Form No. 3353–518 Rev. A ProCore 648 Aerator Model No.
Warning Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starting and Stopping the Engine . . . . . . . . . . . . The Safety Interlock System . . . . . . . . . . . . . . . . Service Latches . . . . . . . . . . . . . . . . . . . . . . . . . . Install Tine Holders, Turf Guards and Tines . . . . Setting the Coring Depth . . . . . . . . . . . . . . . . . . . Manual Ground Following . . . . . . . . . . . . . .
Introduction This manual uses two other words to highlight information. Important calls attention to special mechanical information and Note: emphasizes general information worthy of special attention. Read this manual carefully to learn how to operate and maintain your product properly. The information in this manual can help you and others avoid injury and product damage. Although Toro designs and produces safe products, you are responsible for operating the product properly and safely.
• Never remove gas cap or add fuel with engine running. Allow engine to cool before refueling. Do not smoke. • Do not operate on slopes when grass is wet. Slippery conditions reduce traction and could cause sliding and loss of control. • Never refuel or drain the aerator indoors. • Do not make sudden turns or rapid speed changes. • Check that operator’s presence controls, safety switches and shields are attached and functioning properly. Do not operate unless they are functioning properly.
Sound Power Level • Keep all parts in good working condition and all hardware tightened. Replace all worn or damaged decals. This unit has a guaranteed sound power level of: 102 dBA/1 pW, based on measurements of identical machines per Directive 2000/14/EC and amendments. • Use only Toro-approved attachments. Warranty may be voided if used with unapproved attachments. Vibration Level Sound Pressure Level This unit does not exceed a vibration level of 2.
107-7534 1. Warning—read the Operator’s Manual. 2. Warning—remove the ignition key and read the instructions before servicing or performing maintenance. 3. Entanglement hazard, belt—stay away from moving parts. 4. Crushing hazard of hand or foot—keep bystanders a safe distance from the machine. 5. Crushing hazard of hand and body—engage the service latch when the coring head is raised; read the instructions before servicing or performing maintenance. 6.
106-8853 1. Read the Operator’s Manual. 106-8856 2. Coring depth 1. Read the Operator’s Manual. 93-9084 1. Lift point 2. Tie-down point 107-7555 93-6696 1. Stored energy hazard—read the Operator’s Manual.
106-8855 1. Move the lever up to drive in reverse. 2. Move the lever down to drive forward. 3. Disengage the PTO and raise the head. 4. Engage the PTO and lower the head. 5. Warning—stop the engine and read the instructions before servicing or performing maintenance. 6. Warning—stop the engine before fueling. 7. Entanglement hazard, shaft—do not carry passengers. 8.
Specifications Engine Tires Kohler, 2 cylinder, air cooled, gasoline engine.19 HP (14.2 kW) @ 3000 rpm. Torque –32.5 lb–ft. @ 3000 rpm (44.1 N–m) 32.7 lb–ft max (44.3 N–m) @ 2400 rpm. High Idle–3400 rpm. Low Idle–1400 rpm. Displacement 41 cu–in. (674 cc). Air Filter–Dry, large capacity, replaceable element. Oil Filter–External, spin–on. Fan–High flow blower. Front & Rear–20x10–10, 2 ply rated, smooth tread, tubeless, Inflated to 12 psi, demountable rims.
Accessory Chart ProCore 648 Optional Accessories 48” (1.2 meter) wide Model Number 09200 Windrower Kit 09220 Tire Scrapers 09225 Extra Weight 99–6166–01 Tine Heads Required 10 Mini Tine Head 5 Needle Tine Head 1.6” spacing 1.6” spacing 3/8” shank size Model No. 09222 Model No. 09221 Turf Holders Required Turf Holders Required 105–1110 qty 2 105–1110 qty 2 105–1111 qty 1 105–1111 qty 1 Tines Tines 60 Required 30 Required Classic Tine Options 3/8” 9.5mm 3/16” 4.
Setup Note: Determine the left and right sides of the machine from the normal operating position. Loose Parts Chart Note: Use this chart as a checklist to ensure all parts necessary for assembly have been shipped. If any of these parts are missing, total setup cannot be completed. Description Qty. Locknuts, 1/2–20 3 Cable guide 1 Capscrews, 5/16 x 1/2 in. 2 Hood plate 1 Pop rivet 3 Capscrew, #10–24 x 2 in. 1 Nut, #10–24 1 Locknut, #10–24 1 Capscrew, 1/4–20 x 1 in.
4. Insert the cable guide around the cables. Note: To raise the coring head, after uncrating the machine, start the engine and depress the RESET button. Refer to the Operation section of this manual for more information. 5. Mount the cable guide to the top of the fork with (2) 5/16 x 1/2” capscrews (Fig. 3). Install the Rear Wheels Activate, Charge and Connect the Battery 1. Remove the (8) lug nuts securing the rear of the aerator to the packaging. 2. Mount a wheel to each hub with (4) lug nuts (Fig.
2 Warning 5 Charging the battery produces gasses that can explode. 4 Never smoke near the battery and keep sparks and flames away from battery. 6. Connect a 3 to 4 amp battery charger to the battery posts. Charge the battery at a rate of 3 to 4 amps until the specific gravity is 1.250 or higher and the temperature is at least 60_ F (16_ C) with all cells gassing freely. 1 7. When the battery is charged, disconnect the charger from the electrical outlet and battery posts.
Secure Rear Hood Secure Belt Cover (Required for CE) (Required for CE) 1. Secure the hood plate to the rear hood with (3) pop rivets (Fig. 7). 1. Insert a 1/4 x 1 inch capscrew thru the belt cover latch lever and secure with a 1/4 locknut (Fig. 8 & 9). 2. Thread a #10 nut onto a #10 x 2 inch capscrew. 3. Insert the capscrew thru the hood plate (Fig. 7). 1 2 1 Figure 8 1. Belt cover Figure 6 2. Latch lever 1. Rear hood 2 2 1 1 3 Figure 9 1. Latch lever Figure 7 1. Hood plate 2.
Before Operating 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. Recommended Gasoline Use UNLEADED Regular Gasoline suitable for automotive use (85 pump octane minimum). Leaded regular gasoline may be used if unleaded regular is not available. • Fill the fuel tank outdoors, in an open area, when the engine is cold. Wipe up any gasoline that spills.
Filling the Fuel Tank 1 Fuel tank capacity is approximately 7.5 gal (28.4 l) 2 1. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 2. Clean around each fuel tank cap and remove the cap (Fig. 10). Add unleaded regular gasoline to fuel tank until the level is 1/4 to 1/2 inch (6 mm to 13 mm) below the bottom of the filler neck. This space in the tank allows gasoline to expand. Do not fill the fuel tank completely full. Figure 11 1 1.
Check Hydraulic System Fluid Group 3 Hydraulic Fluid (Biodegradable) ISO VG 32/46 anti-wear hydraulic fluid The hydraulic system is designed to operate on anti–wear hydraulic fluid. The machines reservoir is filled at the factory with approximately 1.75 gallons of high quality hydraulic fluid. Check level of hydraulic fluid before engine is first started and daily thereafter. Appropriate hydraulic fluids are listed below.
Check the Tire Pressure 1 Maintain the air pressure in the front and rear tires as specified. Uneven tire pressure can cause uneven coring depth. Check the pressure at the valve stem after every 50 operating hours or monthly, whichever occurs first (Fig. 16). Check the tires when they are cold to get the most accurate pressure reading. Pressure: 12 psi (83 kPa) front and rear wheels. Figure 14 1. Hydraulic tank cap 2 4. Remove dipstick from filler neck and wipe it with a clean rag.
Operation Ignition Switch The ignition switch (Fig. 19), which is used to start and stop the engine, has three positions: OFF, RUN, and START. Rotate key clockwise to the START position to engage starter motor. When engine starts, release key and it will move automatically to the ON position. To shut engine off, rotate key counterclockwise to the OFF position. Note: Determine the left and right sides of the aerator from the normal operating position (Fig. 17).
Throttle Control Manual Ground Follow Selector Switch The throttle (Fig. 19) is used to operate engine at various speeds. Moving throttle forward increases engine speed—FAST; backward decreases engine speed—SLOW. The throttle regulates the speed of the coring head and controls the ground speed of the traction unit. Rotate switch to down position to turn off the TrueCoret feature (Fig. 19) Remove screw to access manual ground switch. 3 System Reset Press system reset switch (Fig.
Important Do not engage starter for more than 10 seconds at a time. If engine fails to start allow 30 second cool-down period between attempts. Failure to follow these instructions can burn out starter motor. Testing the Safety Interlock System 5. After the engine starts, move the choke to off . If the engine stalls or hesitates, move the choke back to on for a few seconds. Then move the throttle lever to desired setting. Repeat this as required.
2 1 Figure 24 1 1. Turf guard 2. Turf guard bracket 4. Loosely install a tine clamp to each tine holder with (4) 3/8 x 1–1/2 in. capscrews. (Fig. 26) Do not tighten capscrew. Figure 22 1. Service latch in (raised) locked position 5. Install tines into the #2 and #5 tine holders (Fig. 25) Tighten the capscrews. Install Tine Holders, Turf Guards and Tines GRAPHIC # A wide selection of tine holders, turf guards and tines are available for the aerator.
6. Check that the tines line up with the center of the gaps in the turf guards (Fig. 27). Adjust turf guards as required and tighten the nuts. 1 1 2 1 Figure 27 Figure 28 1. Aeration depth lever 7. Install remaining tines into #1, 3, 4 & 6 tine holder. Torque all tine holder capscrews to 30 ft.–lbs. 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.
2. Using a 5/8 in. wrench, rotate the by-pass valve counterclockwise 1 turn to push/pull. This allows hydraulic fluid to by-pass the pump enabling the wheels to turn (Fig. 31). 1 2 2 1 Figure 29 1. Lynch pin 2. Spacers & depth pin 3. Remove locking capscrew and nut from selector switch (Fig. 30). Figure 31 1. By–pass valve Important Do not rotate by-pass valve more than 1 turn. This prevents the valve from coming out of the body and causing fluid to run out.
Use a heavy–duty trailer or truck to transport the aerator. Ensure that the trailer or truck has all necessary lighting and marking as required by law. Please carefully read all the safety instructions. Knowing this information could help you, your family, pets or bystanders avoid injury. To reset the system after engine is started, depress rocker switch (Fig. 32) to raise coring head and reset the electrical control circuit. To transport the aerator: • Set the parking brake and block the wheels.
Replace broken tines, inspect and correct damage to those still useable. Repair any other machine damage before commencing operation. The ProCore 648 will aerate deeper than most greens aerators. On native or modified push–up greens & tees, the deeper depth and longer hollow tines may have difficulty ejecting the complete core. This is due to harder native soil that sticks in the end of the tine. Side–eject greens/tees tines from Toro will stay cleaner and reduce the time required to clean the tines out.
• If needed, loosen the switch mounting plate and lift to its highest position and re–secure the mounting plate. The higher the switch, the sooner the clutch engages 3. Loosen the capscrews securing the bumper plate. 4. Slide the bumper plate forward and re–secure the capscrews. This allows the Roto–Link bumpers to oscillate properly.
3. Hold the rachet or breaker–bar to relieve the tension on the spring plate and remove the rear carriage bolt. some additional weight transfer may be required. To increase the down pressure of the weight transfer springs, proceed as follows: 4. Rotate the spring plate until it is aligned with the other hole, insert the carriage bolt and tighten nuts. Warning Note: Rotating spring plates upward will increase weight transfer. Sudden release of the spring plates could cause injury.
7. If specific output LED is not illuminated and inputs are in appropriate condition, install new ACM and determine if fault disappears. Output circuits are energized by an appropriate set of input conditions. The three outputs include SVL, SVR and SVQ. Output LED’s monitor relay condition indicating the presence of voltage at one of three specific output terminals.
Maintenance Recommended Maintenance Schedule Maintenance Service Interval After first 8 hours After first 50 Hours Each Use Maintenance Procedure • • • • Hydraulic fluid—check level Hydraulic filter—change Pump belt—re–tension Coring head fasteners–check torque • Engine oil & filter—change • • • • • • • Engine oil—check level Safety System—check Engine air intake—clean1 Belts—check Hydraulic fluid—check level Tires—check pressure Hydraulic lines—check Every 25 Hours • Wash and re–oil air precleaner
Daily Maintenance Checklist Duplicate this page for routine use. For the week of: Maintenance Check Item Mon. Tues. Wed. Thurs. Fri. Sat. Check safety interlock operation. Check parking brake operation. Check fuel level Check the engine oil 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 the tire pressure.
Lubrication Jacking Instructions The aerator has no grease fittings that must be lubricated. Caution 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. Bearings that are greased will rely upon regular maintenance to purge harmful debris from the bearing area.
4. Position the jack stands or hardwood blocks under the front of the frame to support the machine. 3. Jack (or lift) the rear of the machine off the ground. 4. Position the jack stands or hardwood blocks under the frame to support the machine. Jacking the Rear End Servicing the Air Cleaner 1. Chock the front tire to prevent the machine from moving. The foam pre–cleaner must be cleaned and re–oiled after every 25 hours engine operation if engine is operated in clean air conditions.
3. Reinstall on paper cartridge. 1 Inspect paper element every 25 hours of operation and replace if dirty or damaged. Change paper element every 100 hours. Do not wash paper element or do not clean with compressed air as damage will occur. 2 Note: With air cleaner disassembled, check air cleaner components for damage. Replace if necessary. 1. Reinstall element with pre–cleaner, breather seal, spacer, inner cover and nut. Torque nut to 95 in.–lb. (11 N⋅m). 2. Reinstall air cleaner cover, O–ring and knob.
Note: Dispose of the used oil at a certified recycling center. 3 1 2 m–1256 Figure 47 1. Oil filter 2. Gasket 3. Adapter 5. Install the replacement oil filter to the filter adapter. Turn the oil filter clockwise until the rubber gasket contacts the filter adapter, then tighten the filter an additional 1/2 turn (Fig. 47). 1 Figure 46 1. Oil filter 6. Fill the crankcase with the proper type of new oil; refer to Changing the Oil, page 34. 5.
Servicing the Fuel Filter Replace the fuel filter after every 100 operating hours or yearly, whichever occurs first. Replacing the Fuel Filter 1 Never install a dirty filter if it is removed from the fuel line. 2 1. Allow the machine to cool down. 2. Set the parking brake, stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. m–4811 Figure 48 1. Spark plug wire 2. Spark plug 3. Close the fuel shut–off valve (Fig. 50).
Servicing the Fuel Tank Servicing the Hydraulic System Draining The Fuel Tank Warning Danger Hydraulic fluid escaping under pressure can penetrate skin and cause injury. 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. • 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.
Adjusting the Traction Drive for Neutral 3. Apply a thin coat of hydro fluid to the rubber gasket on the replacement filter. The machine must not creep when traction lever is released. If it does creep, an adjustment is required. 4. Install the replacement hydraulic filter onto the filter adapter. Turn the hydraulic oil filter clockwise until the rubber gasket contacts the filter adapter, then tighten the filter an additional 1/2 turn 1.
Checking the Hydraulic Lines 6. Rotate the tie rod until the ball switch just closes or makes contact. Before each use, check the hydraulic lines and hoses for leaks, loose fittings, kinked lines, loose mounting supports, wear, weather and chemical deterioration. Make necessary repairs before operating. 2 Note: Keep areas around hydraulic system clean from debris build up. Warning 3 Hydraulic fluid escaping under pressure can penetrate skin and cause injury.
1 1 Figure 55 1. Side shield Figure 57 Adjusting Pump Belt 1. Pump shield After the initial, eight (8) hours of use, re–adjust the belt tension on the pump drive belt. 3. Loosen the pump belt idler bolt just enough to allow movement within it’s adjustment slot (Fig. 58). 1. Unlatch and remove the belt cover (Fig. 56). 1 1 Figure 58 1. Idler bolt 2. Idler pulley 4. Tap the top of the idler pulley and allow its tensioning spring to adjust the belt tension.
Replacing the Turf Guards Example: Nominal Hole Spacing Setting of 2 inches 21.2 divided by 10 is 2.12, hole spacing is long by .12 inch from nominal (Fig. 60). All turf guards should be replaced if broken or worn to less than 1/4 inch thickness. Broken turf guards can catch and tear turf creating undesirable damage. 21.2 inches (10 holes) Figure 60 18.8 divided by 10 is 1.88, hole spacing is short by .12 inch from nominal (Fig. 61). 18.8 inches (10 holes) 1 Figure 61 Figure 59 1. Turf guard 5.
Check Torque of Coring Head Fasteners Servicing the Fuses The electrical system is protected by fuses (Fig. 65). It requires no maintenance, however, if a fuse blows check component/circuit for malfunction or short. After the initial, eight (8) hours of use, 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. 1. To replace fuses pull out on the fuse to remove it. 2. Install a new fuse.
Maintain the cell level with distilled or demineralized water. Do not fill the cells above the bottom of the split ring inside each cell. Warning Incorrect battery cable routing could damage the tractor and cables causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury. Danger Battery electrolyte contains sulfuric acid which is a deadly poison and causes severe burns. • Always disconnect the negative (black) battery cable before disconnecting the positive (red) cable.
Troubleshooting PROBLEM Starter does not crank Engine g will not start,, starts hard,, or f il to fails t keep k running. i Engine g loses power. p Engine g overheats. POSSIBLE CAUSES CORRECTIVE ACTION 1. Battery is dead. 1. Charge the battery. 2. Electrical connections are corroded or loose. 2. Check electrical connections for good contact. 3. Relay or switch is defective. 3. Contact Authorized Service Distributor. 4. Traction lever not in neutral position. 4.
PROBLEM Abnormal vibration. POSSIBLE CAUSES CORRECTIVE ACTION 1. Engine mounting bolts are loose. 1. Tighten engine mounting bolts. 2. Jackshaft or coring head bearings worn. 2. Replace bearings. 3. Jackshaft or coring head components loose or worn 3. Tighten or replace components. 1. The parking brake is on. 1. Release the parking brake. 2. Hydraulic fluid level low. 2. Add hydraulic fluid. 3. The tow valve is open. 3. Close the tow valve. 4. Hydraulic system is damaged. 4.
PROBLEM Turf lifting/tearing while aerating Front of the hole is dimpled or pushed. POSSIBLE CAUSES CORRECTIVE ACTION 1. Check coring head attitude 1. Refer to the Service Manual for specification. 2. Improper tine selection. 2. Reduce the tine diameter, reduce the tine diameter, reduce the number of tines per head or increase the hole spacing. 3. Excessive depth. 3. Reduce the depth. 4. Hole spacing too close. 4. Increase the hole spacing. 5. Turf conditions (i.e.
83–0020 M L A S W VIO T BK 4 T W VIO 3 2 S L M 2 A FUSE 94–6710 10 A FUSE 218–578 20 A FUSE 109101 IGN. CONN. FRONT OR 5 1 G AB STOP –––– G+M+A RUN –––– B+L+A START ––– B+L+S BK G OR B IGN.
Hydraulic Schematic PSI “ 48
Cleaning and 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. B. 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.
Notes 50
Notes 51
The Toro Aerator 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 Hydrojectr 3000, Hydrojectr 4000, Greens, Fairway Aerator or ProCoret Aerator (“Product”) to be free from defects in materials or workmanship for two years or 500 operational hours*, whichever occurs first.
