before connecting the negative (black) cable. 1 11. Close and latch the battery compartment cover. 4 3 Securing the Rear Hood (CE Only) G010021 Figure 6 1. Battery tray 2.
1 5 Securing the Belt Cover (CE Only) Parts needed for this procedure: 1 Bolt (1/4 x 1 inch) 1 Locknut (1/4 inch) Procedure Figure 7 If you are setting up this machine for use in the European Union (CE), secure the belt cover as follows to comply with CE regulations. 1. Rear hood Insert a Bolt (1/4 x 1 inch) through the belt cover latch lever and secure with a locknut (1/4 inch) (Figure 9 and Figure 10) 2 2 1 3 Figure 8 1. Hood plate 2. Pop rivet 3. Bolt and nuts 1 2.
Product Overview 3 2 1 1 2 Figure 11 1. Operating direction 2. Right side Figure 10 1. Latch lever 3. Left side 2. Bolt and nut Controls 6 Become familiar with all the controls before you start the engine and operate the aerator. Installing the Tine holders, Turf Guards, and Tines No Parts Required Procedure A wide selection of tine holders, turf guards, and tines are available for the aerator.
Parking Brake 1 3 4 To engage the parking brake, move the lever toward the engine. To disengage the parking brake, move the lever forward (Figure 12). Always set the parking brake when you stop the aerator or leave it unattended. 5 Jog the traction lever forward and reverse to release the parking brake. 6 2 Oil Pressure Warning Light The oil pressure warning light (Figure 12) glows when the oil pressure in the engine drops below a safe level.
Choke To start a cold engine, close the carburetor choke by moving choke control (Figure 13) fully forward. After the engine starts, regulate the choke to keep the engine running smoothly. As soon as possible, open the choke by pulling it backward. Manual Ground Follow Selector Switch Rotate the switch to the down position to turn off the TrueCore feature (Figure 13) Remove the bolt to access the manual ground switch.
Specifications Note: Specifications and design are subject to change without notice. Width 50.12 inches (127.3 cm) Wheel base 44.5 inches (113 cm) Track width 38.3 inches (97.3 cm) Coring width 48 inches (122 cm) Length 104.5 inches ((265.4 cm) Height, raised 44 inches (112 cm) Height, Lowered 44 inches (112 cm) Height, handle 41 inches (104 cm) Weight without fuel 1590 lb (721 kg) Ground clearance 4.75 inches (12.
Operation In certain conditions during fueling, static electricity can be released causing a spark which can ignite the gasoline vapors. A fire or explosion from gasoline can burn you and others and can damage property. Note: Determine the left and right sides of the machine from the normal operating position. If you leave the key in the ignition switch, someone could accidently start the engine and seriously injure you or other bystanders.
• Cleans the engine while it runs Checking the Engine Oil Level • Eliminates gum-like varnish buildup in the fuel system, which causes hard starting Service Interval: Before each use or daily (Check the oil when the engine is cold.) Important: Do not use fuel additives containing methanol or ethanol. The engine is shipped with oil in the crankcase; however, the oil level must be checked before and after the engine is first started. Add the correct amount of gas stabilizer/conditioner to the gas.
Checking the Hydraulic Fluid Note: When changing from one type of hydraulic fluid to another, be certain to remove all the old fluid from the system, as some fluids are incompatible with others. Service Interval: Before each use or daily Biodegradable Hydraulic Fluid - Mobil 224H ISO VG 32/46 anti-wear hydraulic fluid Mobil EAL Envirosyn H, ISO Grade 68 The hydraulic reservoir is filled at the factory with approximately 1.75 US gallons (6.6 l) of high quality hydraulic fluid.
Starting and Stopping the Engine 1 Starting the Engine 1. Release the traction lever (bail) and set the parking brake. 2. Move the choke control to the On position before starting a cold engine. Note: A warm or hot engine may not require choking. After the engine starts, move the choke control to the Run position. 3. Move the throttle control to the Fast position before starting a cold engine. 4. Turn the ignition key to start. When the engines starts, release the key. Figure 18 1.
The Safety Interlock System 1 If safety interlock switches are disconnected or damaged the aerator could operate unexpectedly causing personal injury. • Do not tamper with the interlock switches. • Check the operation of the interlock switches daily and replace any damaged switches before operating the aerator. Figure 20 1. Service latch in (lowered) storage position Understanding the Safety Interlock System 3. Pivot the service latch rearward and insert it onto the coring head pin (Figure 21).
5. Install tines into the #2 and #5 tine holders (Figure 25) Tighten the bolts. #6 1 #5 #4 #3 #2 #1 2 G010038 Figure 22 1. Tine arm 2. Tine holder 3. Loosely install the turf guards to the turf guard brackets with 4 turf guard clamps and 12 flange nuts (Figure 23). Do not tighten the fasteners. 1 G010040 Figure 25 1. Number 5 tine holder Note: The turf guard clamps and flange nuts are shipped secured to the turf guard brackets (Figure 23). 2. Number 2 tine holder 6.
Setting the Coring Depth 1 To set the coring depth of the aerator, proceed as follows: 2 1. Select the preferred tine for your application. 2. Lay the tine on the tine depth decal (Figure 27) with one end lined up with the desired depth of aeration (refer to the tine overlay on the decal). 1 2 2 Figure 28 1. Lynch pin 2. Spacers and depth pin 2. Position the spacers above or below the bracket to attain the desired coring depth. • Thick spacers equate to 3/4 inch (19 mm) increments. Figure 27 1.
Pushing/Pulling the Aerator by Hand Resetting the System Control Circuit Important: Never tow the aerator faster than 1 MPH because hydraulic component damage may occur. If the coring head is ever left in the aerating position (run out of fuel, forget to install service latch for storage, mechanical failure of engine/pump, etc.
carefully read all the safety instructions. Knowing this information could help you, your family, pets, or bystanders avoid injury. Driving on street or roadway without turn signals, lights, reflective markings, or a slow moving vehicle emblem is dangerous and can lead to accidents causing personal injury. Important: Do not use the Hydroject trailer/tote to trailer this aerator.
Using the Line Marker 2 Use the line marker to align aeration rows (Figure 35). 1 2 Figure 36 G010050 1 1. Weight transfer springs Figure 35 1. Line marker (storage position) 2. Line marker (alignment position) 2. Spring plate 2. Insert a 1/2 inch ratchet or breaker bar into the square hole in the spring plate (Figure 37). 2 1 Adjusting the Weight Transfer The machine is designed to transfer weight from the traction unit to the coring head to help maintain hole depth in various soil structures.
lb (28.5 kg) to the machine. Up to two plates can be added. Refer to the Parts Catalog for these part numbers. The ACM does not connect to an external computer or hand held device, cannot be reprogrammed, and does not record intermittent fault troubleshooting data. Aerator Control Module (ACM) The decal on the ACM only includes symbols. Three LED output symbols are shown in the output box. All other LED’s are inputs. The chart below identifies the symbols.
Entrance/Exit • Always maintain awareness of what lies ahead in the direction of forward travel. Avoid operation in close proximity of buildings, fences, and other equipment. If the entrance/exit hole quality is deteriorating, the clutch may not be engaging soon enough. Check the following: • Look behind frequently to ensure that the machine is operating properly and alignment is maintained with previous passes. • The no.
Front Hole Dimpled or Pushed (Solid Tines or Softer Soil Conditions) When aerating with longer solid tines (i.e. 3/8 x 4 inches long) or needle type tines, the front of the holes may become slotted or tufted. To regain excellent hole quality for this configuration, slow the engine high idle speed down to 2800–2900 RPM. The hole spacing is not affected as the traction and coring head speeds are both a function of engine speed.
Maintenance Note: Determine the left and right sides of the machine from the normal operating position. Recommended Maintenance Schedule(s) Maintenance Service Interval Maintenance Procedure After the first 8 hours • Adjust the pump belt. • Change the hydraulic fluid and the return and charge filters. • Check the torque of the coring head fasteners. After the first 50 hours • Change the engine oil and filter. Before each use or daily • Check the engine oil level.
Daily Maintenance Checklist Duplicate this page for routine use. Maintenance Check Item For the week of: Mon. Tues. Wed. Thurs. Fri. Sat. Sun. Check the safety interlock operation. Check parking brake operation. Check the engine oil level. Check fuel level Check the air cleaner. Check the engine for debris. Check unusual engine noises. Check unusual operating noises. Check the hydraulic fluid level. Check the hydraulic hoses for damage. Check for fluid leaks. Check instrument operation.
Premaintenance Procedures Jacking the Rear End 1. Chock the front tire to prevent the machine from moving. Important: To prevent wheel motor damage, do not use rear wheel motor as a jacking point. Jacking Instructions 2. Place the jack securely under the frame plate just inside of the rear wheel (Figure 41). When changing attachments, tires, or performing other service, use the correct blocks, hoists, and jacks. Make sure the machine is parked on a solid, level surface such as a concrete floor.
Lubrication Checking the Coring Head Bearings 1 Service Interval: Yearly—Check the coring head bearings. Every 500 hours—Inspect the coring head bearings, if needed, replace. The aerator has no grease fittings that must be lubricated. Important: Bearings rarely fail from defects in materials or workmanship. The most common reason for failure is moisture and contamination working its way past the protective seals.
Engine Maintenance 1. Wash the foam pre-filter in liquid soap and warm water. When clean, rinse it thoroughly. Servicing the Air Cleaner 2. Dry the pre-filter by squeezing it in a clean cloth (do not wring). Service Interval: Every 25 hours—Clean the foam air filter element and check the paper element for damage. Every 100 hours—Replace the paper air filter element. 3. Put one or two ounces of oil on the pre-filter (Figure 44). Removing the Filters 1.
4. Install the air cleaner cover and secure with the knob (Figure 43). 5. Close the hood. Changing the Engine Oil and Filter Service Interval: After the first 50 hours Every 100 hours—Change the engine oil and filter. 1 Note: Change oil and filter more frequently when operating conditions are extremely dusty or sandy. Figure 47 Oil Type: Detergent oil (API service SH, SJ, SL, or higher) 1. Oil filter Crankcase Capacity: w/filter, 2.1 qt. (2 l) Viscosity: See table below Figure 48 1. Oil filter 2.
14. Slowly add additional oil to bring the level to the F (full) mark on the dipstick. 15. Replace the fill cap. Servicing the Spark Plugs Service Interval: Every 200 hours—Check the spark plugs. Ensure that the air gap between the center and side electrodes is correct before installing each spark plug. Use a spark plug wrench for removing and installing the spark plugs and a gapping tool/feeler gauge to check and adjust the air gap. Install new spark plugs if necessary. Figure 50 1.
Draining the Fuel Tank Fuel System Maintenance In certain conditions, gasoline is extremely flammable and highly explosive. A fire or explosion from gasoline can burn you and others and can damage property. Replacing the Fuel Filter Service Interval: Every 100 hours/Yearly (whichever comes first) • Drain gasoline from the fuel tank when the engine is cold. Do this outdoors in an open area. Wipe up any gasoline that spills. Important: Never install a dirty filter if it is removed from the fuel line. 1.
Electrical System Maintenance The battery cables must be tight on the terminals to provide good electrical contact. Servicing the Battery Incorrect battery cable routing could damage the machine and cables causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury. Service Interval: Every 25 hours—Check the electrolyte level and clean the battery. Every 25 hours—Check the battery cable connections.
Drive System Maintenance Adjusting the Traction Drive for Neutral The machine must not creep when traction lever is released. If it does, an adjustment is required. 1. Park the aerator on a level surface, shut the engine off, and engage the parking brake. 2. Jack up the machine so the front wheel and one rear wheel is just off the ground. Place jack stands under machine. Refer to Jacking Instructions. 1 Figure 52 1. Fuse block 3. Loosen the locknut on the traction adjustment cam (Figure 53).
8. Remove the jack stands and lower the machine to the ground. Belt Maintenance 9. Test the machine to make sure it does not creep. Adjusting the Pump Belt Checking the Tire Pressure Service Interval: After the first 8 hours 1. Unlatch and remove the belt cover (Figure 55). Service Interval: Every 50 hours/Monthly (whichever comes first) Check to ensure that the air pressure in all tires is 12 psi (83 kPa). Check the tires when they are cold to get the most accurate pressure reading.
Controls System Maintenance Resetting the Ground Following System If the True Core ground following system requires service of any kind (with the exception of turf guard replacement) or if the tine holders are contacting the turf guards when set in the deepest setting, the depth adjustment tie rod may need to be reset. 1. Rotate the LH turf guard mounting bracket (Figure 58) up until a locking pin (5/16 drill rod or bolt) can be inserted between the bracket and the depth setting tube welded to the frame.
Hydraulic System Maintenance 1. Set the parking brake, stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 2. Place a drain pan under the filters, remove the old filters, and wipe the filter adapter gasket surface clean (Figure 59). Hydraulic fluid escaping under pressure can penetrate skin and cause injury.
Aerator Maintenance 1 Checking the Torque of the Coring Head Fasteners Service Interval: After the first 8 hours Check the coring head fasteners to ensure proper torque is maintained. Fastener torque requirements are listed on the reference service decal located on the coring head. 2 Figure 60 1. Test port G2 2. Test port G1 • Test Port G 1 (Figure 60) is used to assist in trouble shooting the lift circuit pressure.
Replacing the Turf Guards All turf guards should be replaced if broken or worn to less than 1/4 inch (6 mm) thickness. Broken turf guards can catch and tear turf creating undesirable damage. 1 G010069 Figure 64 1. 21.2 inches (10 holes) 18.8 divided by 10 is 1.88, hole spacing is short by .12 inch from nominal (Figure 65). 1 G010070 Figure 65 1. 18.8 inches (10 holes) 1 G010068 5.
Coring Head Timing Storage The coring head timing marks are easily identified by the marks in the casting. 1. Set the parking brake and turn the ignition key to off. Remove spark plug wire. Remove the key. 2. Remove grass, dirt, and grime from the external parts of the entire machine, especially the engine and hydraulic system. Clean dirt and chaff from the outside of the engine’s cylinder head fins and blower housing. 3. Service the air cleaner; refer to Servicing the Air Cleaner. 4.
Note: A fuel stabilizer/conditioner is most effective when mixed with fresh gasoline and used at all times. G. Run engine to distribute conditioned fuel through the fuel system (5 minutes). H. Stop engine, allow to cool and drain the fuel tank; refer to Draining the Fuel Tank. I. Restart engine and run it until it stops. J. Choke the engine. Start and run engine until it will not start. K. Dispose of fuel properly. Recycle as per local codes.
Troubleshooting Problem Starter does not crank The engine will not start, starts hard, or fails to keep running. The engine loses power. The engine overheats. Abnormal vibration. The aerator does not drive. The coring head does not drive. Possible Cause Corrective Action 1. Traction lever not in neutral position. 1. Move traction lever to neutral position 2. The battery is dead. 3. Electrical connections are corroded or loose. 4. Neutral switch incorrectly adjusted. 5.
Problem The head bounces while aerating. Possible Cause Corrective Action 1. The ground is too hard. 1. Refer to Operating Tips. 2. Relief setting/Restriction orifice. 2. Dynamic response of lift system. Adjust the system pressures. Refer to the Service Manual. 1. The switch bundle needs adjustment. 1. Adjust the switch. Refer to the Service Manual. 2. The head lowers too slowly. 2. Check the function of the SVQ solenoid. Quad (or mini) tine hole spacing. 1. The holes are not evenly spaced. 1.
Schematics G010075 Electrical Schematic (Rev.
G010076 Hydraulic Schematic (Rev.
Notes: 53
Notes: 54
Notes: 55
Toro General Commercial Products Warranty A Two-Year Limited Warranty Conditions and Products Covered The Toro Company and its affiliate, Toro Warranty Company, pursuant to an agreement between them, jointly warrant your Toro Commercial Product (“Product”) to be free from defects in materials or workmanship for two years or 1500 operational hours*, whichever occurs first. This warranty is applicable to all products with the exception of Aerators (refer to separate warranty statements for these products).
