Form No. 3449-672 Rev B ProCore® 648 Aerator Model No. 09200—Serial No. 410100000 and Up Register at www.Toro.com.
Whenever you need service, genuine Toro parts, or additional information, contact an Authorized Service Dealer or Toro Customer Service and have the model and serial numbers of your product ready. Figure 1 identifies the location of the model and serial numbers on the product. Write the numbers in the space provided. This product complies with all relevant European directives; for details, please see the separate product specific Declaration of Conformity (DOC) sheet.
Contents Engine Maintenance ........................................... 34 Engine Safety ................................................... 34 Servicing the Air Cleaner .................................. 34 Engine Oil Specification.................................... 35 Checking the Engine-Oil Level.......................... 35 Changing the Engine Oil and Filter.................... 35 Servicing the Spark Plugs................................. 36 Cleaning the Engine Screen .............................
Safety • Keep the machine away from bystanders while it General Safety • Keep clear of any discharge opening. Keep is moving. bystanders and pets away from the machine. • Keep children out of the operating area. Never This product is capable of causing personal injury. Always follow all safety instructions to avoid serious personal injury. allow children to operate the machine.
decal106-8835 106-8835 1. On/off 2. Output 7. Head low 8. Head high 3. Solenoid valve lower 9. Transport (1) 4. Solenoid valve raise 10. Aerate (4) 5. Solenoid valve quick 11. Ground following 6. Input 12. OK to lower decal106-8856 106-8856 1. Read the Operator's Manual. decal140-8962 140-8962 1. Entanglement hazard, belt—stay away from moving parts; keep all guards in place. 2. Warning—do not touch hot surfaces. decal106-8853 106-8853 1. Read the Operator’s Manual. 2.
decal140-2269 140-2269 3. Bolt size 1. Read the Operator’s Manual. 2. Wrench size 4. Torque decalbatterysymbols Battery Symbols Some or all of these symbols are on your battery. 1. Explosion hazard 6. Keep bystanders away from the battery. 2. No fire, open flame, or smoking 7. Wear eye protection; explosive gases can cause blindness and other injuries. 3. Caustic liquid/chemical burn hazard 4. Wear eye protection. 8. Battery acid can cause blindness or severe burns. 9.
decal106-8854 106-8854 1. Read the Operator’s Manual. 4. Engine—start 7. To start the engine, turn the ignition key and unlock the parking brake; read the Operator’s Manual. 2. Engine—shut off 5. Read the Operator’s Manual; move the 8. To shut off the engine, press the switch switch up to turn ground following on; to disengage the PTO, lock the parking move the switch down and install the brake, and turn the ignition key to the spacers to turn ground following off.
decal115-4716 115-4716 1. Warning—read the Operator’s Manual; do not operate this machine unless you are trained. 7. Warning—shut off the engine before performing maintenance. 8. Entanglement hazard, belt; crushing hazard of hand or 2. Crushing hazard—walk in front and face forward while foot—stay away from moving parts, keep all guards and operating the machine; do not walk backwards and face away shields in place; keep bystanders away.
Setup Loose Parts Use the chart below to verify that all parts have been shipped. Procedure Description 1 2 3 4 5 6 7 Use Qty. Wheel assembly 2 Install the rear wheels. Locknut (1/2 inch) Cable guide Bolt (5/16 x 1/2 inch) Latch lock Tap bolt Internal tooth lock washer Lanyard Pop rivet Bolt (1/4 x 1 inch) Locknut (1/4 inch) CE decal Production year decal 3 1 2 2 2 2 1 1 1 1 1 1 No parts required – Install the tine holders, turf guards, and tines. No parts required – Charge the battery.
1 2 Installing the Rear Wheels Installing the Handle Parts needed for this procedure: Parts needed for this procedure: 2 Wheel assembly Procedure 1. 2. Remove the 8 lug nuts securing the rear of the machine to the packaging. 3 Locknut (1/2 inch) 1 Cable guide 2 Bolt (5/16 x 1/2 inch) Procedure Mount a wheel assembly onto each rear wheel hub (Figure 3). 1. Carefully rotate the handle to the front of the machine. Use caution not to damage the cables. 2.
3 4 Securing the Rear Hood (CE Only) Securing the Belt Cover (CE Only) Parts needed for this procedure: Parts needed for this procedure: 2 Latch lock 1 Lanyard 2 Tap bolt 1 Pop rivet 2 Internal tooth lock washer 1 Bolt (1/4 x 1 inch) 1 Locknut (1/4 inch) Procedure Procedure If you are setting up this machine for use in the European Union (CE), secure the rear hood as follows to comply with CE regulations. 1.
5 Applying the CE Decal and the Production Year Decal CE Only Parts needed for this procedure: g012264 Figure 7 1. Belt cover hole 1 CE decal 1 Production year decal 3. Pop rivet 2. Lanyard Procedure 3. After completing all the necessary CE requirements, apply the CE decal and the production year decal to the fork leg (Figure 9). Thread the bolt into the latch lever (Figure 8). g012265 Figure 8 1. Bolt 2. Latch lever 3. Nut g243051 Figure 9 1. Apply the decals here.
Product Overview 6 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 machine. Install the setup appropriate for your application as described in Installing Tine Holders, Turf Guards, and Tines (page 22). g010150 Figure 10 1. Forward (operating direction) 3. Left side 2.
Parking-Brake Lever • RUN—when the engine starts, release the key and Important: Always engage the parking brake • when you stop the machine or leave it unattended. • To engage the parking brake, move the parking-brake lever toward the operator handle (Figure 11). • it moves automatically to the ON position. OFF—rotate the key counterclockwise to the OFF position to shut off the engine. Note: You may need to move the machine forward or backward slightly when engaging the parking brake.
Aeration Depth Lever to perform the other maintenance procedures based on a 100, 200, or 500 hour schedule. Move the lever to the desired depth of aeration (Figure 14). Note: These reminders display starting 3 hours prior to the service interval time and flash at regular intervals for 6 hours. Choke Use the choke when starting a cold engine (Figure 12). Manual Ground Follow Selector Switch Rotate the switch to the down position to turn off the TrueCore feature (Figure 12).
Specifications Attachments/Accessories Note: Specifications and design are subject to A selection of Toro approved attachments and accessories is available for use with the machine to enhance and expand its capabilities. Contact your authorized Toro distributor or go to www.Toro.com for a list of all approved attachments and accessories. change without notice. Width 127 cm (50.1 inches) Wheel base 113 cm (44.5 inches) Track width 97 cm (38.
Operation Adding Fuel Note: Determine the left and right sides of the machine from the normal operating position. Fuel Specification • For best results, use only clean, fresh (less than 30 days old), unleaded gasoline with an octane rating of 87 or higher ((R+M)/2 rating method). Before Operation • Ethanol: Gasoline with up to 10% ethanol Before Operation Safety (gasohol) or 15% MTBE (methyl tertiary butyl ether) by volume is acceptable. Ethanol and MTBE are not the same.
Understanding the Safety Interlock System The safety interlock system prevents the engine from starting unless the traction bail is in the NEUTRAL position. Testing the Safety Interlock System Service Interval: Before each use or daily 1. If running, shut off the engine. 2. While holding the traction bail forward or backward, start the engine. g010026 Figure 15 The engine should not start. 1. Fuel-tank cap 3. Move the traction bail to the and start the engine. 3. 4.
• Before starting a cold engine, move the • Stop the machine, shut off the engine, remove the key, wait for all moving parts to stop, and inspect the tines after striking an object or if there is an abnormal vibration in the machine. Make all necessary repairs before resuming operation. • • Always maintain proper tire pressure. • Reduce traction speed on rough roads and choke control to the ON position. When starting a warm or hot engine, you may not need to use the choke. 3.
Using the Line Marker Walk in a forward direction while operating the machine, do not walk and face rearward when operating the machine. 5. Engage the PTO and lower the coring head. 6. Disengage the PTO and raise the coring head. 7. To stop the machine, release the traction bail. Use the line marker to align aeration rows (Figure 17). Setting the Coring Depth 1. Park the machine on a level surface, shut off the engine, engage the parking brake, and remove the key. 2.
g010036 Figure 18 1. Service latch in (lowered) storage position g010043 4. Figure 20 Pivot the service latch rearward and insert it onto the coring head pin (Figure 19). Secure the latch with the clip ring. 1. Lynch pin 3. 2. Spacers and depth pin Position the spacers above or below the bracket to attain the desired coring depth. • Thick spacers equate to 19 mm (3/4 inch) increments. • Thin spacer equates to 9.5 mm (3/8 inch) depth increment.
Installing Tine Holders, Turf Guards, and Tines 5. Loosely install a tine clamp to each tine holder (Figure 24) with 4 bolts (3/8 x 1-1/2 inches). Do not tighten the bolts. A wide selection of tine holders, turf guards, and tines are available for the machine. Choose the required components per the accessory chart in Attachments and Accessories. 1. Raise the coring head and lock it in position with the service latch. 2.
1. Park the machine on a level surface, shut off the engine, engage the parking brake, and remove the key. 2. Loosen the carriage bolt nuts securing the spring brackets to the coring head (Figure 27). Do not remove them. g010042 Figure 26 1. Gaps in the turf guards 8. Install the remaining tines into the #1, 3, 4, and 6 tine holders. Torque all tine holder bolts to 40.6 N∙m (30 ft-lb). g010051 Replacing Tines Figure 27 1.
Adding Additional Weight 4. With the increased weight transfer, it is possible to aerate firm enough ground that the weight transfer begins to lift the rear 2 tires off the ground. This may lead to irregular hole spacing. Disengage the parking brake before pushing/pulling the machine. Important: Do not operate the engine with the bypass valve open for more than 10 to 15 seconds. 5. If this occurs, you can add an additional weight plate to the rear frame axle tube. Each cast weight adds 28.
Moving the Machine when the Coring Head is Lowered core. This is due to harder native soil that sticks in the end of the tine. Side-eject greens/tees tines from Toro stay cleaner and reduce the time required to clean the tines out. You will eventually eliminate this condition with continued aeration and top-dressing programs. If the engine fails or you cannot be start it with the coring head lowered and the tines engaged in the soil, perform the following steps: 1.
Adjusting the #4 Proximity Switch You can place the #4 proximity switch in two different positions on the proximity switch bracket; use the upper position for aeration depth settings A-D and the lower position for aeration depth settings E-H. Note: By default, the #4 proximity switch is in the lower position for improved entry hole performance and depth, and it should remain there during most aeration activities.
Adjusting the #3 Proximity Switch 1. to the highest position and secure the mounting plate (Figure 33). Park the machine on a level surface; engage the parking brake; shut off the engine; remove the key; and wait for all movement to stop before leaving the machine Note: Raising the switch causes the clutch to engage sooner. 6. Tighten the locknut (Figure 33). 2. Lift the latch lever for the hood and lift the hood from the machine (Figure 31). 7.
After Operation If slowing the engine speed does not work to the remedy hole quality for the larger solid tines, the Roto-Link damper mechanism may require a stiffer setting. A stiffer Roto-Link setting may help eliminate the front of the hole from being deformed. However, under most conditions, the factory setting works best.
Hauling the Machine WARNING Driving the machine 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. Do not operate the machine on a public street or roadway. g010047 Figure 34 Important: Use full-width ramps for loading the machine onto a trailer or truck. 1. Tie down g010048 Figure 35 1. Load the machine onto the trailer or truck (coring head forward—preferred). 2.
Maintenance Note: Determine the left and right sides of the machine from the normal operating position. Maintenance Safety • Perform only those maintenance instructions CAUTION If you leave the key in the ignition switch, someone could accidently start the engine and seriously injure you or other bystanders. • • Engage the parking brake, shut off the engine, remove the key, and secure the coring head with the service latch before servicing or adjusting to the machine.
Daily Maintenance Checklist Duplicate this page for routine use. For the week of: Mon. Maintenance Check Item 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.
Raising the Machine 5. Position the jack stands or hardwood blocks under the front of the frame to support the machine. CAUTION If the machine is not properly supported by blocks or jack stands, the machine may move or fall, which may result in personal injury. Raising the Rear End • When changing attachments, tires, or performing other service, use the correct blocks, hoists, and jacks. • Make sure that the machine is parked on a solid, level surface such as a concrete floor. 1.
Lubrication Checking the Coring Head Bearings Service Interval: Yearly—Inspect the coring head bearings and replace them if necessary. Every 500 hours—Inspect the coring head bearings and replace them if necessary. g010057 The machine has no grease fittings to lubricate. Figure 39 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 4. Carefully slide the foam pre-filter off the paper element (Figure 40). Engine Safety 5. Unscrew the cover nut and remove the cover, spacer, and paper filter (Figure 40). • Shut off the engine before checking the oil or adding oil to the crankcase. Do not change the governor speed or overspeed the engine. • Cleaning the Foam Pre-Filter Important: Replace the foam element if it is torn or worn. Servicing the Air Cleaner 1.
Installing the Filters day. If it has already been run, allow the oil to drain back down to the sump for at least 10 minutes before checking. 1. Park the machine on a level surface, shut off the engine, engage the parking brake, and remove the key. 2. Clean around the oil dipstick (Figure 44) so dirt cannot fall into the filler hole and damage the engine. Important: To prevent engine damage, always operate the engine with the complete foam and paper air cleaner assembly installed. 1.
4. 5. When the oil has drained completely, replace the plug. 11. Note: Dispose of the used oil at a certified recycling center. Remove the oil fill cap and slowly pour approximately 80% of the specified amount of oil in through the valve cover. 12. Place a shallow pan or rag under the filter to catch oil (Figure 45). Check the oil level; refer to Checking the Engine-Oil Level (page 35). 13. Slowly add additional oil to bring the level to the F (full) mark on the dipstick. 14.
Fuel System Maintenance Important: Never clean the spark plugs. Always replace the spark plugs when they have a black coating, worn electrodes, an oily film, or cracks. DANGER Under certain conditions, fuel and fuel vapors are highly flammable and explosive. A fire or explosion from fuel can burn you and others and can cause property damage. • Fill the fuel tank outdoors, in an open area, when the engine is off and is cold. Wipe up any fuel that spills. • Do not fill the fuel tank completely full.
5. Install a new filter and move the hose clamps close to the filter (Figure 49). 6. Wipe up any spilled fuel. 7. Open the fuel-shutoff valve (Figure 49). Electrical System Maintenance Electrical System Safety Draining the Fuel Tank • Disconnect the battery before repairing the machine. Disconnect the negative terminal first and the positive last. Connect the positive terminal first and the negative last. DANGER In certain conditions, fuel is extremely flammable and highly explosive.
WARNING 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. • Always connect the positive (red) battery cable before connecting the negative (black) cable. 1. Unlatch and open the battery compartment cover. 2. Remove the battery from the battery compartment: A.
Servicing the Battery Service Interval: Yearly—Check the battery cable connections. The battery cables must be tight on the terminals to provide good electrical contact. WARNING 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. g010020 Figure 51 1.
F. 4. Checking the Fuses Coat the cable terminals and battery posts with Grafo 112X skin-over grease (Toro Part No. 505-47). The electrical system is protected by fuses (Figure 52). It requires no maintenance; however, if a fuse blows, check the component/circuit for a malfunction or short. Close and latch the battery compartment cover. 1. To replace fuses, pull out on the fuse to remove it. 2. Install a new fuse. g010074 Figure 52 1.
Aerator Control Module (ACM) The decal on the ACM includes only symbols. The 3 LED output symbols are shown in the output box. All other LEDs are inputs. The chart below identifies the symbols. The Aerator Control Module is a potted electronic device produced in a 1-size-fits-all configuration. The module uses solid-state and mechanical components to monitor and control electrical features required for safe product operation. decal106-8835 Figure 54 1. On/off 2. Output 7. Head low 8. Head high 3.
Drive System Maintenance 3. Loosen the locknut on the traction adjustment cam (Figure 56). Checking the Tire Pressure Service Interval: Every 50 hours/Monthly (whichever comes first) Park the machine on a level surface, shut off the engine, engage the parking brake, and remove the key. Check to ensure that the air pressure in all tires is 83 kPa (12 psi). Check the tires when they are cold to get the most accurate pressure reading. Important: Uneven tire pressure can cause uneven coring depth.
Belt Maintenance Adjusting the Pump Belt Service Interval: After the first 8 hours 1. Park the machine on a level surface, shut off the engine, engage the parking brake, and remove the key. 2. Unlatch and remove the belt cover (Figure 57). g010067 Figure 59 1. Idler bolt 5. 2. Idler pulley Tap the top of the idler pulley and allow the tensioning spring to adjust the belt tension. Note: Do not apply more belt tension than the tensioning spring allows as damage to the components may result. 6.
Controls System Maintenance Secure the left and right jam nuts on the tie rod. 9. Connect the ball switch to the wire harness. 10. Resetting the Ground Following System If the True Core ground following system requires service of any kind (except for replacing the turf guard) or if the tine holders are contacting the turf guards when set in the deepest setting, you may need to reset the depth adjustment tie rod. 1.
Hydraulic System Maintenance Material Properties: Hydraulic System Safety Viscosity, ASTM D445 cSt @ 40°C (104°F) 55 to 62 Viscosity Index ASTM D2270 140 to 152 Pour Point, ASTM D97 -37°C to -43°C (-35°F to -46°F) Industry Specifications: API GL-4, AGCO Powerfluid 821 XL, Ford New Holland FNHA-2-C-201.00, Kubota UDT, John Deere J20C, Vickers 35VQ25, and Volvo WB-101/BM • Seek immediate medical attention if fluid is injected into skin.
1. Park the machine on a level surface, shut off the engine, engage the parking brake, and remove the key. 2. Place a drain pan under the filters, remove the old filters, and wipe the filter adapter gasket surface clean (Figure 64). g010028 Figure 62 1. Hydraulic-tank cap 4. Remove the dipstick from the filler neck and wipe it with a clean rag. Insert the dipstick into the filler neck; then remove it and check the level of the fluid.
Aerator Maintenance Hydraulic System Test Ports The test ports are used to test the pressure in the hydraulic circuits. Contact your authorized Toro distributor for assistance. Checking the Fastener Torque • Test Port G 2 (Figure 65) is used to assist in Service Interval: After the first 8 hours trouble shooting the traction charge circuit. Park the machine on a level surface, shut off the engine, engage the parking brake, and remove the key.
g010064 1. Park the machine on a level surface, shut off the engine, engage the parking brake, and remove the key. 2. Unlatch and remove the belt cover (Figure 57). 3. Remove the 2 pump shield mounting nuts and remove the shield (Figure 58). 4. In an open space that is free to aerate (i.e. sample plot), set the aerator spacing lever to the desired hole spacing and make an aeration pass of at least 4.5 m (15 ft). 5.
Storage 1. Park the machine on a level surface; engage the parking brake; shut off the engine; remove the key; and wait for all movement to stop before leaving the machine. 2. Disconnect the spark-plug wire. 3. Remove grass, dirt, and grime from the external parts of the entire machine, especially the engine and the hydraulic system. Clean dirt and chaff from the outside of the cylinder-head fins of the engine and blower housing. 4.
F. switch and keep it out of reach of children or other unauthorized users. Add a petroleum-based stabilizer/conditioner to fuel in the tank. Follow mixing instructions from stabilizer manufacture. Do not use an alcohol-based stabilizer (ethanol or methanol). 16. Note: A fuel stabilizer/conditioner is most effective when mixed with fresh fuel and is always used. G. Run the engine to distribute conditioned fuel through the fuel system for 5 minutes. H.
Troubleshooting Problem The starter does not crank. The engine does not start, starts hard, or fails to keep running. The engine loses power. The engine overheats. There is abnormal vibration. The machine does not drive. Possible Cause Corrective Action 1. The traction bail is not in the NEUTRAL position. 1. Move the traction bail to the position 2. The battery is discharged. 3. The electrical connections are corroded or loose. 4. The neutral switch is incorrectly adjusted. 5.
Problem The coring head does not drive. The head bounces while aerating. Possible Cause 1. The hydraulic-fluid level is low. 1. Add hydraulic fluid. 2. 3. 4. 5. 6. 2. 3. 4. 5. 6. The tow valve is open. A belt is worn or loose. The clutch is worn. A switch or relay is worn. The hydraulic system is damaged. Close the tow valve. Adjust or replace the belts. Replace the clutch. Replace the switch or relay. Contact your authorized Toro distributor. 1. The ground is too hard. 1. Refer to Operating Tips.
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California Proposition 65 Warning Information What is this warning? You may see a product for sale that has a warning label like the following: WARNING: Cancer and Reproductive Harm—www.p65Warnings.ca.gov. What is Prop 65? Prop 65 applies to any company operating in California, selling products in California, or manufacturing products that may be sold in or brought into California.
The Toro 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 Hydroject or ProCore Aerator (“Product”) to be free from defects in materials or workmanship for two years or 500 operational hours*, whichever occurs first. This warranty is applicable to all products (refer to separate warranty statements for these products).
