Form No. 3365-684 Rev A ProCore® 648 Aerator Model No. 09200—Serial No. 310000401 and Up To register your product or download an Operator's Manual or Parts Catalog at no charge, go to 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 The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. 1 Figure 1 This spark ignition system complies with Canadian ICES-002. 1.
Contents Changing the Engine Oil and Filter ..................... 36 Servicing the Spark Plugs.................................... 37 Fuel System Maintenance ....................................... 38 Replacing the Fuel Filter ..................................... 38 Draining the Fuel Tank....................................... 38 Electrical System Maintenance................................ 39 Servicing the Battery........................................... 39 Fuses........................................
Safety – Do not smoke. – Never refuel or drain the aerator indoors. 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.
Slope Operation • Do not operate near drop-offs, ditches, steep banks, or water. Wheels dropping over edges can cause rollovers, which may result in serious injury or death. • Charge batteries in an open well ventilated area, away from spark and flames. Unplug the charger before connecting or disconnecting it from the battery. Wear protective clothing and use insulated tools. • Do not operate on slopes when grass is wet. Slippery conditions reduce traction and could cause sliding and loss of control.
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. 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. 3. Caustic liquid/chemical burn hazard 4. Wear eye protection 5. Read the Operator’s Manual. 106-8856 1. 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. Keep bystandersa safe distance from the battery.
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.
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 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) 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 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).
WARNING 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 8.
2 WARNING 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.
2 1 Figure 8 Figure 7 1. Tap bolt 2. Latch lock 1. Belt cover 3. Internal lock washer (inside of hood) 4. Hood 2. Latch lever 2. Using the hole in the belt cover, install the lanyard assembly with a pop rivet (Figure 9). 2. Using a pliers or adjustable wrench, thread an internal lock washer onto each bolt (1-2 threads) to secure bolt (Figure 7). 5 Securing the Belt Cover (CE Only) Parts needed for this procedure: 1 Lanyard 1 Pop rivet 1 Bolt (1/4 x 1 inch) 1 Locknut (1/4 inch) Figure 9 1.
Product Overview Figure 10 1. Bolt 2. Latch lever Figure 11 3. Nut 1. Operating direction 2. Right side 6 3. Left side Controls 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) Ground clearance 4.75 inches (12.
Operation DANGER 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. • Always place gasoline containers on the ground away from your vehicle before filling.
Checking the Engine Oil Level Add the correct amount of gas stabilizer/conditioner to the gas. Service Interval: Before each use or daily (Check the oil when the engine is cold.) Note: A fuel stabilizer/conditioner is most effective when mixed with fresh gasoline. To minimize the chance of varnish deposits in the fuel system, use fuel stabilizer at all times. The engine is shipped with oil in the crankcase; however, the oil level must be checked before and after the engine is first started.
Important: Do not overfill the crankcase with oil because this may cause engine damage. Do not run the engine with oil below the low mark because the engine may be damaged as a result. perhaps some slight loss of efficiency at high ambient temperatures compared to the Type 46/68 fluids. Important: For operating conditions where sustained ambient temperatures are 95 degrees F (35 degrees C) or higher Toro highly recommends the use of Mobil 1 15W–50 synthetic oil. 6.
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 CAUTION 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 Understanding the Safety Interlock System 1. Service latch in (lowered) storage position 3.
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. WARNING 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.
Operating Tips stomper arm. Attempt to maintain a symmetrical tine configuration to evenly load the stomper arms. • Reduce aerator penetration (depth setting), if ground is hard packed. Clean up cores, water turf, and re–aerate at a deeper penetration. General WARNING Always be aware of obstacles that may be in the area of operation. Plan your aeration path to avoid contact with any obstacle by you or the machine. Aeration of soil types built on top of hard subsoils (i.e.
begin to lift the turf or damage to the root zone is excessive, proceed as follows: • Increase the hole spacing • Decrease tine size • Decrease tine depth • Remove some of the tines and bearing damage due to excessive water pressure will be avoided. A brush may be used to remove caked-on material. Use mild detergent to clean the covers. Applying a coat of auto wax periodically will retain the cover’s glossy finish. After cleaning, inspect for machine damage, oil leakage, component and tine wear.
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 2. Place the jack securely under the frame plate just inside of the rear wheel (Figure 41). 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.
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. Every 100 hours—Replace the paper air filter element. Service Interval: Yearly—Check the coring head bearings. Every 500 hours—Inspect the coring head bearings, if needed, replace. 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). 3. Put one or two ounces of oil on the pre-filter (Figure 44). Service Interval: After the first 50 hours Every 100 hours—Change the engine oil and filter. Note: Change oil and filter more frequently when operating conditions are extremely dusty or sandy.
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.
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. 1. Allow the machine to cool down. 2. Close the fuel shut–off valve (Figure 51). Figure 50 1. Center electrode insulator 2. Side electrode 3. Air gap (not to scale) 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). Servicing the Battery 3. Loosen the hose clamp at the fuel filter and slide it up the fuel line away from the fuel filter (Figure 51). 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.
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. If corrosion occurs at the terminals, disconnect the cables (negative (–) cable first) and scrape clamps and terminals separately.
Drive System Maintenance 1 Checking the Tire Pressure 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. Important: Uneven tire pressure can cause uneven coring depth. Figure 54 1. Traction adjustment cam 4. Start engine and release the parking brake.
Belt Maintenance Adjusting the Pump Belt Service Interval: After the first 8 hours 1. Unlatch and remove the belt cover (Figure 55). Figure 57 1. Idler bolt 2. Idler pulley 4. Tap the top of the idler pulley and allow its 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. 1 G010065 5. Secure the belt idler bolt. Figure 55 6. Install the pump shield and belt cover. 1.
Controls System Maintenance Hydraulic System Maintenance WARNING Resetting the Ground Following System 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.
1 2. Place a drain pan under the filters, remove the old filters, and wipe the filter adapter gasket surface clean (Figure 59). 2 Figure 60 1. Test port G2 2. Test port G1 1 2 • Test Port G 1 (Figure 60) is used to assist in trouble shooting the lift circuit pressure. Figure 59 1. Hydraulic return filter 2. Hydraulic charge filter 3. Apply a thin coat of hydraulic fluid to the rubber gasket on the replacement filters. 4. Install the replacement hydraulic filters onto the filter adapters.
Aerator Maintenance Replacing the Turf Guards Checking the Fastener Torque 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. 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.
Coring Head Timing 1 The coring head timing marks are easily identified by the marks in the casting. G010069 Figure 64 1. 21.2 inches (10 holes) 1 18.8 divided by 10 is 1.88, hole spacing is short by .12 inch from nominal (Figure 65). 1 G010070 1 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. Figure 67 1.
Storage Note: A fuel stabilizer/conditioner is most effective when mixed with fresh gasoline and used at all times. 1. Set the parking brake and turn the ignition key to off. Remove spark plug wire. Remove the key. G. Run engine to distribute conditioned fuel through the fuel system (5 minutes). 2. Remove grass, dirt, and grime from the external parts of the entire machine, especially the engine and hydraulic system.
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.
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.
