Toro 648 manual

Part No. 04129S L (Rev . C) Service Manual ProCore R 648 Preface The pur pose of this public ation is to pr ovide t he service technic ian with inf orm ation f or t roubles hooting, test ing and repair of maj or syst ems and co mponents on the ProCor e 648. REFE R TO THE O PERA TOR’S MANUALS FO R OP- ERA T ING , MAI NTE NANCE A ND ADJUS TM ENT IN[...]

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T able Of Contents Chapter 1 – Safety Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . 1 – 2 Jacking Instructions . . . . . . . . . . . . . . . . . . . . . . . . . 1 – 4 Safety and Instruction Decals . . . . . . . . . . . . . . . . 1 – 5 Chapter 2 – Product Records and Maintenance Product Records . . . . . . . . . .[...]

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Chapter 1 Safety T able of Contents SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . 2 Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 While Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Maintenance and Service . . . . . . . . . . . . . . . . . . . . 3 JACKING INSTRUCTIONS . . . . . [...]

Rev . C ProCor e 648 Page 1 - - 2 Safety Safety Instructions The P roCore 648 is designed and t est ed t o offer s afe serv ice when operated and maintained proper ly . Al- though hazar d cont rol and ac cident pr event ion part ially are dependent upon t he design and conf igurat ion of t he machine, thes e fac tor s are also dependent upon the aw[...]

7. Anytime the machine is parked (short or long term), 8. D o not park on slopes unless wheels are chocked or install the service latch to secure the coring head in the blocked. raised position. This eliminates the risk of the coring head accidentally lowering to the ground. Maintenance and Service 1. Before servicing or making adjustments, positio[...]

2 Jacking Instructions CAUTION er jack stands, the machine may move or fall, Frame jacking point Figure 1 1 When changing attachments, tires or perform- ing 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 attach- ments that may [...]

Safety and Instruction Decals Numerous safety and instruction decals are affixed to th e ProCore 648. If any decal becomes illegible or dam- aged, install a new decal. Part numbers for replacement decals are listed in your Parts Catalog. Order replace- ment decals from your Authorized T oro Distributor . Safety ProCore 648 Page 1 – 5 Safety[...]

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Chapter 2 Product Records and Maintenance T able of Contents PRODUCT RECORDS . . . . . . . . . . . . . . . . . . . . . . . . . 1 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 EQUIV ALENTS AND CONVERSIONS . . . . . . . . . . . 2 Decimal and Millimeter Equivalents . . . . . . . . . . . . 2 U.S. to Metric Conversions . . . [...]

Rev . C 0.09375 ProCore 648 Page 2 - - 2 Product Records and Maintenance Equivalents and Conversions[...]

T orque Specifications Recommended fastener torque values are listed in the following tables. For critical applications, as determined by T oro, either the recommended torque or a torque that is unique to the application is clearly identified and spe- cified in this Service Manual. These T orque Specifications for the installation and tightening of[...]

Standard T orque for Dry , Zinc Plated and Steel Fasteners (Inch Series) Grade 1, 5 & SAE Grade 1 Bolts, Screws, Studs & SAE Grade 5 Bolts, Screws, Studs & SAE Grade 8 Bolts, Screws, Studs & Thread Size 8 with Thin Sems with Regular Height Nuts Sems with Regular Height Nuts Sems with Regular Height Nuts Height Nuts (SAE J995 Grade 2[...]

Standard T orque for Dry , Zinc Plated and Steel Fasteners (Metric Fasteners) Thread Size Thread Size Class 8.8 Bolts, Screws and Studs with Regular Height Nuts Regular Height Nuts (Class 8 or Stronger Nuts) Class 10.9 Bolts, Screws and Studs with Regular Height Nuts Regular Height Nuts (Class 10 or Stronger Nuts) M5 X 0.8 57 + 5 in–lb 640 + 60 N[...]

Other T orque Specifications SAE Grade 8 Steel Set Screws Wheel Bolts and Lug Nuts Thread Size Thread Size Recommended T orque 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 Thread Si[...]

Chapter 3 Kohler Engine T able of Contents INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 SPECIFICATIONS 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL INFORMA TION . . . . . . . . . . . . . . . . . . . . . 4 Fuel Shutoff V alve . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 ADJUSTMENTS 5 . . [...]

Introduction This Chapter gives information about specifications a nd repair of the Kohler engine used in the ProCore 648. General engine maintenance procedures are described in your Operator ’s Manual. Information on engine trou- bleshooting, testing, disassembly , and reassembly is identified i n the Kohler Engine Service Manual that is in- clu[...]

Specifications Item Description Make / Designation Kohler , CH23S, 4–stroke, V–T win Air Cooled, OHV Number of Cylinders 2 Bore x Stroke 3.15” x 2.64” (80 mm x 67 mm) T otal Displacement 41.1 Cubic Inches (674 cc) Compression Ratio 8.5:1 Dry W eight (approximate) 90 Pounds (41 Kilograms) Fuel Unleaded, Regular Gasoline (Minimum 87 Octane) F[...]

General Information Fuel Shutoff V alve The fuel shutof f valve located under the fuel tank (Fig. 1) should be closed when removing the fuel tank or en- gine from the machine. Additionally , close the shutof f valve if the machine is being transported on a trailer or when placing the machine in long term storage. 1 Figure 1 1. Fuel shutoff valve (u[...]

Adjustments Adjust Choke Control Proper choke operation is dependent upon proper ad- justment of choke control cable. 1. Park machine on a level surface, fully raise coring head, engage parking brake, stop engine and remove key from the ignition switch. 2. Re mo v e air cleaner cover from engine to view choke plate in carburetor . 3. Move choke con[...]

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ProCore 648 Page 3 – 7 Kohler Engine Service and Repairs Cooling System T o ensure proper engine cooling, make sure the grass screen, cooling fins and other external surfaces of the engine are kept clean at all times. NOTE: Perform this maintenance procedure at the in- terval specified in the Operator ’s Manual. IMPORT ANT : The engine that pow[...]

ProCore 648 Page 3 – 8 Kohler Engine Fuel System Figure 5 1. Fuel tank 2. Fuel cap 3. Hose clamp 4. Fuel hose 5. Fuel shut–off valve 6. Hose clamp 7. Fuel hose 8. Flat washer (4 used) 9. Clamp 10. Cap screw (4 used) 1 1. Flange bushing (4 used) 12. Machine frame FRONT RIGHT 2 1 3 9 8 7 6 4 8 10 10 5 6 11 12 30 to 60 in–lb (3.4 to 6.8 N–m) A[...]

Fuel T ank Removal (Fig. 5) 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. 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[...]

ProCore 648 Page 3 – 10 Kohler Engine Exhaust System Figure 7 1. Engine 2. Exhaust manifold 3. Hex nut (4 used) 4. Frame 5. Flange nut (2 used) 6. Muffler bracket 7. Flange head screw (3 used) 8. Muffler clamp (2 used) 9. Exhaust elbow 10. Carriage screw (2 used) 1 1. Heat shield 12. Lock washer (2 used) 13. Cap screw (2 used) 14. Flange nut (2 u[...]

Removal (Fig. 7) Installation (Fig. 7) CAUTION haust system. The muffler and exhaust pipe may be hot. T o avoid possible burns, allow the engine and ex- haust system to cool before working on the ex - 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[...]

Rev . C ProCore 648 Page 3 - - 12 Kohle r Engine Engi ne Figur e 8 1. Engine 2. Negat ive batt ery cable 3. Wire harness ground 4. Flange scr ew 5. Lock w asher 6. Exhaus t manifold 7. Hex nut ( 4 used) 8. Cap scr ew ( 4 used) 9. Frame 10. Flange nut (2 used) 1 1. Muffler b racket 12. Flan ge head scr ew ( 3 used) 13. Muf fler clamp (2 u sed) 14. E[...]

ProCore 648 Page 3 – 13 Kohler Engine 7. Disconnect electrical connections from engine. NOTE: Label all electrical connections for reassembly purposes. A. Remove harness red wire and positive battery cable from the starter motor solenoid stud (Fig. 9). B. Disconnect negative battery cable and wire har- ness ground wire from the front corner of en[...]

Installation (Fig. 8) B. Wrap hourmeter wire around spark plug wire and 1. Locate m achine on a level surface with key removed from the ignition switch. Chock wheels to keep the ma- chine 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 hydraul[...]

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ProCore 648 Page 3 – 16 Kohler Engine Belt T ensioners Figure 12 1. Engine 2. Hydraulic pump drive pulley 3. Electric clutch 4. Flange nut 5. Hardened washer 6. Cap screw 7. Flat washer 8. Grommet 9. Spacer 10. Cap screw 1 1. Clutch strap 12. Cap screw 13. Flange nut 14. Flat washer 15. Idler arm assembly 16. W asher 17. Idler spacer 18. Idler ar[...]

Removal (Fig. 12) 1. Release tension on idler torsion spring (item 19): CAUTION 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. Push down on the spring end[...]

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Rev . C ProCore 648 Hydraulic System Page 4 - - 1 Chapter 4 Hydraulic System T able of Contents SPECIFICA TIONS 2 ............................. GENERAL INFORMA TION 4 ..................... Hydraulic Hoses 4 ............................ Hydraulic Fitting Installation 4 ................... Pushing/Pulling Machine 6 ..................... Check Hydraul[...]

Specifications Item Description T raction Pump (P1) V ariable displacement piston pump Displacement at full stroke (per revolution) .976 Cubic Inches (16 cc) Forward relief pressure 2900 PSI (200 Bar) Reverse relief pressure 2900 PSI (200 Bar) Charge/Lift Pump (P2) Gear pump Displacement (per revolution) .37 Cubic Inches (6.1 cc) Charge Pressure 40[...]

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General Information Hydraulic Hoses Hydraulic hoses are subject to extreme conditions such as pressure differentials du ring operation and exposure to weather , sun, chemicals, very warm storage condi- tions, or mishandling during operation and mainte- nance. These conditions can cause damage or premature deterioration. Some hoses are more suscep- [...]

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 r eplace the O–ring seal when this type of fit- ting shows signs of leakage. 3. Lubricate the O–ring with a light coating of oil. O–Ring 4. Install the fitting into the p[...]

Pushing/Pulling Machine IMPORT ANT : If push/pull limits are exceeded, se- vere damage to the piston (traction) pump may oc- cur . If it becomes necessary to push/pull the machine, push/ pull at a speed below 1 mph (1.6 kph) , and for a dis- tance less than 100 feet (30.5 meters) . The piston (traction) pump is equipped with a by–pass valve that [...]

Rev . C ProCore 648 Hydraulic System Page 4 - - 7 Hydraulic Schematic Hydraulic Schematic ProCore 648 All solenoids are shown as de - - energized T CHG P PV R1 R2 SVR SVQ SVL ORF1 CYL G1 G2 M2 M3 M1 FORW ARD ’B’ PORT (BOTTOM) ’A ’ PORT (TOP) ’P’ PORT FRONT WHEEL ’P’ PORT ’P’ PORT P2 P1 2900 -- 40 1000 40 -- -- -- -- COMPONENT CI[...]

Rev . C ProCore 648 Hydraulic System Page 4 - - 8 Hydraulic Flow Diagrams Working Pressure Low Pressure (Charge) Return or Suction Flow T raction Circuit (Forward Shown) T CHG P PV R1 R2 SVR SVQ SVL ORF1 CYL G1 G2 M2 M3 M1 FORW ARD ’B’ PORT (BOTTOM) ’A ’ PORT (TOP) ’P’ PORT FRONT WHEEL ’P’ PORT ’P’ PORT P2 P1 CONTROL MANIFOLD LI[...]

ProCore 648 Hydraulic System Page 4 – 9 T raction Circuit The traction (piston) pump (P1) is driven by the engine through the pulleys and pump drive belt. The traction cir- cuit of the hydraulic system acts essentially as a closed loop. T aking its suction directly from the return side of the wheel motors of the traction circuit, the traction (pi[...]

ProCore 648 Hydraulic System Page 4 – 10 Working Pressure Low Pressure (Charge) Return or Suction Flow Coring Head Raise/Lower Circuits T CHG P PV R1 R2 SVR SVQ SVL ORF1 CYL G1 G2 (ENERGIZED) CONTROL MANIFOLD LIFT CYLINDER (ENERGIZED) ENERGIZED) T CHG P PV R1 R2 SVR SVQ SVL ORF1 CYL G1 G2 (NOT ENERGIZED) CONTROL MANIFOLD LIFT CYLINDER (ENERGIZED)[...]

ProCore 648 Hydraulic System Page 4 – 1 1 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. [...]

Rev . C ProCore 648 Hydraulic System Page 4 - - 12 Special T ools Order these special tools from your T oro Distributor . Hydraulic Pressure T est Kit T oro 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 hi[...]

ProCore 648 Hydraulic System Page 4 – 13 Hydraulic T est Fitting Kit Part Number: TOR4079 This kit includes a variety of O–ring Face Seal fittings t o enable connection of test gauges to the ProCore 648 hy - draulic system. The kit includes: tee’s, unions, reducers, plugs, caps, and male test fittings. Figure 1 1 TORO TEST FITTING KIT (NO. T [...]

ProCore 648 Hydraulic System Page 4 – 14 T roubleshooting The cause of an improperly functioning hydraulic sys- tem is best diagnosed with the use of proper testing equipment and a thorough understanding of the com- plete hydraulic system. A hydraulic system with an excessive increase in heat or noise has a potential for failure. Should either of[...]

ProCore 648 Hydraulic System Page 4 – 15 Problem Possible Cause No traction in either direction Parking brake is engaged. Oil level in reservoir is low . T raction pump by–pass valve is open. Pump drive belt is loose, worn or broken. T raction cable broken or damaged. Charge pressure is low . Hydraulic pump pulley not secure to pump shaft. T ra[...]

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ProCore 648 Hydraulic System Page 4 – 17 T esting 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 T ools section in this Chapter). CAUTION Failure to use gauges with recommended pres-[...]

Rev . C ProCore 648 Hydraulic System Page 4 - - 18 Charge Pressure T est (Using Pressure Gauge) Figure 13 Working Pressure Low Pressure (Charge) Return or Suction Flow Direction T CHG P PV R1 R2 SVR SVQ SVL ORF1 CYL G1 G2 M2 M3 M1 FORW ARD ’B’ PORT (BOTTOM) ’A ’ PORT (TOP) ’P’ PORT FRONT WHEEL ’P’ PORT ’P’ PORT P2 P1 PRESSURE GA[...]

ProCore 648 Hydraulic System Page 4 – 19 Procedure for Charge Pressure T est: 1. Make sure hydraulic oil is at normal operating tem- perature 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[...]

Rev . C ProCore 648 Hydraulic System Page 4 - - 20 Coring Head Raise/Lower Relief (R1) Pressure T est (Using Pressure Gauge) Figure 15 Working Pressure Low Pressure (Charge) Return or Suction Flow Direction T CHG P PV R1 R2 SVR SVQ SVL ORF1 CYL G1 G2 M2 M3 M1 FORW ARD ’B’ PORT (BOTTOM) ’A ’ PORT (TOP) ’P’ PORT FRONT WHEEL ’P’ PORT ?[...]

ProCore 648 Hydraulic System Page 4 – 21 Procedure for Coring Head Raise/Lower Relief (R1) Pressure T est: 1. Make sure hydraulic oil is at normal operating tem- perature 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 eng[...]

Rev . C ProCore 648 Hydraulic System Page 4 - - 22 T raction (Piston) Pump (P1) Flow T est (Using T ester With Flow Meter and Pressure Gauge) Figure 18 Working Pressure Low Pressure (Charge) Return or Suction Flow Direction T CHG P PV R1 R2 SVR SVQ SVL ORF1 CYL G1 G2 M2 M3 M1 FORW ARD ’B’ PORT (BOTTOM) ’A ’ PORT (TOP) ’P’ PORT FRONT WHE[...]

Rev . B ProCore 648 Hydraulic System Page 4 – 23 6. Lift or jack machine so all wheels are off the floor to allow flow through the traction circuit. Support machine with jackstands or blocking. 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 Op[...]

Rev . C ProCore 648 Hydraulic System Page 4 - - 24 T raction Circuit Relief Pressure T est (Using T ester With Flow Meter and Pressure Gauge) Figure 20 Working Pressure Low Pressure (Charge) Return or Suction Flow Direction T CHG P PV R1 R2 SVR SVQ SVL ORF1 CYL G1 G2 M2 M3 M1 FORW ARD ’B’ PORT (BOTTOM) ’A ’ PORT (TOP) ’P’ PORT FRONT WHE[...]

ProCore 648 Hydraulic System Page 4 – 25 Procedure for T raction Circuit Relief Pressure T est: 1. Make sure hydraulic oil is at normal operating tem- perature 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[...]

Rev . C ProCore 648 Hydraulic System Page 4 - - 26 Gear Pump (P2) Flow T est (Using T ester With Flow Meter and Pressure Gauge) Figure 22 Working Pressure Low Pressure (Charge) Return or Suction Flow Direction T CHG P PV R1 R2 SVR SVQ SVL ORF1 CYL G1 G2 M2 M3 M1 FORW ARD ’B’ PORT (BOTTOM) ’A ’ PORT (TOP) ’P’ PORT FRONT WHEEL ’P’ POR[...]

ProCore 648 Hydraulic System Page 4 – 27 Procedure for Gear Pump (P2) Flow T est: 1. Make sure hydraulic oil is at normal operating tem- perature 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 [...]

Rev . C ProCore 648 Hydraulic System Page 4 - - 28 Wheel Motor Efficiency T est (Using T ester With Flow Meter and Pressure Gauge) Figure 24 Working Pressure Low Pressure (Charge) Return or Suction Flow Direction T CHG P PV R1 R2 SVR SVQ SVL ORF1 CYL G1 G2 M2 M3 M1 FORW ARD ’B’ PORT (BOTTOM) ’A ’ PORT (TOP) ’P’ PORT FRONT WHEEL ’P’ [...]

Procedure for Wheel Motor Efficiency T est: 1. Make sure hydraulic oil is at normal operating tem- perature 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 neu- tral position (see Operator ’s Manual). 3. Park m achine on a level surface with the [...]

Service and Repairs General Precautions for Removing and Installing Hydraulic System Components Before Repair or Replacement of Components 1. Before removing any parts from the hydraulic sys- tem, 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 w[...]

Flush Hydraulic System IMPORT ANT : Flush the hydraulic system any time there is a severe component failure or the system is contaminated (oil appears milky or black or con- tains metal particles). IMPORT ANT : Flush hydraulic system when chang- Ing from petroleum base hydraulic fluid, such as Mobil 424, to biodegradable fluid, such as Mobil EAL En[...]

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 compo - nents from not purging the system of a[...]

10. Start engine and operate the traction system at vary- ing speeds for a 10 minute period. 1 1. Stop the machine. Check hydraulic reservoir level and fill if necessary . Check hydraulic components for leaks and tighten any loose connections. 1 2 Figure 27 1. T est port 2. Hydraulic manifold ProCore 648 Page 4 - - 33 Rev . A Hydraulic System Hydra[...]

ProCore 648 Hydraulic System Page 4 – 34 Hydraulic Pump Drive Belt 1. Flange nut (2 used) 2. Hydraulic (traction/charge) pump 3. Key 4. Engine 5. Engine pulley 6. Flange head screw 7. Spring bracket 8. Idler support bracket 9. Idler pulley 10. Flange nut 1 1. T ensioning spring 12. Set screw 13. Hydraulic pump pulley 14. Pump drive belt 15. L bra[...]

Drive Belt Removal (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. 2. R emo ve pump belt cover from machine (see Opera- tor ’s Manual). 3. Remo ve coring head primary drive belt from electric clutch (see Primary[...]

ProCore 648 Hydraulic System Page 4 – 36 Hydraulic Pump Control Assembly 1. Hydraulic pump 2. Cap screw (2 used) 3. Flange nut 4. Lock nut 5. Flange nut (2 used) 6. Control bracket 7. Washer head screw 8. Lock nut 9. Extension spring 10. Speed selector pivot 1 1. Retaining ring 12. Swivel 13. Cap screw 14. T runnion clamp 15. Socket head screw (2[...]

ProCore 648 Hydraulic System Page 4 – 37 Disassembly (Fig. 28) 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. 2. R emo ve pump belt cover from machine (see Opera- tor ’s Manual). 3. R e mo v e two (2) lock nuts that se[...]

ProCore 648 Hydraulic System Page 4 – 38 Hydraulic (T raction/Charge) Pump 1. Hydraulic (traction/charge) pump 2. O–ring 3. O–ring 4. 90 o hydraulic fitting 5. Engine 6. Engine pulley 7. Flange head screw 8. Spring bracket 9. Idler support bracket 10. Idler pulley 1 1. Flange nut 12. T ensioning spring 13. Set screw 14. Pump pulley 15. Pump d[...]

ProCore 648 Hydraulic System Page 4 – 39 2. R emo ve pump belt cover from machine (see Opera- tor ’s Manual). 3. Loosen the flange head screw (item 7) and flange nut (item 1 1) that secure the drive belt idler pulley (item 10). Lift id ler pu lle y t o al low r emoval of drive belt from the hy- draulic pump pulley . IMPORT ANT : Before loosenin[...]

Installation (Fig. 31) 1. Install hydraulic fittings with new o–rings to the hy- draulic pump. Orientate the fittings as noted during dis- assembly . CAUTION pump support to prevent the pump from falling Support hydraulic pump when installing it to the and causing personal injury . 2. Position hydraulic pump assembly to the frame pump support. Se[...]

ProCore 648 Hydraulic System Page 4 – 41 Hydraulic (T raction/Charge) Pump Service 1. Retaining ring 2. Seal 3. Spacer 4. Pump shaft kit 5. Pump housing 6. Thrust washer 7. Spring block 8. Nut (4 used) 9. Trunnion seal kit 10. Pin (2 used) 1 1. O–ring 12. V alve plate 13. Forward relief valve 14. By–pass valve 15. Endcap kit 16. Check ball (2[...]

ProCore 648 Hydraulic System Page 4 – 42 Wheel Motors 1. Rear wheel motor (LH shown) 2. Woodruff key 3. Parking latch support (2 used) 4. Stud (4 used per wheel) 5. Parking latch disc (2 used) 6. Wheel hub 7. Lock nut 8. Bearing plate 9. Lug nut 10. Tire and wheel assembly 1 1. Cap screw (4 used per rear motor) 12. Lock nut (4 used per motor) 13.[...]

ProCore 648 Hydraulic System Page 4 – 43 2. Remove wheel from machine (see Wheel Removal in Service and Repairs section of Chapter 6 – Chassis). IMPORT ANT : T o prevent damage to hydraulic motor , DO NOT hit wheel hub or motor with a hammer dur- ing wheel hub removal or installation. 3. Loosen nut that secures wheel hub to motor shaft. Use whe[...]

ProCore 648 Hydraulic System Page 4 – 44 Wheel Motor Service 1. Dust seal 2. Housing 3. O–ring 4. Shaft seal 5. Axial needle bearing 6. Bearing race 7. Needle bearing 8. Shaft 9. O–ring 10. Spring washer 1 1. Balance plate 12. Disc valve 13. Needle bearing 14. Bearing race 15. Distributor plate 16. Cardan shaft 17. O–ring 18. Gearwheel set [...]

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ProCore 648 Hydraulic System Page 4 – 46 Hydraulic Lift Control Manifold 1. Main frame 2. Cap screws (2 used) 3. Hydraulic lift control manifold 4. Hydraulic oil filter 5. Flange nut (2 used) Figure 38 FRONT RIGHT 1 3 2 5 4[...]

ProCore 648 Hydraulic System Page 4 – 47 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. CAUTION Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hy- draulic oi[...]

ProCore 648 Hydraulic System Page 4 – 48 Hydraulic Lift Control Manifold Service 1. Hydraulic lift control manifold 2. O–ring 3. Quick fitting (2 used) 4. Solenoid valve (SVL port) 5. Nut 6. Solenoid coil 7. Relief valve (R1 port) 8. Solenoid valve (SVQ port) 9. Nut 10. Solenoid valve (SVR port) 1 1. Pres. compensating valve (PV port) 12. #4 pl[...]

Hydraulic Manifold Service 1. Ma k e sure the manifold is clean before removing any cartridge valve. 2. If solenoid cartridge is being serviced, remove nut securing solenoid to the cartridge valve. Carefully slide solenoid off the valve. CAUTION sure in the General Information section of this Operate all hydraulic controls to relieve system pressur[...]

ProCore 648 Hydraulic System Page 4 – 50 Lift Cylinder 1. Main frame 2. Shackle (4 used) 3. Extension spring (2 used) 4. Carriage screw (4 used) 5. Spring plate (2 used) 6. Flange nut (4 used) 7. Clevis pin (4 used) 8. Hair pin (4 used) 9. Retaining ring 10. Thrust washer 1 1. Cylinder pin 12. Spacer (2 used) 13. Lift cylinder 14. O–ring 15. Hy[...]

5. Start engine and allow coring head to fully raise. T u r n engine off. Secure coring head with service latch. CAUTION sure in the General Information section of this Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hy- draulic oil. See Relieving Hydraulic System P res- chapter . 6. Release hydraulic pre[...]

ProCore 648 Hydraulic System Page 4 – 52 Lift Cylinder Service 1. Retaining ring 2. Cylinder tube 3. Rod 4. O–ring 5. Backup ring 6. Retaining ring 7. Seal 8. Head 9. Wiper Figure 44 5 1 3 7 8 9 6 4 2 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 o[...]

Inspection CAUTION Spanner wrench Retaining ring against left side of barrel groove after installing) Us e 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 (Offset end dam[...]

ProCore 648 Hydraulic System Page 4 – 54 Hydraulic Reservoir 1. Hydraulic reservoir 2. Dipstick 3. Cap 4. Shoulder screw 5. T ank strap 6. Cap screw 7. J clip 8. Flat washer 9. Frame 10. O–ring 1 1. Hydraulic adapter 12. O–ring 13. Hydraulic tube 14. Hydraulic tube 15. Suction hose 16. Hose clamp 17. Hydraulic barb fitting 18. Hydraulic tee f[...]

Chapter 5 Electrical System T able of Contents ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . 1 CIRCUIT OPERA TION . . . . . . . . . . . . . . . . . . . . . . . . . 2 OK to Lower Circuit . . . . . . . . . . . . . . . . . . . . . . . . . 2 Lockout Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Electric Clutch Ci[...]

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 opera- tion. OK to Lower Circuit (Fig. 1) Th e ”OK to lower”[...]

GROUND TO GROUND TO SWITCH PROX. SWITCH LOCKOUT CIRCUIT GROUND TO GROUND TO SWITCH PROX. SWITCH LOCKOUT CIRCUIT GROUND TO GROUND TO SWITCH PROX. SWITCH LOCKOUT CIRCUIT (ENERGIZED) (ENERGIZED) (ENERGIZED) (IN RAISE POSITION) CONTROL CURRENT OK TO LOWER AERA TING (TRACTION LEVER IN FORW ARD) TO IGNITION TERMINAL ”L” AERA TION #3 CONTROL MODULE ?[...]

Lockout Circuit (Fig. 2) Th e lockout circuit is used on the ProCore to provide cur- rent 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. Wh e n this circuit is closed, current [...]

GROUND CORING HEAD RAISED TO IGNITION T O AERA TOR SWITCH CONTROL (NOT PRESSED) (ENERGIZED) TERMINAL ”L” (ENERGIZED) TO ELECTRIC CLUTCH MODULE TO IGNITION SWITCH TERMINAL ”A” GROUND AERA TING TO IGNITION TO AERA TOR SWITCH CONTROL (ENERGIZED) TERMINAL ”L” (ENERGIZED) MODULE (NOT PRESSED) TO ELECTRIC CLUTCH TO IGNITION SWITCH TERMINAL ?[...]

Electric Clutch Circuit (Fig. 3) The electric clutch circuit is used on the ProCore to pro- vide current for the electric clutch which rot ates the cor- ing crankshaft. This circuit is composed of the aeration #3 proximity switch, the clutch relay , the electric clutch an d diode D3. The electric clutch circuit relies on the op - eration of the ”[...]

Special T ools Multimeter The multimeter can test electrical components and cir- cuits for current (amps), resistance (ohms) or voltage. NOTE: T oro recommends the use of a DIGIT AL V olt– Ohm–Amp multimeter when testing electrical circuits. Th e high impedance (internal resistance) of a digital me- ter in the voltage mode will make sure that e[...]

T roubleshooting CAUTION Remove all especially rings and watches, before doing any electrical trouble- cables unless the test requires battery voltage. jewelry , shooting or testing. Disconnect the battery For effective troubleshooting and repairs, you must have a good understanding of the electrical circuits (see Chapter 8 – Electrical Diagrams)[...]

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[...]

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[...]

Electrical System Quick Checks Battery T est (Open Circuit T est) Use a multimeter to measure the voltage between the battery terminals. Set the multimeter to the DC volts setting. The battery should be at a temperature of 60 o to 100 o F (16 o to 38 o C). The ignition key should be in the OFF position and all accessories turned off. Connect the po[...]

Check Operation of Safety Interlock System CAUTION operating the machine. 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 Interlock switch operation is[...]

Component T esting For accurate resistance and/or continuity checks, elec- trically 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 V olt power connection can be performed through voltage drop tests without disconnecting th[...]

1 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. IMPORT ANT : If the e[...]

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 rela y , clutch relay , neutral switch (start) relay and lockout latch relay . The remain- in g two (2) relays are attached under the handle console (Fig. 14): neutral switch (latch) relay and latc[...]

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 m odule inputs. See OK to Lower Cir- cuit in the Circuit Operation section of this chapter for additional raise/lower switch inform[...]

Ground Follow Switch The ground follow switch is located on the side of the control panel (Fig. 18). This rocker switch allows the T rue Core TM 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 positi[...]

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, t[...]

Solenoid V alve Coil Th e 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 illu- minated when the solenoid valve coils a[...]

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 lo w and head high limit switches provide inputs for the T rue Core TM ground following sy[...]

Fuses The fuse block is located behind the console cover (Fig. 27). 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[...]

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). The reverse and neutral proximity switches are mounted on the control handle under the handle con- sole (Fig. 29). They use sensing plates [...]

Proximity Switch T est 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. 2. Locate proximity switch to be tested. Disconnect proximity switch from machine wiring harness. 3. Check the continuity of the switch by connecting a [...]

Aerator Control Module The ProCore 648 is equipped with an Aerator Control Module to monitor and control electrical components re - quired for safe operation. This Module is located on the inside of the console cover (Fig. 33). Inputs from the start (ignition), head low limit, head high limit, transport limit #1 proximity switch, aeration #4 proxim[...]

Control Module Outputs 3. Th e SVR output LED will be illuminated in two situa- 1. Th e SVQ output LED will be illuminated in two situa- tions: A. Both ”OK to lower” and transport #1 LED’s are not illuminated. B. ”OK to lower” LED is illuminated and aerate #4 LED is not illuminated. 2. T h e SVL output LED will be illuminated in three sit[...]

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–ener- gized. When the ”OK to lower” latching circuit is [...]

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 har- ness at various locations (see Wire Harness Drawings in Chapter 8 – Electrical Diagrams). Diode T est 3 2 The[...]

Service and Repairs NOTE: See the Kohler Engine Service Manual for en- gine 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. 3. Leave cables disconnected if the battery is stored o [...]

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. CAUTION When working with batteries, use extreme cau- eyes. Always wear safety goggles and a face shield when working with batteries. tion to avoi[...]

T esting 1. T o 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. CAUTION Follow the manufacturer ’ s instructions when us- ing a battery[...]

Charging T o minimize possible damage to the battery and allow the battery to be fully charged, the slow charging meth- od is presented here. This charging method can be ac- complished with a constant current battery charger which is available in most shops. CAUTION Follow the manufacturer ’ s instructions when us- ing a battery charger . NOTE: U[...]

ProCore 648 Page 5 – 32 Electrical System Electric Clutch 1. Drive belt 2. Electric clutch 3. Hardened washer 4. Cap screw 5. Flange nut 6. Flat washer 7. Brake grommet 8. Cap screw 9. Spacer 10. Clutch strap 1 1. Idler mounting bracket 12. Lock nut 13. Cap screw 14. Hardened washer 15. Idler pulley 16. T orsion spring 17. Spacer 18. Flange bushi[...]

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. 2. R emo ve pump belt cover from machine (see Opera- tor ’s Manual). 3. Rem ove muffler heat shield (see Exhaust System in the Service and Repairs section [...]

ProCore 648 Page 5 – 34 Electrical System Solenoid V alve Coil A solenoid valve coil on the hydraulic lift control manifold (Fig. 41) can be replaced without opening the hydraulic system. 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 he[...]

Chapter 6 Chassis T able of Contents SPECIFICA TIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 SPECIAL T OOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SERVICE AND REP AIRS . . . . . . . . . . . . . . . . . . . . . . 4 Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Parking Brake . [...]

Specifications Item Description Front and Rear T ires Size 19 x 10.5 – 8, 2 Ply , Tubeless Pressure 12 PSI (.83 Bar) Wheel lug nut torque 45 to 55 ft–lb (61 to 75 N–m) Wheel hub nut torque 190 to 230 ft–lb (258 to 312 N–m) Chassis Page 6 – 2 ProCore 648[...]

Rev . C ProCore 648 Page 6 - - 3 Chassis Special T ools Order special tools from your T oro Distributor . Wheel Hub Puller Part Number: TOR4097 The wheel hub puller allows safe removal of the wheel hub from the shaft of wheel motors. Figure 1 Chassis[...]

ProCore 648 Page 6 – 4 Chassis Service and Repairs Wheels 1. Tire and wheel assembly 2. Lug nut 3. Front wheel weight 4. Wheel weight adapter 5. Weight stud 6. Thrust washer 7. Lock nut 8. Bearing plate 9. Lock nut 10. Wheel hub 1 1. Parking latch disc 12. Wheel stud Figure 2 6 7 1 3 2 5 4 FRONT RIGHT 1 2 4 5 6 8 11 9 10 12 12 10 9 8 45 to 55 ft?[...]

Wheel Removal (Fig. 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. 2. Jack machine from ground and support machine with blocking or jack stands (see Operator’s Manual and Jacking Instructions in Chapter 1 – Safety).[...]

ProCore 648 Page 6 – 6 Chassis Parking Brake Figure 4 1. Extension spring 2. Bushing 3. Retaining ring 4. Parking latch pivot 5. Flange nut 6. Shoulder bolt 7. Compression spring 8. Parking latch clevis 9. Hair pin 10. Parking latch link 1 1. Roll pin 12. Parking latch bar 13. Lock nut 14. Tire and wheel assembly 15. Lug nut (4 used per wheel) 16[...]

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 [...]

ProCore 648 Page 6 – 8 Chassis Parking Brake Cable 1. Control handle 2. Grommet 3. Steering arm 4. Lower handle cover 5. Washer head screw (6 used) 6. Flange nut 7. Brake cable 8. Flat washer 9. Cotter pin 10. Brake lever 1 1. Bushing 12. Brake spacer 13. Cap screw 14. Knob Figure 5 2 5 1 4 3 8 9 12 13 6 7 10 11 14 FRONT RIGHT[...]

ProCore 648 Page 6 – 9 Chassis 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. 2. Re m o v e six (6) washer head screws that secure low- er handle cover to control handle. Remove lo[...]

ProCore 648 Page 6 – 10 Chassis Steering Assembly 1. Grommet 2. Stud (3 used) 3. Steering arm 4. Cap screw (5 used) 5. Slotted hex nut 6. W asher 7. Bearing cone 8. Bearing cup 9. Frame 10. Steering stop 1 1. Cap screw (2 used) 12. Cable guide 13. Cotter pin 14. Steering spindle 15. Lock nut (3 used) 16. Lock nut (4 used) 17. Wheel motor 18. Cap [...]

Disassembly (Fig. 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. 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[...]

Rev . B ProCore 648 Page 6 – 12 Chassis T raction Control Cable Removal 1. Remove traction control cable from hydraulic pump control (Fig. 10) and traction lever on handle and (Fig. 1 1). 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 [...]

Chapter 7 Coring Head T able of Contents GENERAL INFORMA TION . . . . . . . . . . . . . . . . . . . . . 2 Coring Head Operation . . . . . . . . . . . . . . . . . . . . . . . 2 Coring Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Coring Head Service Latch . . . . . . . . . . . . . . . . . . . . 3 Coring Head Adjustments . . . [...]

General Information Coring Head Operation The coring head of the Procore 648 consists of a frame that pivots for aerating depth control, a coring crank- shaft, 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 [...]

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 us ing 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[...]

ProCore 648 Page 7 – 4 Coring Head Service and Repairs Rotolink Dampers 1. Lock nut 2. Hardened D washer 3. Flange head screw 4. Stud 5. Bumper plate 6. Ca p screw 7. Lock nut 8. Hardened washer 9. Damper link 10. Bearing 1 1. Stomper arm 12. Flan g e nut 13. Cap screw 14. Rubber bumper 15. Rotolink damper 16. Damper standoff 17. Damper top space[...]

Disassembly (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. 2. Remove rotolink components as needed using Fig- ure 4 as a guide. Assembly (Fig. 4) 1. If studs (item 4) were removed from damper (item 15), thread stu[...]

ProCore 648 Page 7 – 6 Coring Head Stomper Arms 1. Coring frame 2. Cap screw 3. Flat washer 4. Retaining ring 5. Ball bearing 6. Stomper arm 7. Pulley 8. Bearing housing 9. Crankarm 10. Square key 1 1. Coupling 12. Spacer tube Figure 5 FRONT RIGHT 9 10 11 12 1 2 3 4 5 6 7 8 4 5 6 2 2 3 3 150 to 170 ft–lb (203 to 230 N–m) 150 to 170 ft–lb (2[...]

Removal (Fig. 5) 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. 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 Rotol[...]

ProCore 648 Page 7 – 8 Coring Head Coring Crankshaft Bearing Housings 1. Cap screw 2. Flat washer 3. Spacer tube 4. Stomper arm 5. Ball bearing 6. Retaining ring 7. Crankarm 8. Ball bearing 9. Bearing housing 10. Spacer 1 1. Crankarm 12. Square key 13. Coupling (#5 shown) 14. Lock nut 15. Coupling plate 16. Iso mount 17. Cap screw (4 used per pla[...]

ProCore 648 Page 7 – 9 Coring Head 7. Disassemble bearing housing assembly: A. Re mo ve cap screw (item 1) and flat washer (item 2) that fasten crankarms together . T ake note of align- ment of identification number on crankarm with tim- ing mark on bearing housing (Fig. 9). B. Slide crankarms from bearing housing. C. If necessary , remove bearin[...]

ProCore 648 Page 7 – 10 Coring Head Primary Drive Belt 1. Primary drive belt 2. Electric clutch 3. Hardened washer 4. Cap screw 5. Flange nut 6. Flat washer 7. Brake grommet 8. Cap screw 9. Spacer 10. Clutch strap 1 1. Idler mounting bracket 12. Lock nut 13. Cap screw 14. Hardened washer 15. Idler pulley 16. T orsion spring 17. Spacer 18. Flange [...]

Removal (Fig. 1 1) 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. 2. Remove belt cover (see Operator ’s Manual). 3. Remove exhaust system shield (see Exhaust Sys- tem Removal in the Service and Repairs section of Chapter[...]

ProCore 648 Page 7 – 12 Coring Head Secondary Drive Belt 1. Secondary drive belt 2. Cap screw 3. Secondary pulley 4. Cap screw 5. Flange bushing 6. Idler pulley 7. Idler pivot tube 8. Idler arm 9. Lock nut 10. Carriage screw (2 used) 1 1. Flange nut (2 used) 12. Idler spring arm 13. Extension spring (2 used) 14. Coring crankshaft pulley 15. #1 st[...]

NOTE: If desired, extension spring tension can be re- moved 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). 3. Lift idler pulley to release tension on seco[...]

ProCore 648 Page 7 – 14 Coring Head Coring Head Drive Jackshaft 1. Primary pulley 2. T aper lock bushing 3. Lock washer 4. Cap screw 5. Set screw 6. Woodruff key 7. Jackshaft 8. Cap screw (2 used per bearing) 9. Flange mount bearing 10. Plug 1 1. Set screw 12. Lock nut (2 used per bearing) 13. Secondary pulley 14. Secondary drive belt 15. Coring [...]

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 [...]

ProCore 648 Page 7 – 16 Coring Head Coring Head Pivot (H–Frame) 1. Coring frame 2. H–frame 3. Hex nut 4. Lock washer 5. Rod end (LH thread) 6. Jam nut (LH thread) 7. Upper link 8. Jam nut 9. Rod end 10. Flange bushing (4 used) 1 1. Main frame 12. Thrust washer 13. Carriage screw 14. Pivot shaft 15. Flange nut Figure 21 2 3 4 6 8 10 1 5 7 9 3 [...]

ProCore 648 Page 7 – 17 Coring Head Disassembly (Fig. 21) 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. 2. Re m o ve belt cover and rear hood from machine (see Operator ’s Manual). 3. Chock wheels to prevent the machi[...]

8. Disconnect upper end of lift cylinder from coring head frame (Figs. 22 and 23): A. Remove retaining ring from one end of cylinder pin that secures lift cylinder to coring head 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. C. Rotate lift cyl[...]

Chapter 8 Electrical Diagrams T able of Contents ELECTRICAL SCHEMA TIC Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . 3 ELECTRICAL CIRCUIT DRA WINGS Start Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Lower Coring Head . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Aerating (Level Ground Sur[...]

This page is intentionally blank. Electrical Diagrams Page 8 – 2 ProCore 648[...]

Page 8 – 3 Electrical Schematic ProCore 648 All relays and solenoids are shown as de–energized. All ground wires are black.[...]

Page 8 – 4 Start Engine Power Current Control Current Indication Current ProCore 648 (ENERGIZED) (NOT ENERGIZED) (NOT ENERGIZED) (NOT ENERGIZED) (NOT ENERGIZED) (NOT ENERGIZED) (NEUTRAL POSITION)[...]

Page 8 – 5 Lower Coring Head Power Current Control Current ProCore 648 (ENERGIZED) (NOT ENERGIZED) (RUN) (NOT ENERGIZED) (NOT IN NEUTRAL) (ENERGIZED) (HEAD BEING LOWERED) (ON) (HEAD BEING LOWERED) (HEAD BEING LOWERED) (HEAD BEING LOWERED) (IN FORWARD) (HEAD BEING LOWERED) (ENERGIZED) (PRESSED TO LOWER) (ENERGIZED) (ENERGIZED) (NOT ENERGIZED) (NOT[...]

Page 8 – 6 Aerating Power Current Control Current ProCore 648 (ENERGIZED) (NOT ENERGIZED) (RUN) (NOT ENERGIZED) (NOT IN NEUTRAL) (ENERGIZED) (ON) (HEAD LOWERED) (HEAD LOWERED) (HEAD LOWERED) (IN FORWARD) (HEAD LOWERED) (ENERGIZED) (NEUTRAL POSITION) (NOT ENERGIZED) (ENERGIZED) (HEAD LOWERED) (ENERGIZED) (NOT ENERGIZED) (NOT ENERGIZED) Coring Head[...]

Page 8 – 7 Aerating Power Current Control Current ProCore 648 (ENERGIZED) (NOT ENERGIZED) (RUN) (NOT ENERGIZED) (NOT IN NEUTRAL) (ENERGIZED) (ON) (HEAD LOWERED) (CLOSED BY TURF GUARD) (HEAD LOWERED) (IN FORWARD) (HEAD LOWERED) (ENERGIZED) (NEUTRAL POSITION) (NOT ENERGIZED) (ENERGIZED) (HEAD LOWERED) (ENERGIZED) (NOT ENERGIZED) Coring Head Fully L[...]

Page 8 – 8 Aerating Power Current Control Current ProCore 648 (ENERGIZED) (NOT ENERGIZED) (RUN) (NOT ENERGIZED) (NOT IN NEUTRAL) (ENERGIZED) (ON) (CLOSED BY TURF GUARD) (HEAD LOWERED) (HEAD LOWERED) (IN FORWARD) (HEAD LOWERED) (ENERGIZED) (NEUTRAL POSITION) (ENERGIZED) (ENERGIZED) (HEAD LOWERED) (ENERGIZED) (NOT ENERGIZED) (NOT ENERGIZED) Coring [...]

Page 8 – 9 Raise Coring Head Power Current Control Current ProCore 648 (ENERGIZED) (NOT ENERGIZED) (RUN) (NOT ENERGIZED) (NOT IN NEUTRAL) (ENERGIZED) (HEAD LOWERED) (ON) (HEAD LOWERED) (HEAD LOWERED) (HEAD LOWERED) (ENERGIZED) (NEUTRAL POSITION) (ENERGIZED) (HEAD LOWERED) (ENERGIZED) (NOT ENERGIZED) Traction Lever Moved from Forward Aerator Contr[...]

Page 8 – 10 T ransport Power Current Control Current ProCore 648 (ENERGIZED) (NOT ENERGIZED) (RUN) (NOT ENERGIZED) (NOT IN NEUTRAL) (ENERGIZED) (ON) (HEAD RAISED) (NEUTRAL POSITION) (ENERGIZED) (NOT ENERGIZED) T raction Lever Moved to Forward Aerator Control Module ON ON ON SVL SVR SVQ ProCore 648 Aerator (NOT ENERGIZED) (NOT ENERGIZED) (IN FORWA[...]

Page 8 – 1 1 ProCore 648 Wire Harness Drawing 5 4 2 3 1 4 3 5 2 1[...]

MAGNETO LOW OIL PRESSURE P5 REVERSE P16 SWITCH NEUTRAL SW . RELA Y (ST ART) P4 J5 IGNITION SWITCH P1 FUSE BLOCK P27 ACM 1 P9 S M L G B BLUE ORANGE BLACK BLACK VIOLET VIOLET WHITE/BLACK YELLOW YELLOW BLACK PINK/BLACK 1 2 3 4 5 A B A B C D E F 1A 1B 2A 2B 1 2 3 4 5 SP1 1 2 3 4 5 6 7 8 SP7 SP9 1 BLACK PINK/BLACK BLACK VIOLET BLACK BLACK BLACK BLACK YE[...]