Form No. 3361-632 Rev C ProCore® 648 Aerator Model No. 09200—Serial No. 290000001 and Up To register your product or download an Operator's Manual or Parts Catalog at no charge, go to www.Toro.com.
Warning Model No. 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. Serial No. This manual identifies potential hazards and has safety messages identified by the safety alert symbol (Figure 2), which signals a hazard that may cause serious injury or death if you do not follow the recommended precautions. This spark ignition system complies with Canadian ICES-002.
Contents Changing the Engine Oil and Filter ..................... 37 Servicing the Spark Plugs.................................... 38 Fuel System Maintenance ....................................... 39 Replacing the Fuel Filter ..................................... 39 Draining the Fuel Tank....................................... 40 Electrical System Maintenance................................ 40 Servicing the Battery........................................... 40 Fuses........................................
Safety – Never refuel or drain the aerator indoors. • Check that the operator presence controls, safety switches, and shields are attached and functioning properly. Do not operate unless they are functioning properly. 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.
• Do not operate on slopes when grass is wet. Slippery conditions reduce traction and could cause sliding and loss of control. • Keep all parts in good working condition and all hardware tightened. Replace all worn or damaged decals. • Do not make sudden turns or rapid speed changes. • Use only Toro-approved attachments. The warranty may be voided if the machine is used with unapproved attachments. • Reduce speed and use extreme caution on slopes.
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. 106-8856 3. Caustic liquid/chemical burn hazard 4. Wear eye protection 1. Read the Operator’s Manual. 5. 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.
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) Hood plate Pop rivet Nut (#10) Bolt (#10 x 2 inch) Locknut (#10) Bolt (1/4 x 1 inch) Locknut (1/4 inch) 3 1 2 2 2 1 3 1 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).
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 1. Battery compartment 8.
2 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.
1 5 Securing the Belt Cover (CE Only) Parts needed for this procedure: 1 Bolt (1/4 x 1 inch) 1 Locknut (1/4 inch) Procedure Figure 7 If you are setting up this machine for use in the European Union (CE), secure the belt cover as follows to comply with CE regulations. 1. Rear hood Insert a Bolt (1/4 x 1 inch) through the belt cover latch lever and secure with a locknut (1/4 inch) (Figure 9 and Figure 10) 2 2 1 3 Figure 8 1. Hood plate 2. Pop rivet 3. Bolt and nuts 1 2.
Product Overview 2 1 Figure 11 1. Operating direction 2. Right side Figure 10 1. Latch lever 3. Left side 2. Bolt and nut Controls 6 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) Weight without fuel 1590 lb (721 kg) Ground clearance 4.75 inches (12.
Operation 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. Note: Determine the left and right sides of the machine from the normal operating position. If you leave the key in the ignition switch, someone could accidently start the engine and seriously injure you or other bystanders.
• Cleans the engine while it runs Checking the Engine Oil Level • Eliminates gum-like varnish buildup in the fuel system, which causes hard starting Service Interval: Before each use or daily (Check the oil when the engine is cold.) Important: Do not use fuel additives containing methanol or ethanol. The engine is shipped with oil in the crankcase; however, the oil level must be checked before and after the engine is first started. Add the correct amount of gas stabilizer/conditioner to the gas.
Checking the Hydraulic Fluid 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. Service Interval: Before each use or daily The hydraulic reservoir is filled at the factory with approximately 1.75 US gallons (6.6 l) of high quality hydraulic fluid. Check the level of the hydraulic fluid before the engine is first started and daily thereafter.
Note: When changing from one type of hydraulic fluid to another, be certain to remove all the old fluid from the system, as some fluids are incompatible with others. 1 Biodegradable Hydraulic Fluid - Mobil 224H ISO VG 32/46 anti-wear hydraulic fluid Mobil EAL Envirosyn H, ISO Grade 68 Note: This synthetic biodegradable hydraulic fluid is not compatible with the UTHF fluids.
Starting and Stopping the Engine The Safety Interlock System Starting the Engine If safety interlock switches are disconnected or damaged the aerator could operate unexpectedly causing personal injury. 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. • Do not tamper with the interlock switches. • Check the operation of the interlock switches daily and replace any damaged switches before operating the aerator.
1 1 2 G010038 Figure 22 Figure 20 1. Tine arm 1. Service latch in (lowered) storage position 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. 3. Pivot the service latch rearward and insert it onto the coring head pin (Figure 21). Secure it with the clip ring. Note: The turf guard clamps and flange nuts are shipped secured to the turf guard brackets (Figure 23).
Setting the Coring Depth 5. Install tines into the #2 and #5 tine holders (Figure 25) Tighten the bolts. #6 #5 #4 #3 #2 To set the coring depth of the aerator, proceed as follows: #1 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 1 2 G010040 Figure 25 1. Number 5 tine holder 2. Number 2 tine holder 6.
Pushing/Pulling the Aerator by Hand 1 Important: Never tow the aerator faster than 1 MPH because hydraulic component damage may occur. 2 1. Set the parking brake, turn the ignition key to the Off position, and remove the ignition key. 2. Locate the by-pass valve between the engine and hydrostatic pump (Figure 30). 3. Using a 5/8 inch wrench, rotate the by-pass valve counterclockwise 1 turn. This allows the hydraulic fluid to by-pass the pump enabling the wheels to turn (Figure 30). 2 Figure 28 1.
Resetting the System Control Circuit 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. 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.
Using the Line Marker Use the line marker to align aeration rows (Figure 35). 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. Do not operate aerator on a public street or roadway. 2 G010050 1 Figure 35 1. Line marker (storage position) 1 2.
2 lb (28.5 kg) to the machine. Up to two plates can be added. Refer to the Parts Catalog for these part numbers. Aerator Control Module (ACM) 1 The Aerator Control Module is a potted electronic device produced in a one size fits all configuration. The module uses solid state and mechanical components to monitor and control electrical features required for safe product operation. Figure 36 1. Weight transfer springs 2. Spring plate 2.
Operating Tips The ACM does not connect to an external computer or hand held device, cannot be reprogrammed, and does not record intermittent fault troubleshooting data. General 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. 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. With the mini tine head or larger solid tine use, the turf root structure is important to preventing turf damage due to tearing of the root zone.
Upon Completion After daily use, thoroughly wash the machine with a garden hose without a nozzle so contamination and seal 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. Remove, clean, and oil the tines.
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.
Premaintenance Procedures Jacking the Rear End 1. Chock the front tire to prevent the machine from moving. Important: To prevent wheel motor damage, do not use rear wheel motor as a jacking point. Jacking Instructions 2. Place the jack securely under the frame plate just inside of the rear wheel (Figure 41). 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.
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.
Draining the Fuel Tank Electrical System Maintenance 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. Servicing the Battery Service Interval: Every 25 hours—Check the electrolyte level and clean the battery. • Drain gasoline from the fuel tank when the engine is cold. Do this outdoors in an open area. Wipe up any gasoline that spills. Every 25 hours—Check the battery cable connections.
The battery cables must be tight on the terminals to provide good electrical contact. 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. 1 • Always connect the positive (red) battery cable before connecting the negative (black) cable. Figure 52 1.
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 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 1. Set the parking brake, stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 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 • Test Port G 1 (Figure 60) is used to assist in trouble shooting the lift circuit pressure. 1 2 Figure 59 1. Hydraulic return filter 2. Hydraulic charge filter 3.
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. 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. 3. Service the air cleaner; refer to Servicing the Air Cleaner. 4.
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.
Notes: 53
Notes: 54
Notes: 55
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.
