Form No. 3380-385 Rev A ProCore® 648 Aerator Model No. 09200—Serial No. 314000001 and Up Register at www.Toro.com.
This product complies with all relevant European directives, for details please see the separate product specific Declaration of Conformity (DOC) sheet. WARNING CALIFORNIA Proposition 65 Warning 1 This product contains a chemical or chemicals known to the State of California to cause cancer, birth defects, or reproductive harm. The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. Figure 1 1.
Contents Electrical System Maintenance ....................................38 Servicing the Battery...............................................38 Fuses ....................................................................39 Drive System Maintenance .........................................39 Checking the Tire Pressure ......................................39 Adjusting the Traction Drive for Neutral....................39 Belt Maintenance ......................................................
Safety • Allow engine to cool before refueling. • Never refuel the machine indoors. • Never store the machine or fuel container where there is 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. Failure to comply with the instruction may result in personal injury or death.
• Use care when approaching blind corners, shrubs, trees, connecting or disconnecting it from the battery. Wear protective clothing and use insulated tools. or other objects that may obscure vision. • Always be aware of obstacles that may be in the area of • Keep all parts in good working condition and all hardware operation. Plan your aeration path to avoid contact with any obstacle by you or the machine. tightened. Replace all worn or damaged decals. • Use only Toro-approved attachments.
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 1. Stored energy hazard—read the Operator's Manual. 106-8835 1. On/off 2. Output 3. Solenoid valve lower 4. Solenoid valve raise 7. Head low 8. Head high 9. Transport (1) 10. Aerate (4) 5. Solenoid valve quick 11. Ground following 6. Input 12. OK to lower 93-9084 1. Lift point 2.
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 6. Keep bystanders a safe distance 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. Flush eyes immediately with water and get medical help fast. 5.
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—stop 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. Operator’s Manual. 3.
115-4716 1. Warning—do not operate this machine unless you are trained. 7. Warning—stop the engine and read the instructions before servicing or performing maintenance. 2. Crushing hazard—Walk in a forward direction while operating 8.
Setup Loose Parts Use the chart below to verify that all parts have been shipped. Procedure Description 1 2 3 4 5 6 Use Qty. Wheel assembly 2 Locknut (1/2 inch) Cable guide Bolt (5/16 x 1/2 inch) Bolt (1/4 x 1 inch) Flange nut (5/16 inch) Latch lock Tap bolt Internal tooth lock washer Lanyard Pop rivet Bolt (1/4 x 1 inch) Locknut (1/4 inch) 3 1 2 2 2 2 2 2 1 1 1 1 No parts required – Install the rear wheels. 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: 2 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.
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. 8. Insert the battery into the tray in the battery compartment (Figure 6) Position the battery so the terminals are to the outside.
10. First, secure the positive cable (red) to the positive (+) battery terminal with a carriage bolt and nut (Figure 6), then the negative cable (black) to the negative (–) terminal of the battery with a carriage bolt and nut (Figure 6). Slide the rubber boot over the positive terminal to prevent a possible short from occurring. Important: Make sure there is clearance between the battery cables and the speed selector lever. Verify that the speed selector lever does not come within 1 inch (2.
2 1 Figure 10 1. Bolt 2. Latch lever Figure 8 1. Belt cover 3. Nut 2. Latch lever 6 2. Using the hole in the belt cover, install the lanyard assembly with a pop rivet (Figure 9). 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. Install the setup appropriate for your application as described in Installing the Tine holders, Turf Guards, and Tines in Operation. Figure 9 1.
Product Overview Always set the parking brake when you stop the aerator or leave it unattended. Jog the traction lever forward and reverse to release the parking brake. Oil Pressure Warning Light The oil pressure warning light (Figure 12) glows when the oil pressure in the engine drops below a safe level. If low oil pressure ever occurs, stop the engine and determine the cause. Repair the damage before starting the engine again. Raise, Lower/Engage Switch Figure 11 1.
1 3 starts, regulate the choke to keep the engine running smoothly. As soon as possible, open the choke by pulling it backward. 4 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. 5 System Reset 6 2 Press the system reset switch (Figure 13) to raise the coring head if the system becomes disabled (e.g., engine out of fuel, etc.) 7 Aeration Depth Lever Figure 13 1. Ignition 5.
Specifications Note: Specifications and design are subject to change without notice. Width 127.3 cm (50.12 inches) Wheel base 113 cm (44.5 inches) Track width 97.3 cm (38.3 inches) Coring width 122 cm (48 inches) Length 265.4 cm (104.5 inches) Height, raised 112 cm (44 inches) Height, Lowered 112 cm (44 inches) Height, handle 104 cm (41 inches) Ground clearance 12.1 cm (4.
Operation DANGER 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. • Fill the fuel tank outdoors, in an open area, when the engine is cold. Wipe up any gasoline that spills. • Never fill the fuel tank inside an enclosed trailer. • Do not fill the fuel tank completely full. Add gasoline to the fuel tank until the level is 6 to 13 mm (1/4 to 1/2 inch) below the bottom of the filler neck.
because the fuel system could be damaged. Do not mix oil with gasoline. 1 WARNING Gasoline is harmful or fatal if swallowed. Long–term exposure to vapors can cause serious injury and illness. • Avoid prolonged breathing of vapors. • Keep face away from nozzle and gas tank or conditioner opening. • Keep gas away from eyes and skin. Using Stabilizer/Conditioner Figure 15 Use a fuel stabilizer/conditioner in the traction unit to provide the following benefits: 1.
Checking the Engine Oil Level 6. Install the filler tube cap and dipstick. Service Interval: Before each use or daily (Check the oil when the engine is cold.) Checking the Hydraulic Fluid The engine is shipped with oil in the crankcase; however, the oil level must be checked before and after the engine is first started. Service Interval: Before each use or daily The hydraulic reservoir is filled at the factory with approximately 6.6 liters (1.75 US gallons) of high quality hydraulic fluid.
Biodegradable Hydraulic Fluid - Mobil 224H ISO VG 32/46 anti-wear hydraulic fluid Mobil EAL Envirosyn H, ISO Grade 68 4. Remove dipstick from filler neck and wipe it with a clean rag. Insert dipstick into filler neck; then remove it and check level of fluid. Fluid level should be up to mark on dipstick (Figure 19). Note: This synthetic biodegradable hydraulic fluid is not compatible with the UTHF fluids.
choke back to the On position for a few seconds. Then move the throttle lever to desired setting. Repeat this as required. If the safety system does not operate as described above, have an Authorized Service Distributor repair the safety system immediately. Stopping the Engine Installing the Service Latches 1. Move the throttle lever to the Slow position. Install the service latches before performing service on the coring head or when storing the machine for more than a couple of days. 2.
2 1 G010039 Figure 23 1. Turf guard 1 2. Turf guard clamp 4. Loosely install a tine clamp to each tine holder with 4 bolts (3/8 x 1-1/2 inches) (Figure 24). Do not tighten the bolts. Figure 21 1. Service latch in (raised) locked position 1 Installing Tine Holders, Turf Guards, and Tines A wide selection of tine holders, turf guards, and tines are available for the aerator. Choose the required components per the accessory chart in Attachments and Accessories. 2 1.
1 6. Check that the tines line up with the center of the gaps in the turf guards (Figure 26). Adjust the turf guards as required and tighten the nuts. 2 1 1 Figure 27 Figure 26 1. Aeration depth lever 1. Gaps in the turf guards 2. Overlay on decal 3. Determine which letter setting the other end of the tine lines up with and set the depth control lever to the corresponding letter setting. 7. Install the remaining tines into the #1, 3, 4, and 6 tine holders. Torque all tine holder bolts to 40.
2. 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. • With all spacers on the top side, the depth setting is 10.7 cm (4-1/4 inches). 1 3. Remove locking bolt and nut from selector switch (Figure 29). 1 Figure 30 1. By-pass valve Important: Do not rotate the by-pass valve more than 1 turn.
Trailer Recommendations Weight 721 kg (1590 lb) or 805 kg (1775 lb) with two optional weights Width 130 cm (51 inches) minimum Length 267 cm (105 inches) minimum Ramp Angle 3.5/12 pitch (16 degrees) maximum Load Direction Coring head forward (preferred) Vehicle Tow Capacity Greater than gross trailer weight (GTW) G010046 1 Transport the aerator as follows: Figure 31 1. Set the parking brake and block the wheels. 1. Circuit reset switch 2. Load the aerator onto the trailer.
1 2 G010050 1 Figure 35 Figure 32 1. Line marker (storage position) 1. Tie down 2. Line marker (alignment position) 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. However, if the soil structure is firm enough to not allow full aeration depth some additional weight transfer may be required.
2 1 Figure 37 1. Square hole in bracket 1 2. Rear carriage bolt Figure 38 1. Aerator control module 3. Hold the ratchet or breaker bar to relieve the tension on the spring plate and remove the rear carriage bolt. The module monitors inputs including head low, head high, transport, aerate, and ground following. The module is divided into inputs and outputs. Inputs and outputs are identified by green LED indicators mounted on the printed circuit board. Power is identified by a red LED indicator. 4.
• Look behind frequently to ensure that the machine is operating properly and alignment is maintained with previous passes. • Always clear the area of all damaged machine parts, such as broken tines, etc., to prevent their being picked up by mowers or other turf maintenance equipment. • Replace broken tines and inspect and correct damage to those still usable. Repair any other machine damage before commencing operation. • When aerating with less than the full width of the Figure 39 1. On/off 2.
Note: Alter half of the Roto-Links (3 arms) and test the difference on a sample plot. If the hole quality upon entrance is slotted (pulled forward) or the coring head fails to engage before contacting the turf, the engagement position switch may require adjustment. 1. Remove the lock nuts securing the Roto-Link damper assembly to the coring head frame. • Verify that the switch assembly along side the H-Frame is no more than 1.5 mm (0.06 inches) from the target plate 2. Remove the top damper–spacer (1.
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, tiller handle fasteners and wheel lug nuts. After the first 50 hours • Change the engine oil and filter.
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.
Jacking Instructions CAUTION 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. Prior to raising the machine, remove any attachments that may interfere with the safe and proper raising of the machine. Always chock or block wheels. Use jack stands or solid wood blocks to support the raised machine.
Lubrication Engine Maintenance Checking the Coring Head Bearings Servicing the Air Cleaner Service Interval: Every 25 hours—Clean the foam air filter element and check the paper element for damage. Service Interval: Yearly—Check the coring head bearings. Every 500 hours—Inspect the coring head bearings, if needed, replace. Every 100 hours—Replace the paper air filter element. Removing the Filters The aerator has no grease fittings that must be lubricated. 1.
Changing the Engine Oil and Filter 1. Wash the foam pre-filter in liquid soap and warm water. When clean, rinse it thoroughly. 2. Dry the pre-filter by squeezing it in a clean cloth (do not wring). Service Interval: After the first 50 hours 3. Put one or two ounces of oil on the pre-filter (Figure 44). Every 100 hours—Change the engine oil and filter. Note: Change oil and filter more frequently when operating conditions are extremely dusty or sandy.
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. Type: Champion RC12YC or equivalent. Air Gap: 0.75 mm (0.03 inch) 1 Removing the Spark Plugs Figure 47 1.
Fuel System Maintenance Replacing the Fuel Filter Service Interval: Every 100 hours/Yearly (whichever comes first) Important: Never install a dirty filter if it is removed from the fuel line. Figure 50 1. Center electrode insulator 1. Allow the machine to cool down. 3. Air gap (not to scale) 2. Close the fuel shut–off valve (Figure 51). 2. Side electrode 2 2. Check the gap between the center and side electrodes (Figure 50). 3. Bend the side electrode (Figure 50) if the gap is not correct.
Electrical System Maintenance 1. Park the machine on a level surface to ensure the fuel tank drains completely. Then, set the parking brake, and turn the ignition key to off. Remove the key. 2. Close the fuel shut–off valve (Figure 51). 3. Loosen the hose clamp at the fuel filter and slide it up the fuel line away from the fuel filter (Figure 51). Servicing the Battery 4. Pull the fuel line off fuel filter (Figure 51). Open the fuel shut-off valve and allow gasoline to drain into a gas can or drain pan.
Drive System Maintenance 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.
Belt Maintenance 1 Adjusting the Pump Belt Service Interval: After the first 8 hours 1. Unlatch and remove the belt cover (Figure 55). Figure 54 1. Traction adjustment cam 4. Start engine and release the parking brake. 1 WARNING G010065 The engine must be running so the final adjustment of the traction adjustment cam can be performed. This could cause personal injury. Figure 55 1.
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. Figure 57 1. Idler bolt 1.
Hydraulic System Maintenance WARNING Hydraulic fluid escaping under pressure can penetrate skin and cause injury. Fluid injected into the skin must be surgically removed within a few hours by a doctor familiar with this form of injury or gangrene may result. • If hydraulic fluid is injected into the skin it must be surgically removed within a few hours by a doctor familiar with this type of injury. Gangrene may result if this is not done.
Aerator Maintenance 1 Checking the Fastener Torque Service Interval: After the first 8 hours Check the coring head fasteners, tiller handle fasteners and wheel lug nuts 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 6 mm (1/4 inch) thickness. Broken turf guards can catch and tear turf creating undesirable damage. 1 G010070 Figure 65 1. 18.8 inches (10 holes) 5. If an adjustment is needed, turn the pump stop bolt (Figure 66) closer to the stop plate to decrease hole spacing or turn the stop bolt away from the stop plate to increase hole spacing. 1 1 G010068 Figure 63 1.
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. 1 3. Service the air cleaner; refer to Servicing the Air Cleaner. 4.
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. Important: Do not store stabilizer/conditioned gasoline over 90 days. 9. Remove the spark plugs and check the condition; refer to Servicing the Spark Plugs.
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.
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Toro Commercial Aerator 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 Hydroject or ProCore Aerator (“Product”) to be free from defects in materials or workmanship for two years or 500 operational hours*, whichever occurs first.
