Form No.
Revision History Revision Date -- 2004 Initial Issue. A 2006 Updated Engine chapter. B 2009 Updated Hydraulic System chapter. C 2009 Updated Hydraulic System chapter. D 02/2018 Added revision history. E 06/2018 Updated the traction control cable compression spring length. F 04/2020 Updated electrical diagrams chapter. © THE TORO COMPANY 2020 Description This document and all information contained herein is the sole property of The Toro Company (and/or its affiliated companies).
Reader Comments The Toro Company Technical Assistance Center maintains a continuous effort to improve the quality and usefulness of its publications. To do this effectively, we encourage user feedback. Please comment on the completeness, accuracy, organization, usability, and readability of this manual by an e-mail to servicemanuals@toro.
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Part No. 04129SL (Rev. F) Service Manual ProCoreR 648 Preface The purpose of this publication is to provide the service technician with information for troubleshooting, testing and repair of major systems and components on the ProCore 648. REFER TO THE OPERATOR’S MANUALS FOR OPERATING, MAINTENANCE AND ADJUSTMENT INSTRUCTIONS. Space is provided in Chapter 2 of this book to insert the Operator’s Manuals and Parts Catalogs for your machine.
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Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . 1 -- 2 Jacking Instructions . . . . . . . . . . . . . . . . . . . . . . . . . 1 -- 4 Safety and Instruction Decals . . . . . . . . . . . . . . . . 1 -- 5 Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . 5 -- 1 Circuit Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 -- 2 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 -- 7 Troubleshooting . . . . . . . . . . . . . . . .
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Safety Table of Contents SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . While Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance and Service . . . . . . . . . . . . . . . . . . . . JACKING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . SAFETY AND INSTRUCTION DECALS . . . . . . . . . .
Safety Instructions The ProCore 648 is designed and tested to offer safe service when operated and maintained properly. Although hazard control and accident prevention partially are dependent upon the design and configuration of the machine, these factors are also dependent upon the awareness, concern and proper training of the personnel involved in the operation, transport, maintenance and storage of the machine. Improper use or maintenance of the machine can result in injury or death.
8. Do not park on slopes unless wheels are chocked or blocked. Maintenance and Service 1. Before servicing or making adjustments, position machine on level surface, raise coring head, set parking brake, stop engine and remove key from the ignition switch. Install the service latch to secure the coring head in the raised position. 2. Make sure machine is in safe operating condition by keeping all nuts, bolts and screws tight. 3.
Jacking Instructions 1 CAUTION When changing attachments, tires or performing other service, use correct blocks, hoists and jacks. Make sure machine is parked on a solid level surface such as a concrete floor. Prior to raising 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.
Safety and Instruction Decals ProCore 648 Page 1 – 5 Safety Numerous safety and instruction decals are affixed to the ProCore 648. If any decal becomes illegible or damaged, install a new decal. Part numbers for replacement decals are listed in your Parts Catalog. Order replacement decals from your Authorized Toro Distributor.
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Chapter 2 Product Records and Maintenance PRODUCT RECORDS . . . . . . . . . . . . . . . . . . . . . . . . . MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EQUIVALENTS AND CONVERSIONS . . . . . . . . . . . Decimal and Millimeter Equivalents . . . . . . . . . . . . U.S. to Metric Conversions . . . . . . . . . . . . . . . . . . . TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . Fastener Identification . . . . . . . . . . . . . . . . . . . . . . .
Equivalents and Conversions 0.09375 Product Records and Maintenance Page 2 -- 2 Rev.
Recommended fastener torque values are listed in the following tables. For critical applications, as determined by Toro, either the recommended torque or a torque that is unique to the application is clearly identified and specified in this Service Manual. These Torque Specifications for the installation and tightening of fasteners shall apply to all fasteners which do not have a specific requirement identified in this Service Manual.
Standard Torque for Dry, Zinc Plated and Steel Fasteners (Inch Series) Thread Size Grade 1, 5 & 8 with Thin Height Nuts SAE Grade 1 Bolts, Screws, Studs & Sems with Regular Height Nuts (SAE J995 Grade 2 or Stronger Nuts) in–lb in–lb N–cm 10 + 2 13 + 2 147 + 23 # 6 – 32 UNC # 6 – 40 UNF # 8 – 32 UNC 13 + 2 25 + 5 # 10 – 24 UNC 30 + 5 SAE Grade 8 Bolts, Screws, Studs & Sems with Regular Height Nuts (SAE J995 Grade 5 or Stronger Nuts) in–lb N–cm in–lb N–cm 15 + 2 170 + 20 23 + 2 260 + 20
Standard Torque for Dry, Zinc Plated and Steel Fasteners (Metric Fasteners) Class 8.8 Bolts, Screws and Studs with Regular Height Nuts (Class 8 or Stronger Nuts) Class 10.9 Bolts, Screws and Studs with Regular Height Nuts (Class 10 or Stronger Nuts) M5 X 0.8 57 + 5 in–lb 640 + 60 N–cm 78 + 7 in–lb 885 + 80 N–cm M6 X 1.0 96 + 9 in–lb 1018 + 100 N–cm 133 + 13 in–lb 1500 + 150 N–cm M8 X 1.25 19 + 2 ft–lb 26 + 3 N–m 27 + 2 ft–lb 36 + 3 N–m M10 X 1.
Other Torque Specifications SAE Grade 8 Steel Set Screws Wheel Bolts and Lug Nuts Recommended Torque Thread Size Recommended Torque** Thread Size Square Head Hex Socket 1/4 – 20 UNC 140 + 20 in–lb 73 + 12 in–lb 5/16 – 18 UNC 215 + 35 in–lb 145 + 20 in–lb 3/8 – 16 UNC 35 + 10 ft–lb 18 + 3 ft–lb 1/2 – 13 UNC 75 + 15 ft–lb 50 + 10 ft–lb 7/16 – 20 UNF Grade 5 65 + 10 ft–lb 88 + 14 N–m 1/2 – 20 UNF Grade 5 80 + 10 ft–lb 108 + 14 N–m M12 X 1.25 Class 8.
Chapter 3 Kohler Engine Table of Contents 2 3 4 4 5 5 5 SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 7 Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Belt Tensioners . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Introduction This Chapter gives information about specifications and repair of the Kohler engine used in the ProCore 648. General engine maintenance procedures are described in your Operator’s Manual. Information on engine troubleshooting, testing, disassembly, and reassembly is identified in the Kohler Engine Service Manual that is included at the end of this section. Most repairs and adjustments require tools which are commonly available in many service shops.
Specifications Item Description Make / Designation Kohler, CH23S, 4–stroke, V–Twin Air Cooled, OHV Number of Cylinders 2 Bore x Stroke 3.15” x 2.64” (80 mm x 67 mm) Total Displacement 41.1 Cubic Inches (674 cc) Compression Ratio 8.5:1 90 Pounds (41 Kilograms) Fuel Unleaded, Regular Gasoline (Minimum 87 Octane) Fuel Tank Capacity 7.5 U.S. Gallons (28.
General Information Fuel Shutoff Valve The fuel shutoff valve located under the fuel tank (Fig. 1) should be closed when removing the fuel tank or engine from the machine. Additionally, close the shutoff valve if the machine is being transported on a trailer or when placing the machine in long term storage. 1 Figure 1 1.
Adjustments Adjust Choke Control Proper choke operation is dependent upon proper adjustment of choke control cable. 1 1. Park machine on a level surface, fully raise coring head, engage parking brake, stop engine and remove key from the ignition switch. 2. Remove air cleaner cover from engine to view choke plate in carburetor. 2 Kohler Engine 3. Move choke control lever to RUN position. Check that choke plate in carburetor is fully open. 4. Move choke control lever to CHOKE position.
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Service and Repairs Cooling System To ensure proper engine cooling, make sure the grass screen, cooling fins and other external surfaces of the engine are kept clean at all times. 1 1 NOTE: Perform this maintenance procedure at the interval specified in the Operator’s Manual. 3 1. Park machine on a level surface, fully raise coring head, engage parking brake, stop engine and remove key from the ignition switch. IMPORTANT: Never clean engine with pressurized water.
Fuel System 2 RIGHT FRONT 1 12 Anti–seize Lubricant 3 8 7 4 9 6 5 11 6 8 10 10 30 to 60 in–lb (3.4 to 6.8 N–m) Figure 5 1. 2. 3. 4. Fuel tank Fuel cap Hose clamp Fuel hose 5. 6. 7. 8. Fuel shut–off valve Hose clamp Fuel hose Flat washer (4 used) 9. 10. 11. 12. Clamp Cap screw (4 used) Flange bushing (4 used) Machine frame Check Fuel Lines and Connections DANGER Because gasoline is highly flammable, use caution when storing or handling it. Do not smoke while filling the fuel tank.
Fuel Tank Removal (Fig. 5) 2 1. Park machine on a level surface, fully raise coring head, engage parking brake, stop engine and remove key from the ignition switch. Secure coring head with service latch. 3 2. Close tank fuel shut–off valve. Disconnect fuel hose from the fuel filter (Fig. 6). 3. Use shut–off valve to empty fuel tank into a suitable container. 1 4. Remove fuel tank using Figure 5 as a guide. Fuel Tank Installation (Fig. 5) Figure 6 1. Fuel shut–off valve 2. Fuel filter 3.
Exhaust System 17 to 21 ft–lb (23.1 to 28.5 N–m) 1 FRONT RIGHT 3 4 6 2 11 7 5 7 8 8 9 10 12 13 14 15 Figure 7 1. 2. 3. 4. 5. Engine Exhaust manifold Hex nut (4 used) Frame Flange nut (2 used) Kohler Engine 6. 7. 8. 9. 10. Muffler bracket Flange head screw (3 used) Muffler clamp (2 used) Exhaust elbow Carriage screw (2 used) Page 3 – 10 11. 12. 13. 14. 15.
Removal (Fig. 7) Installation (Fig. 7) NOTE: Make sure exhaust manifold and engine sealing surfaces are free of debris or damage that may prevent a tight, leak–free seal. The muffler and exhaust pipe may be hot. To avoid possible burns, allow the engine and exhaust system to cool before working on the exhaust system. 1. If exhaust manifold was removed, place exhaust gaskets on the engine exhaust manifold studs. Secure exhaust manifold to engine with four hex nuts. Torque hex nuts from 17 to 21 ft–lb (23.
Engine 1 2 3 FRONT RIGHT 4 5 6 7 9 11 16 12 8 19 10 12 13 13 14 21 15 17 18 19 8 19 20 Figure 8 1. 2. 3. 4. 5. 6. 7. Engine Negative battery cable Wire harness ground Flange screw Lock washer Exhaust manifold Hex nut (4 used) 8. 9. 10. 11. 12. 13. 14. Cap screw (4 used) Frame Flange nut (2 used) Muffler bracket Flange head screw (3 used) Muffler clamp (2 used) Exhaust elbow Removal (Fig. 8) 1.
7. Disconnect electrical connections from engine. NOTE: Label all electrical connections for reassembly purposes. 2 1 A. Remove harness red wire and positive battery cable from the starter motor solenoid stud (Fig. 9). B. Disconnect negative battery cable and wire harness ground wire from the front corner of engine base (Fig. 10). Locate and retrieve starwasher from between engine and wire connectors. 3 C. Unplug machine harness connector from electric clutch. Figure 9 1. Solenoid stud 2.
Installation (Fig. 8) B. Wrap hourmeter wire around spark plug wire and secure with cable tie. 1. Locate machine on a level surface with key removed from the ignition switch. Chock wheels to keep the machine from moving. 2. Make sure that all parts removed from the engine during maintenance or rebuilding are reinstalled to the engine. 3. If electric clutch and hydraulic pump drive pulley were removed from engine crankshaft (Fig. 11): C.
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Belt Tensioners 26 27 26 41 to 49 ft–lb (55.6 to 66.4 N–m) 25 4 28 23 29 21 20 30 19 18 31 16 15 23 32 24 4 33 14 23 12 34 41 to 49 ft–lb (55.6 to 66.4 N–m) 22 17 1 13 Anti–seize Lubricant 11 8 9 4 7 8 9 10 2 7 6 3 5 50 to 55 ft–lb (67.8 to 74.6 N–m) Figure 12 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Engine Hydraulic pump drive pulley Electric clutch Flange nut Hardened washer Cap screw Flat washer Grommet Spacer Cap screw Clutch strap Cap screw Kohler Engine 13. 14. 15. 16.
Removal (Fig. 12) Installation (Fig. 12) 1. Release tension on idler torsion spring (item 19): 1. Install belt tensioner components to engine using Figure 12 as a guide. 2. Install the hydraulic pump drive belt and primary drive belt (coring head). Be careful when removing or applying tension from or to the torsion spring of the idler pulley. The spring is under heavy load and may cause personal injury. A. Insert nut driver or small piece of pipe onto the end of the torsion spring. B.
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Chapter 4 Hydraulic System SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 4 Hydraulic Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Hydraulic Fitting Installation . . . . . . . . . . . . . . . . . . . 4 Pushing/Pulling Machine . . . . . . . . . . . . . . . . . . . . . 6 Check Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . 6 Relieving Hydraulic System Pressure . . . . . . . . . .
Specifications Item Description Traction Pump (P1) Displacement at full stroke (per revolution) Forward relief pressure Reverse relief pressure Variable displacement piston pump .976 Cubic Inches (16 cc) 2900 PSI (200 Bar) 2900 PSI (200 Bar) Charge/Lift Pump (P2) Displacement (per revolution) Charge Pressure Gear pump .37 Cubic Inches (6.1 cc) 40 PSI (2.
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General Information Hydraulic Hoses Hydraulic hoses are subject to extreme conditions such as pressure differentials during operation and exposure to weather, sun, chemicals, very warm storage conditions, or mishandling during operation and maintenance. These conditions can cause damage or premature deterioration. Some hoses are more susceptible to these conditions than others. Inspect the hoses frequently for signs of deterioration or damage.
SAE Straight Thread O–Ring Port – Non–adjustable 1. Make sure both threads and sealing surfaces are free of burrs, nicks, scratches, or any foreign material. 2. Always replace the O–ring seal when this type of fitting shows signs of leakage. O–Ring 3. Lubricate the O–ring with a light coating of oil. 4. Install the fitting into the port and tighten it down full length until finger tight. 5. Tighten the fitting to the correct Flats From Finger Tight (F.F.F.T.). Size 4 (1/4 in.
Pushing/Pulling Machine IMPORTANT: If push/pull limits are exceeded, severe damage to the piston (traction) pump may occur. If it becomes necessary to push/pull the machine, push/ pull at a speed below 1 mph (1.6 kph), and for a distance less than 100 feet (30.5 meters). The piston (traction) pump is equipped with a by–pass valve that needs to be rotated counterclockwise (loosened) one turn for pushing/pulling. The by–pass valve should be torqued from 95 to 120 in–lb (10.7 to 13.
Hydraulic Schematic LIFT CYLINDER ORF1 CYL SVR SVL R1 SVQ G1 R2 PV CHG G2 FORWARD CONTROL MANIFOLD T Hydraulic System P FRONT WHEEL ’B’ PORT (BOTTOM) ’P’ PORT M1 ’P’ PORT ’P’ PORT P2 P1 M2 M3 ’A’ PORT (TOP) COMPONENT P1 P2 PV R1 R2 M1 M2 M3 ORF1 CIR GPM PSI .98 .37 ---23.8 12.1 12.1 .050 10.5 4.1 -------- 2900 -40 1000 40 ----- ProCore 648 Hydraulic Schematic All solenoids are shown as de--energized ProCore 648 Page 4 -- 7 Rev.
Hydraulic Flow Diagrams LIFT CYLINDER ORF1 CYL SVR (NOT ENERGIZED) SVL (NOT ENERGIZED) R1 G1 R2 SVQ (NOT ENERGIZED) PV P CHG G2 FORWARD CONTROL MANIFOLD T FRONT WHEEL ’B’ PORT (BOTTOM) ’P’ PORT M1 ’P’ PORT ’P’ PORT P2 P1 M2 M3 ’A’ PORT (TOP) Traction Circuit (Forward Shown) Working Pressure Low Pressure (Charge) Return or Suction Flow Hydraulic System Page 4 -- 8 Rev.
Traction Circuit The traction (piston) pump (P1) is driven by the engine through the pulleys and pump drive belt. The traction circuit of the hydraulic system acts essentially as a closed loop. Taking its suction directly from the return side of the wheel motors of the traction circuit, the traction (piston) pump supplies oil flow to the wheel motors through the supply side of the traction circuit. The gear pump (P2) is attached to the traction pump and is directly coupled to it.
ORF1 CYL R1 SVL (NOT ENERGIZED) SVR (ENERGIZED) G1 R2 SVQ (ENERGIZED) PV P CHG LIFT CYLINDER (EXTENDING) CORING HEAD RAISE CONTROL MANIFOLD G2 T TO TRACTION PUMP FROM GEAR PUMP ORF1 CYL LIFT CYLINDER (RETRACTING) SVL (ENERGIZED) R1 SVR (NOT ENERGIZED) G1 R2 SVQ (ENERGIZED) CONTROL MANIFOLD PV P CHG CORING HEAD LOWER G2 T Coring Head Raise/Lower Circuits FROM GEAR PUMP Hydraulic System Working Pressure Low Pressure (Charge) Return or Suction Flow TO TRACTION PUMP Page 4 – 10 P
Coring Head Raise/Lower Circuits The gear pump (P2) is attached to the traction pump (P1) and is directly coupled to it. The gear pump supplies hydraulic flow for maintaining charge pressure of 40 PSI (2.8 Bar) to the low pressure side of the traction circuit and also for raising the aerator coring head. The gear pump takes its suction from the hydraulic reservoir. When the coring head reaches the aerating position, solenoid valves SVQ and SVL in the hydraulic manifold are de–energized.
Special Tools Order these special tools from your Toro Distributor. Hydraulic Pressure Test Kit Toro Part Number: TOR47009 Use to take various pressure readings for diagnostic tests. Quick disconnect fittings provided attach directly to mating fittings on machine test ports without tools. A high pressure hose is provided for remote readings. Contains one each: 1000 PSI (70 Bar), 5000 PSI (350 Bar) and 10000 PSI (700 Bar) gauges. Use gauges as recommended in Testing section of this chapter.
Hydraulic Test Fitting Kit Part Number: TOR4079 TORO TEST FITTING KIT (NO. TOR4079) This kit includes a variety of O–ring Face Seal fittings to enable connection of test gauges to the ProCore 648 hydraulic system. The kit includes: tee’s, unions, reducers, plugs, caps, and male test fittings. Figure 11 Wheel Hub Puller Part Number: TOR4097 Hydraulic System The wheel hub puller allows safe removal of the wheel hub from the shaft of wheel motors.
Troubleshooting The cause of an improperly functioning hydraulic system is best diagnosed with the use of proper testing equipment and a thorough understanding of the complete hydraulic system. A hydraulic system with an excessive increase in heat or noise has a potential for failure. Should either of these conditions be noticed, immediately stop the machine, turn off the engine, locate the cause of the trouble, and correct it before allowing the machine to be used again.
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Testing The most effective method for isolating problems in the hydraulic system is by using hydraulic test equipment such as pressure gauges and flow meters in the circuits during various operational checks (see Special Tools section in this Chapter). 2. Put caps or plugs on any hydraulic lines left open or exposed during testing or removal of components.
Charge Pressure Test (Using Pressure Gauge) LIFT CYLINDER ORF1 CYL SVR SVL R1 SVQ G1 R2 PV P CHG G2 CONTROL MANIFOLD T PRESSURE GAUGE FORWARD FRONT WHEEL ’B’ PORT (BOTTOM) ’P’ PORT M1 ’P’ PORT P2 P1 M2 ’P’ PORT M3 ’A’ PORT (TOP) Working Pressure Low Pressure (Charge) Return or Suction Flow Direction Figure 13 Hydraulic System Page 4 -- 18 Rev.
Procedure for Charge Pressure Test: 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes. 2. Park machine on a level surface with the coring head fully raised. Make sure engine is off and the parking brake is engaged. Secure coring head with service latch. 3. Read Precautions For Hydraulic Testing in this section. C.
Coring Head Raise/Lower Relief (R1) Pressure Test (Using Pressure Gauge) LIFT CYLINDER ORF1 CYL PRESSURE GAUGE SVR (ENERGIZED) R1 G1 R2 SVL (NOT ENERGIZED) SVQ (ENERGIZED) PV P CHG CONTROL MANIFOLD T G2 FRONT WHEEL ’B’ PORT (BOTTOM) FORWARD ’P’ PORT M1 ’P’ PORT P2 P1 M2 ’P’ PORT M3 ’A’ PORT (TOP) Working Pressure Low Pressure (Charge) Return or Suction Flow Direction Figure 15 Hydraulic System Page 4 -- 20 Rev.
1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes. 2. Park machine on a level surface with the coring head fully raised. Make sure engine is off and the parking brake is engaged. 3. Read Precautions For Hydraulic Testing in this section. CAUTION Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil. C.
Traction (Piston) Pump (P1) Flow Test (Using Tester With Flow Meter and Pressure Gauge) LIFT CYLINDER ORF1 CYL SVR SVL R1 G1 SVQ R2 PV P CHG G2 FORWARD CONTROL MANIFOLD T FRONT WHEEL TESTER ’B’ PORT (BOTTOM) ’P’ PORT M1 ’P’ PORT P2 P1 M2 ’P’ PORT M3 ’A’ PORT (TOP) Working Pressure Low Pressure (Charge) Return or Suction Flow Direction Figure 18 Procedure for Traction (Piston) Pump (P1) Flow Test: 3. Read Precautions For Hydraulic Testing in this section. 1.
7. Attach a heavy chain to the rear of the machine frame and something immovable in the shop to prevent the machine from moving during testing. CAUTION Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil. 8. Clean hose fitting and disconnect hydraulic hose from the lower 45o fitting on the rear side of the traction pump (Fig. 19). NOTE: An alternate testing location would be at the hydraulic hose connection to the P1 port of the front wheel motor.
Traction Circuit Relief Pressure Test (Using Tester With Flow Meter and Pressure Gauge) LIFT CYLINDER ORF1 CYL SVR SVL R1 G1 SVQ R2 PV P CHG G2 CONTROL MANIFOLD T PRESSURE GAUGE FORWARD FRONT WHEEL ’B’ PORT (BOTTOM) ’P’ PORT M1 ’P’ PORT P2 P1 M2 ’P’ PORT M3 ’A’ PORT (TOP) Working Pressure Low Pressure (Charge) Return or Suction Flow Direction NOTE: FORWARD TRACTION CIRCUIT RELIEF PRESSURE TEST IS SHOWN Figure 20 Hydraulic System Page 4 -- 24 Rev.
Procedure for Traction Circuit Relief Pressure Test: 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes. Make sure that traction lever is adjusted to the neutral position (see Operator’s Manual). 2. Park machine on a level surface with the coring head fully raised. Make sure engine is off and parking brake is engaged. Secure coring head with service latch. 3. Read Precautions For Hydraulic Testing in this section. 4.
Gear Pump (P2) Flow Test (Using Tester With Flow Meter and Pressure Gauge) LIFT CYLINDER ORF1 CYL SVR SVL R1 SVQ G1 R2 PV P CHG G2 CONTROL MANIFOLD T TESTER FORWARD FRONT WHEEL ’B’ PORT (BOTTOM) ’P’ PORT M1 ’P’ PORT ’P’ PORT P2 P1 M2 M3 ’A’ PORT (TOP) Working Pressure Low Pressure (Charge) Return or Suction Flow Direction Figure 22 Hydraulic System Page 4 -- 26 Rev.
1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes. 2. Park machine on a level surface with the coring head fully raised. Make sure engine is off and the parking brake is engaged. Secure coring head with service latch. 3. Read Precautions For Hydraulic Testing in this section. CAUTION Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil. 7.
Wheel Motor Efficiency Test (Using Tester With Flow Meter and Pressure Gauge) LIFT CYLINDER ORF1 CYL SVR SVL R1 G1 SVQ R2 PV P CHG G2 CONTROL MANIFOLD T TEST CONNECTION FOR REAR WHEEL MOTOR SHOWN FORWARD FRONT WHEEL ’B’ PORT (BOTTOM) ’P’ PORT CAP P2 P1 M1 ’P’ PORT M2 TESTER ’P’ PORT M3 CAP ’A’ PORT (TOP) Working Pressure Low Pressure (Charge) Return or Suction Flow Direction Figure 24 NOTE: Over a period of time, a wheel motor can wear internally.
Procedure for Wheel Motor Efficiency Test: 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes. Make sure the hydraulic reservoir is full. 2. Make sure that traction lever is adjusted to the neutral position (see Operator’s Manual). 3. Park machine on a level surface with the coring head fully raised. Make sure engine is off and the parking brake is engaged. Secure coring head with service latch.
Service and Repairs General Precautions for Removing and Installing Hydraulic System Components Before Repair or Replacement of Components After Repair or Replacement of Components 1. Before removing any parts from the hydraulic system, park machine on a level surface, fully raise coring head, engage parking brake, stop engine and remove key from the ignition switch. Secure coring head with service latch. 1. Check oil level in the hydraulic reservoir and add correct oil if necessary.
Flush Hydraulic System IMPORTANT: Flush the hydraulic system any time there is a severe component failure or the system is contaminated (oil appears milky or black or contains metal particles). 9. Reattach both spark plug wires. IMPORTANT: Flush hydraulic system when changIng from petroleum base hydraulic fluid, such as Mobil 424, to biodegradable fluid, such as Mobil EAL Envirosyn H. Operate machine under normal operating conditions for at least four (4) hours before draining. 11.
Hydraulic System Start--up NOTE: When initially starting the hydraulic system with new or rebuilt components such as the hydraulic pump, wheel motors or lift cylinder, it is important that this start-up procedure be used. This procedure reduces the chance of damaging the hydraulic system or its components from not purging the system of air. 1.
10.Start engine and operate the traction system at varying speeds for a 10 minute period. 1 11. Stop the machine. Check hydraulic reservoir level and fill if necessary. Check hydraulic components for leaks and tighten any loose connections. 2 Figure 27 2. Hydraulic manifold Hydraulic System 1. Test port ProCore 648 Page 4 -- 33 Rev.
Hydraulic Pump Drive Belt 4 FRONT RIGHT 6 7 2 5 8 3 9 10 11 1 Anti–seize lubricant 12 16 17 13 15 14 Figure 27 1. 2. 3. 4. 5. 6. Flange nut (2 used) Hydraulic (traction/charge) pump Key Engine Engine pulley Flange head screw Hydraulic System 7. 8. 9. 10. 11. 12. Spring bracket Idler support bracket Idler pulley Flange nut Tensioning spring Set screw Page 4 – 34 13. 14. 15. 16. 17.
Drive Belt Removal (Fig. 27) Drive Belt Installation (Fig. 27) 1. Park machine on a level surface, fully raise coring head, engage parking brake, stop engine and remove key from the ignition switch. Secure coring head with service latch. 1. Install pump drive belt to pulleys. 2. Lift idler pulley and insert pump drive belt under idler. 3. Allow tensioning spring to apply tension to idler pulley. Tighten flange head screw (item 6) and flange nut (item 10) to secure belt adjustment. 3.
Hydraulic Pump Control Assembly 13 16 12 17 18 15 21 19 22 11 23 20 14 24 10 7 19 3 28 Loctite #242 3 29 6 28 30 9 5 8 35 31 32 3 36 33 34 37 25 1 27 4 19 31 26 Loctite #242 29 3 RIGHT FRONT 2 Figure 28 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Hydraulic pump Cap screw (2 used) Flange nut Lock nut Flange nut (2 used) Control bracket Washer head screw Lock nut Extension spring Speed selector pivot Retaining ring Swivel Cap screw Hydraulic System 14. 15. 16. 17. 18. 19.
Disassembly (Fig. 28) 10 1. Park machine on a level surface, fully raise coring head, engage parking brake, stop engine and remove key from the ignition switch. Secure coring head with service latch. 7 11 10 8 6 5 2. Remove pump belt cover from machine (see Operator’s Manual). 4 9 3. Remove two (2) lock nuts that secure pump shield to pump (Fig. 29). Remove shield from pump. Locate and retrieve two (2) flat washers from tops of studs on pump control assembly.
Hydraulic (Traction/Charge) Pump 5 FRONT 4 RIGHT 3 2 7 1 29 6 8 9 19 21 10 30 11 2 25 12 28 24 27 2 22 23 26 19 24 20 13 21 Anti–seize lubricant 18 17 14 16 15 Figure 31 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Hydraulic (traction/charge) pump O–ring O–ring 90o hydraulic fitting Engine Engine pulley Flange head screw Spring bracket Idler support bracket Idler pulley 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
2. Remove pump belt cover from machine (see Operator’s Manual). 3. Loosen the flange head screw (item 7) and flange nut (item 11) that secure the drive belt idler pulley (item 10). Lift idler pulley to allow removal of drive belt from the hydraulic pump pulley. IMPORTANT: Before loosening pump pulley, mark position of the pulley on the hydraulic pump shaft. Pulley position is critical for proper alignment of the hydraulic pump drive belt. 8.
Installation (Fig. 31) 1. Install hydraulic fittings with new o–rings to the hydraulic pump. Orientate the fittings as noted during disassembly. CAUTION 7. Place two (2) flat washers to tops of studs on pump control assembly. Position pump shield to pump and secure with two (2) lock nuts. 8. Lift idler pulley and install drive belt to the pump pulley. Adjust drive belt tension (see Operator’s Manual). 9. Install pump belt cover to machine (see Operator’s Manual).
Hydraulic (Traction/Charge) Pump Service 23 1 24 22 2 5 21 19 20 3 4 9 6 7 14 8 10 18 12 11 13 15 17 26 31 25 32 28 29 27 30 Figure 34 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Retaining ring Seal Spacer Pump shaft kit Pump housing Thrust washer Spring block Nut (4 used) Trunnion seal kit Pin (2 used) O–ring 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.
Wheel Motors 190 to 230 ft–lb (258 to 312 N–m) 2 3 1 4 5 6 7 8 12 11 20 10 9 13 19 2 18 7 45 to 55 ft–lb (61 to 75 N–m) 190 to 230 ft–lb (258 to 312 N–m) 14 12 15 4 10 16 6 RIGHT 17 8 45 to 55 ft–lb (61 to 75 N–m) FRONT 15 12 16 9 17 Figure 35 1. 2. 3. 4. 5. 6. 7. Rear wheel motor (LH shown) Woodruff key Parking latch support (2 used) Stud (4 used per wheel) Parking latch disc (2 used) Wheel hub Lock nut 8. 9. 10. 11. 12. 13. 14.
2. Remove wheel from machine (see Wheel Removal in Service and Repairs section of Chapter 6 – Chassis). IMPORTANT: To prevent damage to hydraulic motor, DO NOT hit wheel hub or motor with a hammer during wheel hub removal or installation. 3. If rear wheel motor was removed, slide parking latch link through parking latch bar and secure with hair pin (Fig. 36). 4. Remove caps or plugs that were put on any hydraulic lines or fittings during disassembly. 3. Loosen nut that secures wheel hub to motor shaft.
Wheel Motor Service 1 2 3 4 6 5 6 7 8 9 10 11 12 13 16 14 15 18 19 20 22 17 21 Figure 37 1. 2. 3. 4. 5. 6. 7. 8. Dust seal Housing O–ring Shaft seal Axial needle bearing Bearing race Needle bearing Shaft 9. 10. 11. 12. 13. 14. 15. NOTE: The three wheel motors on the ProCore 648 are similar in construction but are different from each other. The front wheel motor (24 c.i.
Hydraulic System This page is intentionally blank.
Hydraulic Lift Control Manifold 2 3 4 1 RIGHT FRONT 5 Figure 38 1. Main frame 2. Cap screws (2 used) Hydraulic System 3. Hydraulic lift control manifold 4. Hydraulic oil filter Page 4 – 46 5.
3. Remove caps or plugs that were put on any hydraulic lines or fittings during disassembly. Removal (Fig. 38) 1. Park machine on a level surface, fully raise coring head, engage parking brake, stop engine and remove key from the ignition switch. Secure coring head with service latch. 4. Lightly oil new o–rings for hydraulic fitting and hose locations. 5. Correctly connect hydraulic fittings and lines to the manifold. Tighten all hydraulic fittings and connections. CAUTION 6.
Hydraulic Lift Control Manifold Service 5 ft–lb (6.8 N–m) 5 ft–lb (6.8 N–m) 9 5 6 6 25 ft–lb (33.9 N–m) 20 ft–lb (27.1 N–m) 7 8 11 4 3 20 ft–lb (27.1 N–m) 10 120 in–lb (13.6 N–m) 2 12 1 13 20 ft–lb (27.1 N–m) 15 14 Figure 40 1. 2. 3. 4. 5. Hydraulic lift control manifold O–ring Quick fitting (2 used) Solenoid valve (SVL port) Nut 6. 7. 8. 9. 10.
Hydraulic Manifold Service CAUTION 1. Make sure the manifold is clean before removing any cartridge valve. CAUTION Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil. See Relieving Hydraulic System Pressure in the General Information section of this chapter. Abrupt movement of internal spools can cause stored fluid to be released suddenly. 6. Clean cartridge valve by submerging valve in clean mineral spirits to flush out contamination.
Lift Cylinder 5 6 4 RIGHT FRONT 3 15 7 9 10 11 14 12 10 2 17 8 9 16 13 9 18 1 11 9 Figure 41 1. 2. 3. 4. 5. 6. Main frame Shackle (4 used) Extension spring (2 used) Carriage screw (4 used) Spring plate (2 used) Flange nut (4 used) 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. Clevis pin (4 used) Hair pin (4 used) Retaining ring Thrust washer Cylinder pin Spacer (2 used) Removal (Fig. 41) Lift cylinder O–ring Hydraulic fitting O–ring Hydraulic hose Coring head frame 4.
5. Start engine and allow coring head to fully raise. Turn engine off. Secure coring head with service latch. 5. Remove plugs from disconnected hose and fitting. 6. Connect hydraulic hose with new o–ring to hydraulic fitting on lift cylinder. Tighten hose connection. CAUTION 7. Install disconnected extension spring to machine in reverse order of disassembly. Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil.
Lift Cylinder Service 4 2 5 6 7 8 9 3 1 Figure 44 1. Retaining ring 2. Cylinder tube 3. Rod 4. O–ring 5. Backup ring 6. Retaining ring Disassembly (Fig. 44) 1. Remove oil from the lift cylinder into a drain pan by slowly pumping the cylinder rod. Plug port and clean the outside of the lift cylinder. 7. Seal 8. Head 9. Wiper 5. Mount rod securely in a vise by clamping vise on the flats of the pivot. Remove retaining ring (item 1) and carefully slide head from the shaft. 6.
Inspection CAUTION Spanner wrench Use eye protection such as goggles when using compressed air 1. Wash all parts in solvent. Dry parts with compressed air. 2. Inspect internal surface of tube for deep scratches, out–of–roundness and bending. Replace if worn or damaged. Retaining ring (Offset end against left side of barrel groove after installing) Figure 46 3. Inspect rod and head for excessive pitting, scoring or wear. Replace any worn or damaged parts. Assembly (Fig. 44) 1.
Hydraulic Reservoir 5 4 6 7 3 8 2 9 1 19 18 10 12 11 12 17 FRONT 14 12 16 RIGHT 13 15 Figure 47 1. 2. 3. 4. 5. 6. 7. Hydraulic reservoir Dipstick Cap Shoulder screw Tank strap Cap screw J clip 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. Flat washer Frame O–ring Hydraulic adapter O–ring Hydraulic tube Inspecting Reservoir (Fig. 47) Hydraulic tube Suction hose Hose clamp Hydraulic barb fitting Hydraulic tee fitting O–ring 3.
Chapter 5 Electrical System Table of Contents ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . 1 CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 2 OK to Lower Circuit . . . . . . . . . . . . . . . . . . . . . . . . . 2 Lockout Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Electric Clutch Circuit . . . . . . . . . . . . . . . . . . . . . . . . 6 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 TROUBLESHOOTING . . . . . . . . .
Circuit Operation NOTE: This section provides information concerning three sequential, electrical circuits that are used on the ProCore 648. Use these descriptions along with the electrical diagrams and schematics found in Chapter 8 – Electrical Diagrams to better understand circuit operation. OK to Lower Circuit (Fig. 1) The ”OK to lower” circuit is one of the inputs used by the aerator control module to allow current output to the raise and lower hydraulic solenoid valves (SVL, SVR and SVQ).
TO IGNITION SWITCH TERMINAL ”L” TRACTION LEVER IN NEUTRAL OR REVERSE CONTROL MODULE ”OK TO LOWER” LED IS NOT ILLUMINATED GROUND TO AERATOR CONTROL MODULE OK TO LOWER (NOT ENERGIZED) (IN RAISE POSITION) (ENERGIZED) GROUND TO LOCKOUT CIRCUIT TO IGNITION SWITCH TERMINAL ”L” BEGIN AERATING (TRACTION LEVER IN FORWARD) TO AERATION #3 PROX.
Lockout Circuit (Fig. 2) The lockout circuit is used on the ProCore to provide current for the raise and lower hydraulic solenoid valves (SVL, SVR and SVQ). This circuit is composed of the transport limit #2 proximity switch, the lockout relay, the lockout latch relay, the lift/reset switch and diode D2. When this circuit is closed, current is provided to the aerator control module to allow energizing of the solenoid valves. Lockout circuit protection is provided by fuse F3.
CORING HEAD RAISED TO AERATOR CONTROL MODULE TO IGNITION SWITCH TERMINAL ”L” GROUND (ENERGIZED) (ENERGIZED) (NOT PRESSED) TO ELECTRIC CLUTCH TO IGNITION SWITCH TERMINAL ”A” AERATING TO AERATOR CONTROL MODULE TO IGNITION SWITCH TERMINAL ”L” GROUND (ENERGIZED) (ENERGIZED) (NOT PRESSED) TO ELECTRIC CLUTCH Electrical System TO IGNITION SWITCH TERMINAL ”A” CORING HEAD STRANDED TO AERATOR CONTROL MODULE TO IGNITION SWITCH TERMINAL ”L” GROUND (ENERGIZED) (ENERGIZED) (PRESSED) TO ELECTRIC CLUTCH TO I
Electric Clutch Circuit (Fig. 3) The electric clutch circuit is used on the ProCore to provide current for the electric clutch which rotates the coring crankshaft. This circuit is composed of the aeration #3 proximity switch, the clutch relay, the electric clutch and diode D3. The electric clutch circuit relies on the operation of the ”OK to lower” circuit for completing the clutch circuit (See OK to Lower Circuit in this section). Electric clutch circuit protection is provided by fuse F2.
Special Tools Multimeter The multimeter can test electrical components and circuits for current (amps), resistance (ohms) or voltage. NOTE: Toro recommends the use of a DIGITAL Volt– Ohm–Amp multimeter when testing electrical circuits. The high impedance (internal resistance) of a digital meter in the voltage mode will make sure that excess current is not allowed through the meter. This excess current can cause damage to circuits not designed to carry it.
Troubleshooting For effective troubleshooting and repairs, you must have a good understanding of the electrical circuits (see Chapter 8 – Electrical Diagrams) and components used on this machine. CAUTION Remove all jewelry, especially rings and watches, before doing any electrical troubleshooting or testing. Disconnect the battery cables unless the test requires battery voltage. If the machine has any interlock switches by–passed, they must be reconnected for proper troubleshooting and safety.
Starting Problems (continued) Problem Possible Causes Engine cranks, but does not start. Circuit wiring to engine magneto is grounded (see Chapter 8 – Electrical Diagrams). Circuit wiring to carburetor solenoid is loose, corroded, or damaged (see Chapter 8 – Electrical Diagrams). Engine or fuel system is malfunctioning (see Chapter 3 – Kohler Engine). Engine may be too cold. Engine cranks (but should not) with the traction lever out of the neutral position.
Coring Head Operating Problems Problem Possible Causes Coring head runs (but should not) when raised. Aeration #3 proximity switch is faulty or out of adjustment. Coring head does not lower. Fuse F3 (10 Amp) or F4 (2 Amp) is/are faulty. Raise/lower switch is faulty. SVL valve solenoid is faulty. Aerator Control Module is faulty. ”OK to lower” circuit is not functioning (see OK to Lower Circuit in Circuit Operation section of this chapter). Hydraulic problem exists (see Chapter 4 – Hydraulic System).
Electrical System Quick Checks Battery Test (Open Circuit Test) Use a multimeter to measure the voltage between the battery terminals. Voltage Measured Battery Charge Level 12.68 v (or higher) Fully charged (100%) Set the multimeter to the DC volts setting. The battery should be at a temperature of 60o to 100o F (16o to 38o C). The ignition key should be in the OFF position and all accessories turned off.
Check Operation of Safety Interlock System The Safety Interlock System of the ProCore 648 ensures the following operations: CAUTION Do not disconnect interlock switches. They are for the operator’s protection. Check operation of the switches daily to make sure the interlock system is operating correctly. If a switch is not operating properly, adjust or replace it before operating the machine. Interlock switch operation is described in the ProCore 648 Operator’s Manual.
Component Testing For accurate resistance and/or continuity checks, electrically disconnect the component being tested from the circuit (e.g. unplug the ignition switch connector before doing a continuity check). NOTE: Electrical troubleshooting of any 12 Volt power connection can be performed through voltage drop tests without disconnecting the component. NOTE: See the Kohler Engine Service Manual for engine component testing information.
Engine Oil Pressure Indicator Light The engine oil pressure indicator light is located on the handle control panel (Fig. 10). The indicator light should come on when the ignition switch is in the ON position with the engine not running. Also, it should light with the engine running if the engine oil pressure is insufficient. 1 IMPORTANT: If the engine oil pressure indicator light comes on when the engine is running, shut engine off immediately. Testing 1. Turn the ignition switch to ON.
Relays Six (6) relays are used on the ProCore 648. Four (4) of these relays are attached under the control panel next to the battery (Fig. 13): lockout relay, clutch relay, neutral switch (start) relay and lockout latch relay. The remaining two (2) relays are attached under the handle console (Fig. 14): neutral switch (latch) relay and latching relay. The six relays are identical. The relays are identified by a tag on the wire harness relay connector.
Manual Raise/Lower Switch The manual raise/lower switch is located on the handle control panel (Fig. 16). This rocker switch is one of the components in the ”OK to lower” circuit which is one of the aerator control module inputs. See OK to Lower Circuit in the Circuit Operation section of this chapter for additional raise/lower switch information. 1 The switch terminals are marked as shown in Figure 17. The circuitry of the raise/lower switch is shown in the chart below.
Ground Follow Switch The ground follow switch is located on the side of the control panel (Fig. 18). This rocker switch allows the True CoreTM ground following system to be turned on/ off. The switch is retained in position by a cap screw and nut placed in the switch guard to prevent accidental switch movement. In the normal, upper switch position, the True CoreTM ground following system is ON. The True CoreTM ground following system is OFF when the switch is in the lower position.
Lift Reset Switch The lift reset switch is located on the control panel (Fig. 21). This momentary rocker switch raises the coring head in instances when the coring head has been stranded in the aerating (lowered) position (e.g. engine runs out of gas, coring head stuck). By depressing the lift reset switch, the coring head lift system will reset, the coring head will raise fully and normal coring head operation can resume. The switch terminals are marked as shown in Figure 19.
Solenoid Valve Coil The hydraulic system on the ProCore 648 uses three (3) solenoid valve coils on the hydraulic lift control manifold (Fig. 23). The aerator control module provides current to the solenoid valve coils based on the position of several inputs. A LED on the aerator control module will be illuminated when the solenoid valve coils are energized (Fig. 24). 3 4 2 NOTE: The solenoid does not have to be removed from the cartridge valve for testing. 1.
Head Low and Head High Limit Switches The head low and head high limit switches are attached to the coring depth control housing (Fig. 25). These switches are normally open and close when the switch actuator in the housing is rotated past the switch. The head low and head high limit switches provide inputs for the True CoreTM ground following system on the ProCore 648. 3 1 The Aerator Control Module monitors the operation of the head low and head high limit switches.
Fuses The fuse block is located behind the console cover (Fig. 27). 1 Identification, Function, and Wiring The fuses are held in the fuse block. Use Figure 28 to identify each individual fuse and its correct amperage. Each fuse holder has the following functions: Fuse 1 (20 Amp): Supplies power to ignition switch terminal B. Fuse 2 (10 Amp): Supplies power to electric clutch. Fuse 3 (10 Amp): Supplies power from ignition switch terminal S. Fuse 4 (2 Amp): Supplies power to aerator control module.
Proximity Switches The ProCore 648 uses six (6) identical proximity switches. These switches are normally open switches that close when a sensing plate is positioned near the target end of the switch (Fig. 32). 3 The reverse and neutral proximity switches are mounted on the control handle under the handle console (Fig. 29). They use sensing plates pinned to the traction lever.
Proximity Switch Test 1. Park machine on a level surface, fully raise coring head, engage parking brake, stop engine and remove key from the ignition switch. Secure coring head with service latch. 3 4 5 2 2. Locate proximity switch to be tested. Disconnect proximity switch from machine wiring harness. Tab 3. Check the continuity of the switch by connecting a multimeter (ohms setting) across the switch connector terminals.
Aerator Control Module The ProCore 648 is equipped with an Aerator Control Module to monitor and control electrical components required for safe operation. This Module is located on the inside of the console cover (Fig. 33). 2 Inputs from the start (ignition), head low limit, head high limit, transport limit #1 proximity switch, aeration #4 proximity switch and ground follow switches are monitored by the Module. The condition (open or closed) of the ”OK to lower” circuit is also monitored by the Module.
3. The SVR output LED will be illuminated in two situations: Control Module Outputs 1. The SVQ output LED will be illuminated in two situations: A. Both ”OK to lower” and transport #1 LED’s are not illuminated. A. Both ”OK to lower” and transport #1 LED’s are not illuminated. B. ”OK to lower”, ground follow, aerate #4 and head low limit LED’s are all illuminated. B. ”OK to lower” LED is illuminated and aerate #4 LED is not illuminated. 2. The SVL output LED will be illuminated in three situations: A.
Electric Clutch An electric clutch is used to engage the coring head on the ProCore 648. The electric clutch is mounted on the engine crankshaft and engages when current is applied to the clutch. The clutch also incorporates a magnetic brake to stop clutch rotation when the clutch is de–energized. 8. As an additional test, apply 12 volts to the terminals of the clutch. The clutch should engage. If clutch does not engage when voltage is applied, replace clutch.
Diode Assemblies Diodes D1, D2 and D3 provide logic for the latch relays used in the ProCore 648. Diode D4 is used for circuit protection from voltage spikes when the electric clutch is de–energized. The diodes plug into the wiring harness at various locations (see Wire Harness Drawings in Chapter 8 – Electrical Diagrams). 2 Diode Test 3 1 The diodes (Fig. 37) can be individually tested using a digital multimeter (diode test or ohms setting) and the table to the right. Figure 37 1. Diode 2.
Service and Repairs NOTE: See the Kohler Engine Service Manual for engine component repair information. Battery Storage If the machine will be stored for more than 30 days: 1. Remove the battery and charge it fully (see Battery Service). 2. Either store battery on a shelf or on the machine. 4. Store battery in a cool atmosphere to avoid quick deterioration of the battery charge. 5.
Battery Service The battery is the heart of the electrical system. With regular and proper service, battery life can be extended. Additionally, battery and electrical component failure can be prevented. 2 1 CAUTION When working with batteries, use extreme caution to avoid splashing or spilling electrolyte. Electrolyte can destroy clothing and burn skin or eyes. Always wear safety goggles and a face shield when working with batteries. Figure 38 1.
Testing 1. To properly test a battery, perform a high–discharge test using an adjustable load tester. This is one of the most reliable means of testing a battery as it simulates the cold–cranking test. A commercial battery load tester is required to perform this test. 2. If a battery load tester is not available, the battery can be tested by conducting a hydrometer test of the battery electrolyte. IMPORTANT: Make sure the area around the cells is clean before opening the battery caps. A.
Charging To minimize possible damage to the battery and allow the battery to be fully charged, the slow charging method is presented here. This charging method can be accomplished with a constant current battery charger which is available in most shops. CAUTION Follow the manufacturer’s instructions when using a battery charger. NOTE: Using specific gravity of the battery cells is the most accurate method of determining battery condition. 1.
Electric Clutch 13 14 15 16 FRONT 17 18 RIGHT 19 21 22 18 23 24 20 12 5 25 5 11 10 7 6 6 8 1 9 2 3 8 4 7 6 50 to 55 ft–lb (67.8 to 74.6 N–m) Figure 39 1. 2. 3. 4. 5. 6. 7. 8. 9. Drive belt Electric clutch Hardened washer Cap screw Flange nut Flat washer Brake grommet Cap screw Spacer Electrical System 10. 11. 12. 13. 14. 15. 16. 17. Clutch strap Idler mounting bracket Lock nut Cap screw Hardened washer Idler pulley Torsion spring Spacer Page 5 – 32 18. 19. 20. 21. 22. 23. 24. 25.
Removal (Fig. 39) 1. Park machine on a level surface, fully raise coring head, engage parking brake, stop engine and remove key from the ignition switch. Secure coring head with service latch. 1 2. Remove pump belt cover from machine (see Operator’s Manual). 4 5 3. Remove muffler heat shield (see Exhaust System in the Service and Repairs section of Chapter 3 – Kohler Engine). 2 4. Unplug wiring harness connector from clutch. 5.
Solenoid Valve Coil A solenoid valve coil on the hydraulic lift control manifold (Fig. 41) can be replaced without opening the hydraulic system. 5 ft–lb (6.8 N–m) 5 ft–lb (6.8 N–m) 4 Removal 1. Park machine on a level surface, fully raise coring head, engage parking brake, stop engine and remove key from the ignition switch. Secure coring head with service latch. 1 5 2 3 2. Disconnect the wiring harness electrical connector from the solenoid coil to be replaced. 3.
Chapter 6 Chassis Table of Contents Chassis SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 4 Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Parking Brake Cable . . . . . . . . . . . . . . . . . . . . . . . . 8 Steering Assembly . . . .
Specifications Item Description Front and Rear Tires Size Pressure 19 x 10.5 – 8, 2 Ply, Tubeless 12 PSI (.
Special Tools Order special tools from your Toro Distributor. Wheel Hub Puller Part Number: TOR4097 The wheel hub puller allows safe removal of the wheel hub from the shaft of wheel motors. Chassis Figure 1 ProCore 648 Page 6 -- 3 Rev.
Service and Repairs Wheels 12 11 10 1 9 8 2 45 to 55 ft–lb (61 to 75 N–m) 9 8 3 1 4 12 5 10 6 RIGHT 4 7 5 FRONT 2 45 to 55 ft–lb (61 to 75 N–m) 6 Figure 2 1. 2. 3. 4. Tire and wheel assembly Lug nut Front wheel weight Wheel weight adapter Chassis 5. 6. 7. 8. Weight stud Thrust washer Lock nut Bearing plate Page 6 – 4 9. 10. 11. 12.
Wheel Removal (Fig. 2) 2. If front wheel was removed: 1. Park machine on a level surface, fully raise coring head, engage parking brake, stop engine and remove key from the ignition switch. Secure coring head with service latch. A. If weight studs were removed from wheel weight adapters, thread studs fully into the correct end of the adapter (Fig. 3). B. Position front wheel to wheel hub. 2.
Parking Brake 3 6 7 1 2 4 5 2 5 10 190 to 230 ft–lb (258 to 312 N–m) 8 9 9 3 22 45 to 55 ft–lb (61 to 75 N–m) 20 9 11 14 12 13 21 19 18 RIGHT 15 17 16 FRONT Figure 4 1. 2. 3. 4. 5. 6. 7. 8. Extension spring Bushing Retaining ring Parking latch pivot Flange nut Shoulder bolt Compression spring Parking latch clevis Chassis 9. 10. 11. 12. 13. 14. 15. Hair pin Parking latch link Roll pin Parking latch bar Lock nut Tire and wheel assembly Lug nut (4 used per wheel) Page 6 – 6 16. 17.
Installation (Fig. 4) Removal (Fig. 4) 1. Park machine on a level surface, fully raise coring head, stop engine and remove key from the ignition switch. Secure coring head with service latch. 2. Make sure parking brake is disengaged. 3. Block front wheel. Jack or hoist rear of machine from ground and support machine with blocking or jack stands (see Operator’s Manual and Jacking Instructions in Chapter 1 – Safety). 4. Remove rear wheel assembly (see Wheel Removal in this section).
Parking Brake Cable 14 1 13 2 3 5 12 11 10 6 RIGHT 9 FRONT 8 4 7 Figure 5 1. 2. 3. 4. 5. Control handle Grommet Steering arm Lower handle cover Washer head screw (6 used) Chassis 6. 7. 8. 9. 10. Flange nut Brake cable Flat washer Cotter pin Brake lever Page 6 – 8 11. 12. 13. 14.
Removal (Fig. 3) 1. Park machine on a level surface, fully raise coring head, stop engine and remove key from the ignition switch. Secure coring head with service latch. Make sure that parking brake is not engaged. 5 2. Remove six (6) washer head screws that secure lower handle cover to control handle. Remove lower handle cover. 3. Loosen jam nut that secures parking brake cable to underside of control handle. 4. Remove cotter pin and flat washer that retain brake cable to brake lever.
Steering Assembly 36 5 35 6 34 37 7 33 32 31 8 1 4 9 2 30 10 3 11 19 12 26 18 22 4 29 28 20 26 8 15 27 25 7 24 RIGHT 17 14 23 13 22 FRONT 21 16 Figure 7 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Grommet Stud (3 used) Steering arm Cap screw (5 used) Slotted hex nut Washer Bearing cone Bearing cup Frame Steering stop Cap screw (2 used) Cable guide Cotter pin Chassis 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25.
E. Remove lock nut and cap screw that secure traction control cable to control lever. Locate and retrieve two (2) flat washers. Loosen jam nut that secures parking brake cable to underside of control handle. Disassembly (Fig. 7) 2. Block rear wheels. Jack front of machine from ground and support machine with blocking or jack stands (see Operator’s Manual and Jacking Instructions in Chapter 1 – Safety). 3. Remove front wheel assembly (see Wheel Removal in this section). 4.
Traction Control Cable Removal 1 1. Remove traction control cable from hydraulic pump control (Fig. 10) and traction lever on handle and (Fig. 11). 3 2 2. Remove traction control cable from machine noting routing of cable to aid in correct installation. 3. Disassemble traction control cable using Figure 9 as a guide. Installation 1. Assemble traction control cable using Figure 9 as a guide. Tighten lock nuts (item 6) so that compression spring (item 4) has a length from 7.190 to 7.310 inch (18.2 to 18.
Chapter 7 Coring Head Table of Contents Coring Head GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 2 Coring Head Operation . . . . . . . . . . . . . . . . . . . . . . . 2 Coring Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Coring Head Service Latch . . . . . . . . . . . . . . . . . . . . 3 Coring Head Adjustments . . . . . . . . . . . . . . . . . . . . . 3 SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 4 Rotolink Dampers . . . . . . . . . . . . . .
General Information Coring Head Operation The coring head of the Procore 648 consists of a frame that pivots for aerating depth control, a coring crankshaft, stomper arms with rotolinks to provide vertical tine motion, turf holders, tine holders and aerating tines. Drive for the coring head comes from the engine mounted electric clutch through a primary and secondary drive belt. The primary drive belt drives a jackshaft which in turn drives the coring crankshaft with the secondary drive belt.
Coring Head Service Latch Whenever service is to be performed on coring head components, fully raise coring head and install service latch (Fig. 3). Before using machine, remove service latch from coring head. 1 Figure 3 1. Service latch (in raised, locked position) Coring Head Adjustments See Operator’s Manual for adjustment procedures for the coring head on the ProCore 648. CAUTION Coring Head Never work on the coring head with the engine running.
Service and Repairs Rotolink Dampers 4 1 FRONT RIGHT 2 3 17 13 13 12 12 9 10 11 16 10 15 5 9 16 150 to 170 ft–lb (203 to 230 N–m) 8 14 7 6 10 Figure 4 1. 2. 3. 4. 5. 6. Lock nut Hardened D washer Flange head screw Stud Bumper plate Cap screw 7. 8. 9. 10. 11. 12. Lock nut Hardened washer Damper link Bearing Stomper arm Flange nut 13. 14. 15. 16. 17.
Disassembly (Fig. 4) Assembly (Fig. 4) 1. Park machine on a level surface, fully raise coring head, engage parking brake, stop engine and remove key from the ignition switch. Secure coring head with service latch. 1. If studs (item 4) were removed from damper (item 15), thread stud fully into damper. 2. Remove rotolink components as needed using Figure 4 as a guide. 2. If bearings were removed from damper links, press new bearings into links. 3.
Stomper Arms 3 150 to 170 ft–lb (203 to 230 N–m) 1 2 FRONT RIGHT 12 2 3 11 10 5 6 4 9 8 150 to 170 ft–lb (203 to 230 N–m) 5 4 7 3 ANTISIEZE LUBRICANT 2 STOMPER ARMS #1 AND #2 SHOWN 6 Figure 5 1. 2. 3. 4. Coring frame Cap screw Flat washer Retaining ring 5. 6. 7. 8. Ball bearing Stomper arm Pulley Bearing housing 9. 10. 11. 12. Crankarm Square key Coupling Spacer tube NOTE: The six (6) stomper arms used on the ProCore 648 are identical.
Removal (Fig. 5) Installation (Fig. 5 and 7) 1. Park machine on a level surface, fully raise coring head, engage parking brake, stop engine and remove key from the ignition switch. Secure coring head with service latch. 1. If removed, install ball bearing into upper end of stomper arm and secure with retaining ring. 2. Remove rear hood (see Operator’s Manual). 3. Remove two (2) lock nuts and hardened D washers that secure rotolink damper to coring head frame (see Rotolink Dampers in this section). 4.
Coring Crankshaft Bearing Housings 70 to 80 ft–lb (95 to 108 N–m) 150 to 170 ft–lb (203 to 230 N–m) 23 21 FRONT 24 RIGHT 7 1 5 21 20 22 150 to 170 ft–lb (203 to 230 N–m) 2 8 3 150 to 170 ft–lb (203 to 230 N–m) 11 2 1 6 4 70 to 80 ft–lb (95 to 108 N–m) 8 9 10 17 16 12 ANTISIEZE LUBRICANT 18 ANTISIEZE LUBRICANT 5 4 6 13 2 1 14 14 2 2 15 16 BEARING HOUSING FOR #5 AND #6 STOMPER ARMS SHOWN 150 to 170 ft–lb (203 to 230 N–m) 19 18 Figure 8 1. 2. 3. 4. 5. 6. 7. 8.
7. Disassemble bearing housing assembly: D. Lock nuts that secure rotolink dampers to frame (see Rotolink Damper Installation in this section). A. Remove cap screw (item 1) and flat washer (item 2) that fasten crankarms together. Take note of alignment of identification number on crankarm with timing mark on bearing housing (Fig. 9). 9. After assembly, rotate coring crankshaft by hand to make sure that no binding occurs. B. Slide crankarms from bearing housing. 10.
Primary Drive Belt 13 14 15 16 FRONT 17 18 RIGHT 19 21 22 18 23 24 20 12 5 25 5 11 10 7 6 6 8 1 9 2 3 8 4 7 6 50 to 55 ft–lb (67.8 to 74.6 N–m) Figure 11 1. 2. 3. 4. 5. 6. 7. 8. 9. Primary drive belt Electric clutch Hardened washer Cap screw Flange nut Flat washer Brake grommet Cap screw Spacer Coring Head 10. 11. 12. 13. 14. 15. 16. 17. Clutch strap Idler mounting bracket Lock nut Cap screw Hardened washer Idler pulley Torsion spring Spacer Page 7 – 10 18. 19. 20. 21. 22. 23. 24.
Removal (Fig. 11) Installation (Fig. 11) 1. Park machine on a level surface, fully raise coring head, engage parking brake, stop engine and remove key from the ignition switch. Secure coring head with service latch. 1. Position drive belt to machine pulleys. Make sure that belt is routed under idler pulley. 2. Remove belt cover (see Operator’s Manual). 3. Remove exhaust system shield (see Exhaust System Removal in the Service and Repairs section of Chapter 3 – Kohler Engine). 2.
Secondary Drive Belt 5 8 7 6 5 9 10 4 3 11 12 2 13 1 14 FRONT RIGHT 15 Figure 12 1. 2. 3. 4. 5. Secondary drive belt Cap screw Secondary pulley Cap screw Flange bushing 6. 7. 8. 9. 10. Idler pulley Idler pivot tube Idler arm Lock nut Carriage screw (2 used) 11. 12. 13. 14. 15. Flange nut (2 used) Idler spring arm Extension spring (2 used) Coring crankshaft pulley #1 stomper arm Removal (Fig. 12) 3 1.
NOTE: If desired, extension spring tension can be removed from idler pulley by loosening two (2) flange nuts that secure spring arm to frame. Use 1/2” drive breaker bar inserted into spring arm to hold arm, remove upper carriage screw and flange nut and rotate spring arm to relax spring (Fig. 13). 2 1 3. Lift idler pulley to release tension on secondary drive belt (Fig. 14). While holding idler away from belt, remove belt from secondary drive pulley. Carefully lower idler pulley. 4.
Coring Head Drive Jackshaft 6 5 7 6 8 9 4 10 8 9 3 11 2 11 1 12 10 13 5 2 3 12 4 14 15 FRONT RIGHT Figure 17 1. 2. 3. 4. 5. Primary pulley Taper lock bushing Lock washer Cap screw Set screw 6. 7. 8. 9. 10. Woodruff key Jackshaft Cap screw (2 used per bearing) Flange mount bearing Plug 11. 12. 13. 14. 15. Set screw Lock nut (2 used per bearing) Secondary pulley Secondary drive belt Coring crankshaft 5. Loosen taper lock bushings (Fig. 18): Removal (Fig. 17) 1.
NOTE: Jackshaft rotates counterclockwise as viewed from right side of machine (Fig. 18). 7. Loosen set screw that secures each flange mount bearing locking collar to jackshaft. Using the blind hole in bearing collar as a striking point, unlock collar from jackshaft by rotating the collar in the opposite direction of jackshaft rotation with a punch (Fig. 19). 8. Slide flange mount bearings from jackshaft. 10.
Coring Head Pivot (H–Frame) 15 14 1 2 4 3 14 5 13 6 13 10 12 3 4 7 RIGHT 12 8 FRONT 9 11 Figure 21 1. 2. 3. 4. 5. Coring frame H–frame Hex nut Lock washer Rod end (LH thread) Coring Head 6. 7. 8. 9. 10. Jam nut (LH thread) Upper link Jam nut Rod end Flange bushing (4 used) Page 7 – 16 11. 12. 13. 14. 15.
Disassembly (Fig. 21) 5 6 1. Park machine on a level surface, fully raise coring head, engage parking brake, stop engine and remove key from the ignition switch. Secure coring head with service latch. 7 4 3 2 2. Remove belt cover and rear hood from machine (see Operator’s Manual). 8 1 3. Chock wheels to prevent the machine from moving. 9 4. Remove tine heads from stomper arms to allow coring head to be fully lowered.
A. Remove retaining ring from one end of cylinder pin that secures lift cylinder to coring head frame. 2. Position H–frame to machine frame making sure that thrust washers are placed between H–frame and machine frame. Align both sides of H–frame to pivot shaft holes in machine frame. Slide pivot shaft into H–frame and machine frame. B. Pull cylinder pin from coring head frame and lift cylinder. Locate and retrieve two (2) thrust washers and two (2) spacers as pin is removed. 3.
Chapter 8 Electrical Diagrams Table of Contents Electrical Diagrams ELECTRICAL SCHEMATIC Electrical Schematic (Serial Number Below 403415001) . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Electrical Schematic (Serial Number Above 403415001) . . . . . . . . . . . . . . . . . . . . . . . . . . 4 ELECTRICAL CIRCUIT DRAWINGS Start Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Lower Coring Head . . . . . . . . . . . . . . . . . . . . . . . . . .
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ProCore 648 Electrical Schematic (Serial Number Below 403415001) All relays and solenoids are shown as de-- energized. All ground wires are black.
122--1508 Rev.
(ENERGIZED) (NOT ENERGIZED) (NEUTRAL POSITION) (NOT ENERGIZED) (NOT ENERGIZED) (NOT ENERGIZED) ProCore 648 Start Engine Power Current Control Current Indication Current (NOT ENERGIZED) Page 8 -- 5
ON ON ON ON ON SVQ SVL SVR ProCore 648 Aerator ON Aerator Control Module (RUN) (NOT ENERGIZED) (NOT IN NEUTRAL) (NOT ENERGIZED) (ENERGIZED) (ON) (HEAD BEING LOWERED) (ENERGIZED) (ENERGIZED) (PRESSED TO LOWER) (NOT ENERGIZED) (IN FORWARD) (HEAD BEING LOWERED) (HEAD BEING LOWERED) (HEAD BEING LOWERED) (HEAD BEING LOWERED) (ENERGIZED) (ENERGIZED) ProCore 648 Lower Coring Head Manual Raise/Lower Switch Pressed to Lower Power Current Control Current (NOT ENERGIZED) (HEAD BEING LOWERED)
ON ON ON SVQ SVR SVL ProCore 648 Aerator ON Aerator Control Module (RUN) (NOT ENERGIZED) (NOT IN NEUTRAL) (NOT ENERGIZED) (NOT ENERGIZED) (ON) (HEAD LOWERED) (NOT ENERGIZED) (ENERGIZED) (NEUTRAL POSITION) (NOT ENERGIZED) (IN FORWARD) (HEAD LOWERED) (HEAD LOWERED) (HEAD LOWERED) (HEAD LOWERED) ProCore 648 Aerating (ENERGIZED) (ENERGIZED) Coring Head Fully Lowered Level Ground Surface Power Current Control Current (ENERGIZED) (ENERGIZED) (HEAD LOWERED) Page 8 -- 7
ON ON ON ON ON SVQ SVR SVL ProCore 648 Aerator ON Aerator Control Module (RUN) (NOT ENERGIZED) (NOT ENERGIZED) (NOT IN NEUTRAL) (NOT ENERGIZED) (ON) (CLOSED BY TURF GUARD) (ENERGIZED) (ENERGIZED) (NEUTRAL POSITION) (NOT ENERGIZED) (IN FORWARD) (HEAD LOWERED) (HEAD LOWERED) (HEAD LOWERED) (HEAD LOWERED) ProCore 648 Aerating (ENERGIZED) (ENERGIZED) Coring Head Fully Lowered Low Spot in Turf Encountered (Head High Limit Switch Closed by Turf Guard Movement) Power Current Control Curren
ON ON ON ON ON SVQ SVR SVL ProCore 648 Aerator ON Aerator Control Module (RUN) (NOT ENERGIZED) (NOT IN NEUTRAL) (ENERGIZED) (NOT ENERGIZED) (ON) (HEAD LOWERED) (NOT ENERGIZED) (ENERGIZED) (NEUTRAL POSITION) (NOT ENERGIZED) (IN FORWARD) (HEAD LOWERED) (CLOSED BY TURF GUARD) (HEAD LOWERED) (HEAD LOWERED) ProCore 648 Aerating (ENERGIZED) (ENERGIZED) Coring Head Fully Lowered High Spot in Turf Encountered (Head Low Limit Switch Closed by Turf Guard Movement) Power Current Control Curren
ON ON SVQ ON SVR SVL ProCore 648 Aerator ON ON Aerator Control Module (RUN) (NOT ENERGIZED) (NOT IN NEUTRAL) (ENERGIZED) (ENERGIZED) (ON) (HEAD LOWERED) (NOT ENERGIZED) (NOT ENERGIZED) (NEUTRAL POSITION) (ENERGIZED) (HEAD LOWERED) (HEAD LOWERED) (HEAD LOWERED) (HEAD LOWERED) (ENERGIZED) ProCore 648 Raise Coring Head (ENERGIZED) Traction Lever Moved from Forward Power Current Control Current (ENERGIZED) (NOT ENERGIZED) (HEAD LOWERED) Page 8 -- 10
ON ON ON SVQ SVR SVL ProCore 648 Aerator ON Aerator Control Module (RUN) (NOT ENERGIZED) (NOT ENERGIZED) (NOT IN NEUTRAL) (NOT ENERGIZED) (ON) (HEAD RAISED) (NOT ENERGIZED) (NOT ENERGIZED) (NEUTRAL POSITION) (NOT ENERGIZED) (IN FORWARD) (HEAD RAISED) (HEAD RAISED) (HEAD RAISED) (HEAD RAISED) ProCore 648 Transport (ENERGIZED) (ENERGIZED) Traction Lever Moved to Forward Coring Head Fully Raised Power Current Control Current (ENERGIZED) (NOT ENERGIZED) (HEAD RAISED) Page 8 -- 11
1 3 5 2 4 3 4 5 2 1 ProCore 648 Wire Harness Drawing (Serial Number Below 403415001) Page 8 -- 12
MAGNETO LOW OIL PRESSURE REVERSE SWITCH NEUTRAL SW.
122--1507 Rev.
122--1507 Rev.
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