Form No. 3419-966 Rev A ProCore® 648 Aerator Model No. 09200—Serial No. 401390001 and Up Register at www.Toro.com.
equipped) to access warranty, parts, and other product information. This product complies with all relevant European directives when the appropriate setup procedures are completed; for details please see the separate product specific Declaration of Conformity (DOC) sheet. WARNING CALIFORNIA Proposition 65 Warning This product contains a chemical or chemicals known to the State of California to cause cancer, birth defects, or reproductive harm.
Contents Engine Safety ................................................... 35 Servicing the Air Cleaner .................................. 35 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 ..........................
Safety • Keep the machine a safe distance away from General Safety • Keep clear of any discharge opening. Keep bystanders while it is moving. bystanders and pets a safe distance away from the machine. This product is capable of causing personal injury. Always follow all safety instructions to avoid serious personal injury. • Keep children out of the operating area. Never 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. decal107-7547 107-7547 1. Entanglement hazard, belt—stay away from moving parts. 2. Warning—Do not touch the hot surfaces decal106-8853 106-8853 1. Read the Operator’s Manual. 2.
decal110-4664 110-4664 1. Read the Operator's Manual. 2. Wrench size 3. Bolt size decalbatterysymbols Battery Symbols Some or all of these symbols are on your battery 4. Torque 1. Explosion hazard 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.
decal107-7534 107-7534 1. Warning—read the Operator’s Manual. 3. Entanglement hazard, belt—stay away from moving parts. 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. 2. Warning—remove the ignition key and read the instructions before servicing or performing maintenance. 4. Crushing hazard of hand or foot—keep bystanders a safe distance from the machine. 6.
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 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) CE decal Production year decal 3 1 2 2 2 2 2 2 1 1 1 1 1 1 No parts required – Install the rear wheels. Install the handle. Activate and charge the battery.
2. Mount a wheel assembly onto each rear wheel hub (Figure 3). g010019 Figure 4 g010018 Figure 3 1. Wheel assembly 1. Handle 2. Fork 2. Lug nut 3. Install the lug nuts (Figure 3) and tighten them to 61 to 75 N∙m (45 to 55 ft-lb). 4. Deflate all tires to 83 kPa (12 psi). 3. Secure handle studs to fork with 3 locknuts (1/2 inch) (Figure 4) 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. g010020 Figure 5 8. 1. Battery compartment 3.
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. 11. Close and latch the battery compartment cover. 4 Securing the Rear Hood (CE Only) g010021 Figure 6 1. Battery tray 4.
g010024 g013611 Figure 8 Figure 7 1. Tap bolt 3. Internal lock washer (inside of hood) 2. Latch lock 4. Hood 2. 1. Belt cover 2. 2. Latch lever Using the hole in the belt cover, install the lanyard assembly with a pop rivet (Figure 9). Using a pliers or adjustable wrench, thread an internal lock washer onto each bolt (1 to 2 threads) to secure the bolts (Figure 7). 5 Securing the Belt Cover (CE Only) Parts needed for this procedure: g012264 1 Lanyard 1 Pop rivet 1.
g012265 Figure 10 1. Bolt 2. Latch lever 3. Nut g243051 Figure 11 6 1. Apply the decals here. Applying the CE Decal and the Production Year Decal 7 Installing the Tine Holders, Turf Guards, and Tines CE Only Parts needed for this procedure: 1 CE decal 1 Production year decal No Parts Required Procedure Procedure A wide selection of tine holders, turf guards, and tines are available for the aerator.
Parking Brake Product Overview To engage the parking brake, move the lever toward the engine. To disengage the parking brake, move the lever forward (Figure 13). Always engage the parking brake when you stop the aerator or leave it unattended. Jog the traction lever forward and reverse to disengage the parking brake. Oil Pressure Warning Light The oil pressure warning light (Figure 13) 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 14) 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 14) Remove the bolt to access the manual ground switch. System Reset g010034 Figure 14 1. Ignition 5. Hour meter/tachometer 2.
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 • Do not remove the fuel cap or fill the fuel tank Note: Determine the left and right sides of the machine from the normal operating position. • Do not add or drain the fuel in an enclosed space. while the engine is running or hot. • Do not store the machine or fuel container where there is an open flame, spark, or pilot light, such as on a water heater or other appliance.
2. Clean around the oil dipstick (Figure 17) so dirt cannot fall into the filler hole and damage the engine. g002359 g010026 Figure 17 Figure 16 1. Dipstick 1. Fuel-tank cap 3. Add fuel to the fuel tank, until the level is 6 mm to 13 mm (1/4 to 1/2 inch) below the bottom of the filler neck. Important: This space in the tank allows 3. Remove the dipstick, wipe it clean, and install until it is fully seated (Figure 17). 4. Remove the dipstick and check the oil level on the dipstick.
be used, but they must be only conventional, petroleum-based products, not synthetics or biodegradable fluids. The specifications must fall within the listed range for all of the following material properties and the fluid should meet listed industry standards. Check with your fluid supplier to see if the fluid meets these specifications.
• Wear appropriate clothing, including eye • • • • • • • • hazards, or other hazards. The machine could suddenly roll over if a wheel goes over the edge or the edge caves in. Establish a safety area between the machine and any hazard. protection; slip-resistant, substantial footwear; long pants; and hearing protection. Tie back long hair and do not wear loose jewelry. Do not operate the machine when tired, ill, or under the influence of alcohol or drugs.
Using the Machine CAUTION Children or bystanders may be injured if they move or attempt to operate the aerator while it is unattended. Always remove the ignition key and engage the parking brake when leaving the aerator unattended, even if just for a few minutes. 1. Start the engine. 2. Disengage the parking brake. 3. Look in the direction of your planned path to ensure that it is clear. 4. Move the traction lever down to drive the machine forward.
4. Pivot the service latch rearward and insert it onto the coring head pin (Figure 22). Secure it with the clip ring. g010038 Figure 23 1. Tine arm 4. 2. Tine holder Loosely install the turf guards to the turf guard brackets with 4 turf guard clamps and 12 flange nuts (Figure 24). Do not tighten the fasteners. Note: The turf guard clamps and flange nuts g010037 are shipped secured to the turf guard brackets (Figure 24). Figure 22 1.
6. Install tines into the #2 and #5 tine holders (Figure 26) Tighten the bolts. 4. Insert the new tines into the tine holder. 5. Tighten the bolts to the recommended torque level. 6. Repeat this procedure on the remaining arms. Setting the Coring Depth To set the coring depth of the aerator, proceed as follows: 1. Park the machine on a level surface, shut off the engine, engage the parking brake, and remove the key. 2. Select the preferred tine for your application. 3.
1. 2. Park the machine on a level surface, shut off the engine, engage the parking brake, and remove the key. 5. 6. Remove the lynch pin retaining the spacers and depth pins (Figure 29). Rotate the switch to the down position to turn off True Core feature. Install the locking bolt and nut to ensure that the setting is not accidentally changed. After Operation Safety • Keep all parts of the machine in good working • condition and all hardware tightened. Replace all worn, damaged, or missing decals.
4. Disengage the parking brake before pushing/pulling the machine. Important: Do not operate the engine with 5. the bypass valve open for more than 10 to 15 seconds. To operate the aerator again, rotate the bypass valve clockwise 1 turn (Figure 31). 1. Remove the tine holders from the stomper arms. 2. Open the bypass valve 1 turn. 3. Pull/push the aerator to a nearby location to continue service or load onto a trailer.
g010049 g010050 Figure 35 Figure 36 1. Tie down 1. Line marker (storage position) Hauling the Machine Adjusting the Weight Transfer • Use full-width ramps for loading the machine onto a trailer or truck. • Tie the machine down securely. The machine is designed to transfer weight from the traction unit to the coring head to help maintain hole depth in various soil structures.
be added. Refer to the Parts Catalog for these part numbers. Aerator Control Module (ACM) 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. g010051 Figure 37 1. Weight transfer springs 3. 2. Spring plate Insert a 1/2 inch ratchet or breaker bar into the square hole in the spring plate (Figure 38). g010053 Figure 39 1.
Operating Tips The ACM does not connect to an external computer or handheld device, cannot be reprogrammed, and does not record intermittent fault troubleshooting data. General The decal on the ACM includes only symbols. 3 LED output symbols are shown in the output box. All other LEDs are inputs. The chart below identifies the symbols. 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.
• • • • • Change to a 3-tine head, if attempting to use the • 4-tine head or reduce the number of tines per 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.
and seal and bearing damage due to excessive water pressure. 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. Remove, clean, and oil the tines. Spray a light oil mist on coring head bearings (crank and damper links). Secure the service latch if the aerator is to be stored for more than a couple days.
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. 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.
Jacking the Rear End Lifting the Machine 1. Park the machine on a level surface, shut off the engine, engage the parking brake, and remove the key. 2. Chock the front tire to prevent the machine from moving. CAUTION 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.
4. Jack (or lift) the rear of the machine off the ground. 5. Position the jack stands or hardwood blocks under the frame to support the machine. Lubrication Checking the Coring Head Bearings 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.
Engine Maintenance Engine Safety • Shut off the engine before checking the oil or Carefully slide the foam pre-filter off of the paper element (Figure 44). 5. Unscrew the cover nut and remove the cover, spacer, and paper filter (Figure 44). Cleaning the Foam Pre-filter adding oil to the crankcase. Do not change the governor speed or overspeed the engine. • 4. Important: Replace the foam element if it is torn or worn.
2. Place the air cleaner assembly onto the air cleaner base (Figure 44). 3. Install the cover, spacer and secure it with the cover nut (Figure 44). Torque the nut to 11 N∙m (95 in-lb). 4. Install the air cleaner cover and secure with the knob (Figure 44). Changing the Engine Oil and Filter Service Interval: After the first 50 hours Every 100 hours—Change the engine oil and filter. g010058 Figure 48 Note: Change oil and filter more frequently when 1.
14. Install 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. g004219 Figure 51 1. Center electrode insulator 2. Side electrode Type: Champion RC12YC or equivalent. Air Gap: 0.
Fuel System Maintenance 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. 4. Remove the filter from the fuel lines. 5. Install a new filter and move the hose clamps close to the filter (Figure 52). 6. Wipe up any spilled fuel. 7. Open the fuel-shutoff valve (Figure 52). Draining the Fuel Tank • Fill the fuel tank outdoors, in an open area, when the engine is off and is cold.
Electrical System Maintenance DANGER Battery electrolyte contains sulfuric acid which is fatal if consumed and causes severe burns. Electrical System Safety • Do not drink electrolyte and avoid contact with skin, eyes, or clothing. Wear safety glasses to shield your eyes and rubber gloves to protect your hands. • 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.
Drive System Maintenance WARNING Battery terminals or metal tools could short against metal tractor components causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury. Checking the Tire Pressure • When removing or installing the battery, do not allow the battery terminals to touch any metal parts of the machine.
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 56). g010062 Figure 55 1. Traction adjustment cam 4. Start engine and disengage the parking brake. WARNING The engine must be running so that the final adjustment of the traction adjustment cam can be performed. This could cause personal injury.
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. g010067 Figure 58 1. Idler bolt 5. 1. Park the machine on a level surface, shut off the engine, engage the parking brake, and remove the key. 2.
9. 10. Hydraulic System Maintenance Connect the ball switch to the wire harness. Remove the pin from the turf guard bracket and depth setting tube. Hydraulic System Safety • Seek immediate medical attention if fluid is injected into skin. Injected fluid must be surgically removed within a few hours by a doctor. • Ensure that all hydraulic-fluid hoses and lines are in good condition and all hydraulic connections and fittings are tight before applying pressure to the hydraulic system.
g010061 Figure 61 g010060 Figure 60 1. Hydraulic return filter 1. Test port G2 2. Test port G1 2. Hydraulic charge filter • Test Port G 1 (Figure 61) is used to assist in 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. Turn the each filter clockwise until the rubber gasket contacts the filter adapter, then tighten each an additional 1/2 turn. 5.
Aerator Maintenance Checking the Fastener Torque Service Interval: After the first 8 hours Park the machine on a level surface, shut off the engine, engage the parking brake, and remove the key. Check the coring head fasteners, tiller handle fasteners, and wheel lug nuts to ensure that the proper torque is maintained. Fastener torque requirements are listed on the reference service decal located on the coring head. g010064 Figure 63 1. Side shield 3. Adjust the shield up or down and tighten the nuts.
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 56). 3. Remove the 2 pump shield mounting nuts and remove the shield (Figure 57). 4. In an open space that is free to aerate (i.e. sample plot), set the hole spacing lever to the desired hole spacing and make an aeration pass of at least 4.5 m (15 feet). 5.
Storage 1. Park the machine on a level surface, shut off the engine, engage the parking brake, and remove the key. 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. tank. Follow mixing instructions from stabilizer manufacture. Do not use an alcohol-based stabilizer (ethanol or methanol).
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 aerator does not drive. Possible Cause Corrective Action 1. The traction lever is not in the neutral position. 1. Move the traction lever to the neutral 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 Corrective Action 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 Service distributor. 1. The ground is too hard. 1.
Notes:
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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).
