Page 1 Service Manual ProCore® 648s Aerator Model 09960 20255SL Rev D Original Instructions (EN)
Page 2 06/2024 to the Operation Problems Quick Reference Table and to the Calibrating the Piston (Traction) Pump procedure. © 2024—The Toro ® Company Contact us at www.Toro.com 8111 Lyndale Ave So Bloomington, MN 55044 All rights reserved...
Page 3 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.com...
Page 4 Installation Instructions, and Parts Catalog for your machine and its accessories with this Service Manual for reference. Additional copies of the Operator’s Manuals, Installation Instructions and Parts Catalogs are available at www.Toro.com. The Toro® Company reserves the right to change the product specifications or this publication without notice. Preface Page 4 ProCore®...
Page 5 Service Procedure Icons The following icons appear throughout this service manual to bring attention to specific important details of a service procedure. Critical Process is used to highlight: • installing safety equipment (shields, guards, seat belts, brakes and R.O.P.S. components) that may have been removed. •...
Page 6 Table of Contents Revision History ..........................2 Reader Comments ........................3 Preface ............................4 Chapter 1: Safety ........................1–1 Safety Instructions ....................... 1–2 Think Safety First ......................1–2 Avoiding Injury to Bystander..................1–3 Avoiding Projectile Injuries..................... 1–3 Avoiding Laceration and Amputation Injuries............1–3 Avoiding Burn Injuries .....................
Page 7 General Hydraulic System Problems ................3–67 Hydraulic System Problems Quick Reference Table..........3–67 Troubleshooting—Electrical .................... 3–69 Starting Problems ......................3–70 Starting Problems Quick Reference Table............... 3–70 General Operation Problems ..................3–72 Operation Problems Quick Reference Table............3–72 Chapter 4: Engine ........................4–1 General Information......................
Page 8 Hydraulic Reservoir ....................... 5–48 Hydraulic Pump Drive Belt................... 5–49 Piston (Traction) Pump ....................5–51 Servicing the Piston (Traction) Pump................ 5–57 Gear Pump ........................5–58 Servicing the Gear Pump ..................... 5–60 Front Wheel Motor ......................5–64 Rear Wheel Motors......................5–66 Servicing the Wheel Motor................... 5–68 Lift Manifold ........................
Page 9 Storing the Battery ......................6–68 Battery ..........................6–69 Removing and Installing the Battery................6–71 Inspecting, Maintaining, and Testing the Battery............ 6–72 Charging the Battery ..................... 6–74 Chapter 7: Chassis ........................7–1 General Information......................7–2 Service and Repairs ......................7–3 Wheels..........................7–3 Parking Brake ........................
Page 10 Preface Page 10 ProCore® 648s Aerator 20255SL Rev D...
Page 11 Chapter 1 Safety Table of Contents Safety Instructions ............................1–2 Think Safety First ............................. 1–2 Avoiding Injury to Bystander........................1–3 Avoiding Projectile Injuries........................1–3 Avoiding Laceration and Amputation Injuries..................1–3 Avoiding Burn Injuries ..........................1–3 Avoiding Asphyxiation..........................1–3 Avoiding Electrical Shock........................1–3 Avoiding Injuries from the Battery ......................
Page 12 Think Safety First Toro Products are evaluated for compliance with existing safety standards and specifications. Although hazard control and accident prevention are partially dependent upon the design and configuration of the machine, hazard control and...
Page 13 Avoiding Injury to Bystander Always clear the area of bystanders before starting or testing powered equipment. Avoiding Projectile Injuries Always clear the area of any debris that could be picked up and thrown by the powered equipment. Avoiding Laceration and Amputation Injuries Stay clear of all moving parts whenever the engine is running.
Page 14 Avoiding Injuries from the Battery (continued) • Observe the battery for at least 1 hour to ensure that any reaction has stopped. If the reaction continues, or if any smoke is observed, call your local emergency services immediately. Safe Maintenance Practices Personal Protective Equipment •...
Page 15 Avoiding Fire and Explosions • Use extreme care in handling fuel. Fuel is flammable and its vapors are explosive. • Extinguish all cigarettes, cigars, pipes, and other sources of ignition. • Avoid spilling fuel and never smoke while working with any type of fuel or lubricant.
Page 16 Jacking Instructions DANGER If the machine is not properly raised and supported, the machine may move or fall, which may result in personal injury. • Use only mechanical or hydraulic jacks to raise the machine. • Do not use the hydraulic wheel motors as a jacking or support location. •...
Page 17 Raising the Rear of the Machine Before you lift the machine, remove any attachment that may interfere with correctly raising the machine. 1. Park the machine on a level surface, raise the coring head and engage the service latch, fully raise and latch the handlebar to engage the parking brake, set the key switch to the O position and remove the key from the switch.
Page 18 Raising the Rear of the Machine (continued) Figure 3 Eyelets (coring-head bearing housings) G383241S 4. Carefully raise the rear of the machine. 5. Position jack stands or solid wood blocks under both sides of the machine frame to support the machine and lower the machine onto the jack stands. Safety: Jacking Instructions Page 1–8 ProCore®...
Page 19 Safety and Instructional Decals Numerous safety and instruction decals are affixed to the ProCore 648s Aerator. If any decal becomes illegible or damaged, install a new decal. Decal part numbers are listed in your Parts Catalog, Operator’s Manual, and accessory Installation Instructions.
Page 20 Safety: Safety and Instructional Decals Page 1–10 ProCore® 648s Aerator 20255SL Rev D...
Page 21 Chapter 2 Specifications and Maintenance Table of Contents Specifications..............................2–2 Overall Dimensions ..........................2–2 Engine Specifications..........................2–2 Hydraulic System Specifications ......................2–3 Chassis Specifications..........................2–4 Torque Specifications..........................2–5 Calculating the Torque Values When Using a Drive-Adapter Wrench ........2–5 Fastener Identification ..........................2–6 Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series)........
Page 22 Specifications Overall Dimensions Figure 4 G383189S Engine Specifications Description Item Make/Designation Kohler CH680–3165, 2-cylinder, air cooled, OHV gasoline engine Bore x Stroke 80 x 67 mm (3.15 x 2.64 inches) Total displacement 674 cm (41 in Specifications and Maintenance: Specifications Page 2–2 ProCore®...
Page 23 Engine Specifications (continued) Description Item Governor Mechanical Low idle speed 1,300 to 1,500 rpm High idle speed 3,300 to 3,500 rpm Carburetor Float feed, fixed main jet, and solenoid fuel shut-off Fuel Refer to the Operator’s Manual Fuel pump Pulse type Fuel tank capacity 26.5 L (7 US gallons) Air cleaner...
Page 24 Hydraulic System Specifications (continued) Description Item Displacement (per revolution) 390 cm (23.8 in Danfoss OMEW orbital rotor motor – clockwise Rear wheel motor – RH primary rotation Displacement (per revolution) 198 cm (12.1 in Danfoss OMEW orbital rotor motor – counter- Rear wheel motor –...
Page 25 Torque Specifications The 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.
Page 26 Calculating the Torque Values When Using a Drive- Adapter Wrench (continued) determine proper tightening torque. When using a torque wrench with a drive-adapter wrench, the calculated torque will be lower than the listed torque recommendation. Example: The measured effective length of the torque wrench (distance from the center of the handle to the center of the square drive) is 457 mm (18 inches).
Page 27 Toro recommends replacing fasteners with a locking feature once they have been removed because the effectiveness of the locking feature diminishes with each reuse. If it is necessary to reuse a fastener with a locking feature; apply a thread locking compound (Loctite for example) to the fastener during installation.
Page 28 Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series) SAE Grade 1 SAE Grade 5 SAE Grade 8 Bolts, Screws, Bolts, Screws, Bolts, Screws, Studs, and Sems Studs, and Sems Studs, and Sems Grade 1, 5 and 8 with Regular with Regular with Regular...
Page 29 Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series) (continued) SAE Grade 1 SAE Grade 5 SAE Grade 8 Bolts, Screws, Bolts, Screws, Bolts, Screws, Studs, and Sems Studs, and Sems Studs, and Sems Grade 1, 5 and 8 with Regular with Regular with Regular...
Page 30 Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Metric Fasteners) (continued) Class 8.8 Bolts, Screws, and Studs Class 10.9 Bolts, Screws, and Studs with Regular Height Nuts (Class 8 or with Regular Height Nuts (Class 10 Thread Size Stronger Nuts) or Stronger Nuts) 80 to 99 N·m (59 to 73 ft-lb) 112 to 140 N·m (83 to 103 ft-lb)
Page 31 Other Torque Specifications (continued) Thread Cutting Screws (Zinc Plated Steel) (continued) Type 1, Type 23 or Type F Baseline Torque** Thread Size 11 to 34 (100 to 300 in-lb) 3/8 - 16 UNC **The hole size, material strength, material thickness, and material finish must be considered when determining the specified torque values.
Page 32 Shop Supplies The procedures found in this Service Manual may recommend the use of commonly used shop supplies (lubricants, sealants, and adhesives). A symbol denoting the use of a shop supply may appear in figures that support a procedure. Always refer to the written procedure for specific information regarding the type and the application of a shop supply.
Page 33 Shop Supplies (continued) Supply and Description Image Figure 11 RETAINING COMPOUND (bearings and sleeves) An adhesive used to secure bearings, bushings, and cylindrical parts into housings or onto shafts. When cured, bearing and sleeve retaining compound fills the gap between mating parts with a hard resin that increases load distribution and protects against corrosion.
Page 34 An aerosol lubricant may also be specified. Refer to the specific service procedure for details. G428835 Special Tools Special tools are available from your Toro Distributor or from K-Line Tools at https:// www.klineind.com. Some tools may also be available from a local tool supplier. Hydraulic Pressure Testing Kit K–Line Part No.
Page 35 5 to 55 LPM (1 to 15 GPM). Hydraulic O-Ring Kit Toro Part No. 117-2727 This kit includes O-rings in a variety of sizes for the face seal and port seal hydraulic connections. To help prevent a hydraulic leak, replace the O-rings when you open the hydraulic connection.
Page 36 Hydraulic Hose Kit K–Line Part No. TOR6007 This kit includes the fittings and hoses that are used to connect high flow hydraulic filter kit (TOR6011) to the machine hydraulic traction system components. G493834 Bidirectional High Flow Hydraulic Filter Kit K–Line Part Number: TOR6011 The high flow hydraulic filter kit is designed with large flow (150 L/minute or 40 gallons/ minute) and high pressure (344 bar or 5,000...
Page 37 This excess current can damage the circuits that are not designed to carry it. G493836 Battery Terminal Protector Toro Part No. 107-0392 Use this aerosol spray on the battery terminals, ring terminals, and fork terminals to reduce corrosion problems. Apply the...
Page 38 Wheel Hub Puller K–Line Part Number: TOR4097 The wheel hub puller allows safe removal of the wheel hub from the shaft of the wheel motors. G493839 Hydraulic Test Fitting Kit K–Line Part No. TOR4079 This kit includes a variety of O-ring face seal fittings to let you connect the test gauges into the system. FITTING TYPE SIZE PART NUMBER...
Page 39 Hydraulic Test Fitting Kit (continued) FITTING TYPE SIZE PART NUMBER 4 ORFS (9/16–18) TOR4079–17 Figure 19 6 ORFS (11/16–16) TOR4079–18 8 ORFS (13–16–16) CAP (2 each) TOR4079–19 10 ORFS (1–14) TOR4079–20 G214068S 6 ORFS (11/16–16) to8 SAE-ORB TOR4079–8 (3/4–16) Figure 20 8 ORFS (13–16–16) to8 SAE-ORB TOR4079–9 UNION (1 each)
Page 40 Specifications and Maintenance: Special Tools Page 2–20 ProCore® 648s Aerator 20255SL Rev D...
Page 41 Chapter 3 Troubleshooting Table of Contents Introduction..............................3–2 GEARS—The Systematic Approach to Defining, Diagnosing and Solving Problems ....3–3 Operator Advisories............................. 3–4 Advisory Table ............................3–4 Dialogue Messages............................. 3–6 Message Table ............................3–6 Machine Faults ............................. 3–8 Machine Fault Table ..........................3–8 Using the InfoCenter Display Screens for Troubleshooting.............
Page 42 Introduction The information in this chapter is intended to help troubleshoot machine operation issues. Keep in mind there can be more than one cause for a machine malfunction. Troubleshooting: Introduction Page 3–2 ProCore® 648s Aerator 20255SL Rev D...
Page 43 GEARS—The Systematic Approach to Defining, Diagnosing and Solving Problems 1. Gather Information • Information reported by the customer • Information observed by you • Establish the What, Where and When of the issue 2. Evaluate Potential Causes • Consider possible causes of the problem to develop a hypothesis •...
Page 44 Operator Advisories Operator advisories are automatically displayed by the InfoCenter when a machine function is prevented, and additional action is required. Typically, an advisory can be eliminated with a change in machine controls by the operator. For example, if the operator attempts to engage the coring head (PTO) when the Transport/Aeration switch is in the T position, an advisory appears on the InfoCenter Display...
Page 45 PTO DENIED Note: If Unknown Cause appears as an advisory description, a controller software issue may exist. If you are unable to clear this type of advisory, contact an Authorized Toro Distributor. ProCore® 648s Aerator Page 3–5 Troubleshooting: Operator Advisories...
Page 46 Dialogue Messages When the machine is being calibrated, dialog messages appear in the InfoCenter. These messages are intended to instruct you through the calibration process. Refer to the following table for a list of each dialog message. Message Table Message Number InfoCenter Message Clear Existing Message Return pedal to neutral...
Page 47 Message Table (continued) Message Number InfoCenter Message Verify tines are removed. Continue? Verify storage bracket is removed. Continue? Calibration Failed. Remove storage bracket. ProCore® 648s Aerator Page 3–7 Troubleshooting: Dialogue Messages 20255SL Rev D...
Page 48 Machine Faults Machine faults are generated by the T1: Primary controller to identify an electrical system malfunction (fault) that occurs during machine operation. The fault IDs conform to SAE J2012 standards. When a fault occurs, a red warning light will illuminate and a code for the active fault will appear on the InfoCenter display.
Page 49 Circuit Notes Description Connector Result Frame Ground Swap the T: Primary controller with a known-good unit (contact an Authorized Toro Distributor for assistance). C1014 ETR/RTR/OK to The T: The OK_RUN Inspect the connector for the OK Run - Short to...
Page 50 Frame Ground Connector P23, pin 5 < 2Ω=pass Frame Ground Swap the T: Primary controller with a known-good unit (contact an Authorized Toro Distributor for assistance). C1313 Proportional The T: The LIFT output Inspect the connector for the Solenoid Valve...
Page 51 Frame Ground Connector P15, pin 2 < 2Ω=pass Frame Ground Swap the T: Primary controller with a known-good unit (contact an Authorized Toro Distributor for assistance). C1314 Proportional The T: The LIFT output Inspect the connector for the Solenoid Valve...
Page 52 Frame Ground Connector P15, pin 2 < 2Ω=pass Frame Ground Swap the T: Primary controller with a known-good unit (contact an Authorized Toro Distributor for assistance). C1315 Proportional The T: The LIFT output Inspect the connector for the Solenoid Valve...
Page 53 Open=pass Frame Ground Connector P15, pin 2 < 2Ω=pass Frame Ground Swap the T: Primary controller with a known-good unit (contact an Authorized Toro Distributor for assistance). C1323 Proportional The T: The LOWER Inspect the connector for the Solenoid Valve...
Page 54 Frame Ground service. Connector P14, pin 2 < 2Ω=pass Frame Ground Swap the T: Primary controller with a known-good unit (contact an Authorized Toro Distributor for assistance). C1324 Proportional The T: The LOWER Inspect the connector for the Solenoid Valve...
Page 55 Open=pass Frame Ground Connector P14, pin 2 < 2Ω=pass Frame Ground Swap the T: Primary controller with a known-good unit (contact an Authorized Toro Distributor for assistance). C1325 Proportional The T: The LOWER Inspect the connector for the Solenoid Valve...
Page 56 Frame Ground Connector P14, pin 2 < 2Ω=pass Frame Ground Swap the T: Primary controller with a known-good unit (contact an Authorized Toro Distributor for assistance). C1413 Solenoid 1 - The T: The WHEEL Inspect the connector for the S1...
Page 57 Frame Ground Connector P41, pin 2 < 2Ω=pass Frame Ground Swap the T: Primary controller with a known-good unit (contact an Authorized Toro Distributor for assistance). C1414 Solenoid 1 - The T: The WHEEL Inspect the connector for the S1...
Page 58 Frame Ground Connector P41, pin 2 < 2Ω=pass Frame Ground Swap the T: Primary controller with a known-good unit (contact an Authorized Toro Distributor for assistance). C1415 Solenoid 1 - The T: The WHEEL Inspect the connector for the S1...
Page 59 Frame Ground Connector P41, pin 2 < 2Ω=pass Frame Ground Swap the T: Primary controller with a known-good unit (contact an Authorized Toro Distributor for assistance). C14C3 PTO 1 - Short to The T: The AERATION Inspect the connector for the...
Page 60 Frame Ground Connector P20, pin 5 < 2Ω=pass Frame Ground Swap the T: Primary controller with a known-good unit (contact an Authorized Toro Distributor for assistance). C14C5 PTO 1 - Open The T: The AERATION Inspect the connector for the...
Page 61 Frame Ground Connector P20, pin 5 < 2Ω=pass Frame Ground Swap the T: Primary controller with a known-good unit (contact an Authorized Toro Distributor for assistance). C1544 Height Sensor 1 The T: A hall effect Use the InfoCenter to test the...
Page 62 3 Open=pass Frame Ground Replace the head position sensor. Swap the T: Primary controller with a known-good unit (contact an Authorized Toro Distributor for assistance). C1545 Height Sensor 1 The T: A hall effect Use the InfoCenter to test the...
Page 63 3 Open=pass Frame Ground Replace the head position sensor. Swap the T: Primary controller with a known-good unit (contact an Authorized Toro Distributor for assistance). C1549 Height Sensor 1 The T: A hall effect Use the InfoCenter to test the...
Page 64 Machine Fault Table (continued) Fault Condition/ Additional Fault ID Fault Title Service Actions Circuit Notes Description C1554 Ground The T: A hall effect Use the InfoCenter to test the Following Primary sensor reports ground following sensor Sensor 1 - controller the turf guard operation;...
Page 65 Machine Fault Table (continued) Fault Condition/ Additional Fault ID Fault Title Service Actions Circuit Notes Description an Authorized Toro Distributor for assistance). C1555 Ground The T: A hall effect Use the InfoCenter to test the Following Primary sensor reports ground following sensor...
Page 66 Fault Title Service Actions Circuit Notes Description Swap the T: Primary controller with a known-good unit (contact an Authorized Toro Distributor for assistance). C1561 Coring Head The T: The HEAD If the fault occurs while the coring Speed Sensor -...
Page 67 Sensor LED illuminated=fail 10. Replace the head speed sensor. 11. Swap the T: Primary controller with a known-good unit (contact an Authorized Toro Distributor for assistance). C1562 Coring Head The T: The HEAD...
Page 68 Machine Fault Table (continued) Fault Condition/ Additional Fault ID Fault Title Service Actions Circuit Notes Description Out of Range received the varies with Use the InfoCenter input signals coring head Diagnostics>Aeration>Inputs necessary to crank arm/ to observe the Head RPM enable pulley speed.
Page 69 Sensor LED illuminated=fail 10. Replace the head speed sensor. 11. Swap the T: Primary controller with a known-good unit (contact an Authorized Toro Distributor for assistance). If the fault occurs while the coring head crank arm/pulley is not rotating: Inspect the connector for the clutch relay and main wire harness connector P20.
Page 70 Machine Fault Table (continued) Fault Condition/ Additional Fault ID Fault Title Service Actions Circuit Notes Description P0225 Traction Pedal The T: A dual hall Inspect the connector for the Analog Sensor Primary effect sensor traction input sensor and 1 - Open Circuit controller reports the console wire harness connector...
Page 71 (M), pin 17 Open=pass Frame Ground Replace the traction input sensor. Swap the T: Primary controller with a known-good unit (contact an Authorized Toro Distributor for assistance). P0227 Traction Pedal The T: A dual hall Inspect the connector for the...
Page 72 Connector P11 (M), pin 17 Open=pass Frame Ground Replace the traction input sensor. Swap the T: Primary controller with a known-good unit (contact an Authorized Toro Distributor for assistance). Troubleshooting: Machine Faults Page 3–32 ProCore® 648s Aerator 20255SL Rev D...
Page 73 Frame Ground Connector P43, pin 5 < 2Ω=pass Frame Ground Swap the T: Primary controller with a known-good unit (contact an Authorized Toro Distributor for assistance). P0575 Cruise Control The T: The T: Primary Use the InfoCenter to test the...
Page 74 Machine Fault Table (continued) Fault Condition/ Additional Fault ID Fault Title Service Actions Circuit Notes Description aeration. Cruise Resistance test the main wire is disabled. harness: Connector Result Connector P11, pin 24 < 2Ω=pass Frame Ground Connector P11, pin 35 Open=pass Frame Ground Set the cruise control switch to...
Page 75 Frame Ground Connector P11 (M), pin 22 < 2Ω=pass Frame Ground 10. Swap the T: Primary controller with a known-good unit (contact an Authorized Toro Distributor for assistance). P0615 Start Output - The T: The START Inspect the connector for the...
Page 76 Frame Ground Connector P25, pin 5 < 2Ω=pass Frame Ground Swap the T: Primary controller with a known-good unit (contact an Authorized Toro Distributor for assistance). P0617 Start Output - The T: The START Inspect the connector for the Short to Battery...
Page 77 Frame Ground Connector P25, pin 5 < 2Ω=pass Frame Ground Swap the T: Primary controller with a known-good unit (contact an Authorized Toro Distributor for assistance). P0691 Fan Relay - The T: The T: Primary Inspect the connector for the fan...
Page 78 Fault Title Service Actions Circuit Notes Description Swap the T: Primary controller with a known-good unit (contact an Authorized Toro Distributor for assistance). P0692 Fan Relay - The T: The T: Primary Inspect the connector for the fan Short to Battery...
Page 79 Frame Ground Connector P17, pin 2 < 2Ω=pass Frame Ground Swap the T: Primary controller with a known-good unit (contact an Authorized Toro Distributor for assistance). P110D Traction Coil 1 The T: The T: Primary Inspect the connector for the...
Page 80 Frame Ground Connector P17, pin 2 < 2Ω=pass Frame Ground Swap the T: Primary controller with a known-good unit (contact an Authorized Toro Distributor for assistance). P110E Traction Coil 1 The T: The T: Primary Inspect the connector for the...
Page 81 Frame Ground Connector P17, pin 2 < 2Ω=pass Frame Ground Swap the T: Primary controller with a known-good unit (contact an Authorized Toro Distributor for assistance). P111C Traction Coil 1 The T: The T: Primary Inspect the connector for the...
Page 82 Frame Ground Connector P16, pin 2 < 2Ω=pass Frame Ground Swap the T: Primary controller with a known-good unit (contact an Authorized Toro Distributor for assistance). P111D Traction Coil 1 The T: The T: Primary Inspect the connector for the...
Page 83 Frame Ground Connector P16, pin 2 < 2Ω=pass Frame Ground Swap the T: Primary controller with a known-good unit (contact an Authorized Toro Distributor for assistance). P111E Traction Coil 1 The T: The T: Primary Inspect the connector for the...
Page 84 Frame Ground Connector P16, pin 2 < 2Ω=pass Frame Ground Swap the T: Primary controller with a known-good unit (contact an Authorized Toro Distributor for assistance). P1189 Traction Pump The T: The T: Primary Calibrate the traction pump. 1 - Invalid...
Page 85 Swap the T: Primary controller data for the to determine the with a known-good unit (contact traction input maximum an Authorized Toro Distributor sensor fails amount of for assistance). the data voltage from the integrity traction input check.
Page 86 Machine Fault Table (continued) Fault Condition/ Additional Fault ID Fault Title Service Actions Circuit Notes Description pedal position Connector Result relative to neutral. Connector P11 (M), pin 19 < 2Ω=pass Connector P12 (CH), pin 4 Connector P11 (M), pin 19 Open=pass Frame Ground Connector P11...
Page 87 Machine Fault Table (continued) Fault Condition/ Additional Fault ID Fault Title Service Actions Circuit Notes Description an Authorized Toro Distributor for assistance). P2130 Traction Pedal The T: A dual hall Inspect the connector for the Analog Sensor Primary effect sensor...
Page 88 (M), pin 17 Open=pass Frame Ground Replace the traction input sensor. Swap the T: Primary controller with a known-good unit (contact an Authorized Toro Distributor for assistance). P2132 Traction Pedal The T: A dual hall Inspect the connector for the...
Page 89 Machine Fault Table (continued) Fault Condition/ Additional Fault ID Fault Title Service Actions Circuit Notes Description inputs. Traction Connector Result is disabled. Connector P11 (M), pin 19 < 2Ω=pass Connector P12 (CH), pin 4 Connector P11 (M), pin 19 Open=pass Frame Ground Connector P11 (M), pin 20...
Page 90 Machine Fault Table (continued) Fault Condition/ Additional Fault ID Fault Title Service Actions Circuit Notes Description an Authorized Toro Distributor for assistance). P2152 Wheel Speed The T: The T: Primary Use the InfoCenter to verify Sensor Failure Primary uses input...
Page 91 System voltage=pass Frame Ground Replace the wheel speed sensor. Swap the T: Primary controller with a known-good unit (contact an Authorized Toro Distributor for assistance). P2503 Alternator - The T: The T: Primary Inspect the negative and positive Charging Too...
Page 92 Fuse block slot Connector P26, pin 2 Open=pass Frame Ground Swap the T: Primary controller with a known-good unit (contact an Authorized Toro Distributor for assistance). P2504 Alternator - The T: The T: Primary Test the charging system; refer Charging Too...
Page 93 P10 (CH) , pin E. Replace the InfoCenter. Swap the T: Primary controller with a known- good unit (contact an Authorized Toro Distributor for assistance). If the main relay does not “click” and the InfoCenter displays the ProCore® 648s Aerator Page 3–53...
Page 94 Open=pass Frame Ground D. Swap the T: Primary controller with a known- good unit (contact an Authorized Toro Distributor for assistance). The main relay “clicks” and the InfoCenter displays the splash screen (CAN bus issue). A. Inspect the InfoCenter connector and console wire harness connector P10.
Page 95 P11 (M), pin Open=pass Frame Ground D. Replace the InfoCenter. E. Swap the T: Primary controller with a known- good unit (contact an Authorized Toro Distributor for assistance). U1007 Controller Main The T: The main power Use the InfoCenter Power Relay...
Page 96 Machine Fault Table (continued) Fault Condition/ Additional Fault ID Fault Title Service Actions Circuit Notes Description Harness Result Component Connector P02, Battery voltage pin 2 =pass Frame Ground Replace the main relay (4 terminal). Inspect the key switch connector and main wire harness connector P01.
Page 97 Machine Fault Table (continued) Fault Condition/ Additional Fault ID Fault Title Service Actions Circuit Notes Description Fuse block Slot 10. Inspect the T1 controller connector and main wire harness connector P11. 11. Resistance test main wire harness: Harness Result Component Connector P11, pin 37 <...
Page 98 Fault Title Service Actions Circuit Notes Description 12. Swap the T: Primary controller with a known-good unit (contact an Authorized Toro Distributor for assistance). U1022 TEC Fuse 2 The T: Power for the Test the 7.5A fuse at fuse block...
Page 99 Fault Title Service Actions Circuit Notes Description Swap the T: Primary controller with a known-good unit (contact an Authorized Toro Distributor for assistance). U1025 TEC Fuse 5 The T: Power for the Test the 7.5A fuse at fuse block Failure...
Page 100 Authorized Toro Distributor for assistance). U1117 Source Address The T: The T: Primary Update machine software (contact Contention Primary controller and your Authorized Toro Distributor for Fault controller the InfoCenter assistance). received a must have message unique network from another...
Page 101 U130A Software The T: The T: Primary Update machine software (contact Version Primary controller and your Authorized Toro Distributor for Incompatibility - controller the InfoCenter assistance). InfoCenter detected that must have compatible InfoCenter software for the...
Page 102 Frame Ground function Swap the T: Primary controller properly. The with a known-good unit (contact machine is an Authorized Toro Distributor disabled. for assistance). U1701 Board Internal The T: The T: Primary Voltage test the battery.
Page 103 Using the InfoCenter Display Screens for Troubleshooting The InfoCenter Display Main Information Screens can be used to check the operation of various components. The transport mode and aerate mode screens represent mode switch activity and can be used to verify the circuit switch and its wiring integrity.
Page 104 (circuit wiring or fuse) may exist, or the controller software may require reloading or replacement. Contact your Authorized Toro Distributor for assistance. As an example, while viewing the Diagnostics>Engine>Output screen, if the key...
Page 105 Using the Outputs Screen Note: An inappropriate output reading may indicate an issue with the controller. Contact your Authorized Toro Distributor for assistance with controller reprogramming or replacement. • Once the required conditions are satisfied, Hydrostat Fwd should show an...
Page 106 Troubleshooting—Hydraulic The following tables contain suggestions that can be used to solve performance issues specific to the hydraulic system. The suggestions are not all-inclusive. There can be more than one cause for a machine malfunction. Review the hydraulic schematic found in 9 Appendix A, page 9–1 and information on the hydraulic system operation in the...
Page 107 General Hydraulic System Problems Hydraulic System Problems Quick Reference Table Problem Possible Cause Corrective Action Hydraulic fluid is leaking from The fitting(s), hose(s), or tube(s) Secure or replace loose or the system. are loose or damaged. damaged hydraulic connections. The O-ring(s) or seal(s) are Install a new O-ring(s) or seal(s).
Page 108 Hydraulic System Problems Quick Reference Table (continued) Problem Possible Cause Corrective Action Circuit – Piston (traction) Pump Flow and Relief Pressure Test, page 5–29 in the Hydraulic System chapter of this manual. The wheel motor(s) is worn or Verify wheel motor operation; damaged.
Page 109 Troubleshooting—Electrical CAUTION Remove all the jewelry, especially rings and watches, before doing any electrical troubleshooting or testing. Disconnect the battery cables unless the test requires battery voltage. Pay attention to the InfoCenter display screens. Use the main information screen icons and the operator’s advisories to help troubleshoot electrical issues. For the effective troubleshooting and repairs, you must have a good understanding of the electrical circuits and components that are used on this machine;...
Page 110 Starting Problems Starting Problems Quick Reference Table Problem Possible Cause Corrective Action The starter solenoid clicks, but The battery charge is low. Charge the battery. the starter does not crank. The battery is discharged or Charge and test the battery. damaged.
Page 111 Starting Problems Quick Reference Table (continued) Problem Possible Cause Corrective Action A relay is damaged. Test the start relay and main power relay and replace them if necessary; refer to Component Testing in Chapter 5 – Electrical System. The key switch is damaged. Test the key switch and replace it if necessary;...
Page 112 General Operation Problems Operation Problems Quick Reference Table Problem Possible Cause Corrective Action The battery does not charge. The battery cables are loose or Clean and secure the battery corroded. cables. The ground connection is loose Clean and secure the ground or corroded.
Page 113 Operation Problems Quick Reference Table (continued) Problem Possible Cause Corrective Action The engine is malfunctioning. Troubleshoot the engine; refer to the Kohler Command CH680 Service Manual. The machine stops driving in the The bump-stop switch has been Reset the bump-stop switch by forward direction.
Page 114 Troubleshooting: General Operation Problems Page 3–74 ProCore® 648s Aerator 20255SL Rev D...
Page 115 Chapter 4 Engine Table of Contents General Information............................. 4–2 Operator’s Manual ........................... 4–2 Engine Owner’s Manual ......................... 4–2 Engine Service Manual........................... 4–2 Fuel Shutoff Valve............................ 4–3 Kohler Gasoline Engine.......................... 4–3 Adjustments..............................4–5 Adjusting the Engine Idle Speed ......................4–5 Service and Repairs ............................ 4–6 Engine Cooling System ..........................
Page 116 The engine Owner’s Manual provides information regarding the operation, general maintenance, and maintenance intervals for the KOHLER Command CH680 engine used on your ProCore 648s aerator. A copy of the engine Owner’s Manual is supplied with the machine. Contact your local KOHLER Engine Dealer or visit http:// kohlerpower.com/powerhub/engines.html...
Page 117 Fuel Shutoff Valve Figure 26 Fuel tank Fuel shutoff valve G384457S The fuel shutoff valve located under the fuel tank 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.
Page 118 Kohler Gasoline Engine (continued) is wired as an input to the T1: Primary controller but is not currently being monitored by the controller. Engine: General Information Page 4–4 ProCore® 648s Aerator 20255SL Rev D...
Page 119 Adjustments Adjusting the Engine Idle Speed Refer to the Kohler Command CH680 Service Manual for additional information. ProCore® 648s Aerator Page 4–5 Engine: Adjustments 20255SL Rev D...
Page 120 IMPORTANT The engine that powers the ProCore 648s is air–cooled. Operating the engine with dirty or plugged cooling fins, a blocked grass screen or a plugged or dirty blower housing will result in engine overheating and engine damage.
Page 121 Engine Cooling System (continued) 3. Clean the grass screen and blower housing of dirt and debris. 4. If blower housing removal is necessary for cooling system cleaning, the engine needs to be removed from the machine; refer to Removing the Engine, page 4– IMPORTANT Never operate the engine without the blower housing installed.
Page 122 Fuel System Figure 29 G383362 Hose clamp Hose clamp (3 each) Fuel tank Fuel tank cap Shutoff valve Fuel filter Hose clamp (2 each) Grommet Fuel hose – filter to fuel pump Rollover valve Fuel hose – tank to shutoff valve Washer (4 each) Hose clamp (2 each) Cap screw (4 each)
Page 123 Fuel System (continued) DANGER Gasoline fuel is highly flammable and explosive. A fire or an explosion from the fuel can burn you, burn other people, and damage property. • Use caution whenever you store or handle gasoline fuel. • Do not smoke while filling the fuel tank. •...
Page 124 Fuel System (continued) Removing the Fuel Tank Refer to Figure 29 for this procedure. 1. Park the machine on a level surface, raise the coring head and engage the service latch, fully raise and latch the handlebar to engage the parking brake, set the key switch to the O position and remove key from the switch.
Page 125 Fresh air filter Orifice adapter ProCore 648s aerators are equipped with a fuel evaporative control system designed to collect and store evaporative emissions from the fuel tank. The evaporate control system uses a carbon canister and a series of vent hoses to collect these evaporative emissions.
Page 126 Fuel Evaporative Control System (continued) The carbon canister is mounted to a bracket behind the fuel tank. The evaporative system connection to the engine passes through an orifice (metered restriction) and a vacuum check/purge valve before connecting to the engine intake manifold. The evaporative control system vent connection passes through a fresh air filter before it reaches the carbon canister.
Page 127 Exhaust System Figure 31 G383446S Exhaust elbow Cap screw (3 each) Hex nut (4 each) Carriage bolt (2 each) Heat shield assembly Gasket (2 each) Muffler Exhaust manifold Flange nut (2 each) Muffler clamp (2 each) Removing the Exhaust System Refer to Figure 31 for this procedure.
Page 128 Exhaust System (continued) CAUTION A hot engine and exhaust system can cause burns. Allow the engine and the exhaust system to cool before removing the exhaust system. 3. Remove the heat shield assembly. 4. Loosen the muffler clamps that secure the muffler and exhaust elbow. 5.
Page 129 Primary Drive Figure 32 G384309S Grommet (2 each) Pulley, pump drive Idler, primary drive belt Spacer (2 each) Pump drive belt Torsion spring Idler, pump drive belt Washer Spacer (3 each) Flange bushing (2 each) Primary drive belt Support bracket, inner Idler arm Clutch Spring tab...
Page 130 Primary Drive (continued) Removing the Primary Drive Belt Refer to Figure 32 for this procedure. 1. Park the machine on a level surface, raise the coring head and engage the service latch, fully raise and latch the handlebar to engage the parking brake, set the key switch to the O position and remove key from the switch.
Page 131 Primary Drive (continued) 3. Lubricate the idler grease fitting with high-temperature grease (Mobil XHP-222 or equivalent). 4. Install the muffler and exhaust elbow; refer to Installing the Exhaust System, page 4–14. 5. Test the primary drive belt operation before returning the machine to service. Removing the Primary Drive Refer to Figure 32...
Page 132 Engine Figure 33 G384444S Canister bracket Clutch connector Engine assembly assembly Positive battery cable Carbon canister assembly Negative battery cable Multi-pin engine harness connector Wire harness ground Removing the Engine Refer to Figure 33 for this procedure. 1. Park the machine on a level surface, raise the coring head and engage the service latch, fully raise and latch the handlebar to engage the parking brake, set the key switch to the O position and remove key from the switch.
Page 133 Engine (continued) 5. Close the fuel shutoff valve and remove the fuel tank; refer to Removing the Fuel Tank, page 4–10. 6. Disconnect the evaporative control system hose at the intake manifold. Cover or plug the disconnected hose and the intake manifold inlet to prevent evaporative control system contamination.
Page 134 Engine (continued) 3. Install the hydraulic pump drive pulley and electric clutch to the engine if necessary; refer to Installing the Primary Drive, page 4–17. CAUTION Use an appropriate lift and the lifting lugs provided to prevent the engine from falling and causing personal injury or product damage.
Page 135 Engine (continued) 15. Connect the negative battery cable to battery; refer to Removing and Installing the Battery, page 6–71. 16. Check all wires and hoses to make sure that they do not contact rotating or moving parts. 17. Check the engine oil level and adjust as necessary; refer to the aerator Operator’s Manual.
Page 136 Engine: Service and Repairs Page 4–22 ProCore® 648s Aerator 20255SL Rev D...
Page 137 Chapter 5 Hydraulic System Table of Contents Additional Reference Materials......................... 5–2 General Information............................. 5–3 Relieving Pressure from the Hydraulic System ................5–3 Towing or Moving the Machine by Hand..................... 5–3 Traction Circuit Component Failure..................... 5–5 Hydraulic Hoses ............................5–5 Installing Hydraulic Hoses and Tubes (O-Ring Face Seal Fitting) ..........5–6 Installing the Hydraulic Fittings (SAE Straight Thread O-Ring Fittings)........
Page 138 Additional Reference Materials Poclain PM10 Hydraulic Pump Repair Manual Sauer-Danfoss Hydraulic Motors OMEW Service Manual Hydraulic System: Additional Reference Materials Page 5–2 ProCore® 648s Aerator 20255SL Rev D...
Page 139 General Information Relieving Pressure from the Hydraulic System Release all the pressure in the hydraulic system before you work on the hydraulic system. Note: If you park the machine on an incline or slope, the pressure in the traction circuit does not release. 1.
Page 140 Towing or Moving the Machine by Hand (continued) Figure 34 Bypass valve G384991S 4. Use a 15 mm socket to loosen the bypass valve, then open the valve 1-1/2 revolutions maximum. 5. Use the front tie-down hoop to tow the machine. Figure 35 Front tie-down hoop G342220S...
Page 141 7. After towing and before starting the engine, tighten the bypass valve. Traction Circuit Component Failure The traction circuit of ProCore 648s machines is a closed loop system that includes the hydraulic pump and hydraulic wheel motors. If a component in the traction circuit should fail, unwanted material and contamination from the damaged component will circulate throughout that traction circuit.
Page 142 If the hose has an elbow at one end, tighten the swivel nut on the elbow end before you tighten the nut on the straight end of the hose. For more hydraulic hose information, refer to the Toro Basics Series Training Book Hydraulic Hose Servicing (Part No. 94813SL).
Page 143 Installing Hydraulic Hoses and Tubes (O-Ring Face Seal Fitting) (continued) 1. Ensure that all the threads, the sealing surfaces of the hose/tube, and the fitting are free of burrs, nicks, scratches, or unwanted material. 2. To help prevent a hydraulic leak, replace the face seal O-ring when you open the connection.
Page 144 Installing Hydraulic Hoses and Tubes (O-Ring Face Seal Fitting) (continued) Flats From Wrench Resistance Table Size FFWR 4 (1/4-inch nominal hose or tubing) 1/2 to 3/4 6 (3/8 inch) 1/2 to 3/4 8 (1/2 inch) 1/2 to 3/4 10 (5/8 inch) 1/2 to 3/4 12 (3/4 inch) 1/3 to 1/2...
Page 145 Installing the Hydraulic Fittings (SAE Straight Thread O-Ring Fittings) (continued) 3. Lightly lubricate the O-ring with clean hydraulic fluid. Ensure that the threads of the fitting are clean with no lubricant applied. IMPORTANT Before tightening the fitting, determine the material used for the port the fitting is being installed in.
Page 146 Installing the Hydraulic Fittings (SAE Straight Thread O-Ring Fittings) (continued) Figure 40 Step 1: clearance the lock Step 2: seat the back-up washer Step 3: align the fitting Step 4: tighten the lock nut G494052 1. Ensure that all the threads, the sealing surfaces of fitting, and the component port are free of burrs, nicks, scratches, or unwanted material.
Page 147 Installing the Hydraulic Fittings (SAE Straight Thread O-Ring Fittings) (continued) B. If a torque wrench is not available or if space at the port prevents the use of a torque wrench, hold the fitting in the correct alignment with a wrench and tighten the lock nut with a second wrench.
Page 148 Installing the Hydraulic Fittings (SAE Straight Thread O-Ring Fittings) (continued) Flats From Finger Tight (FFFT) Table (continued) Size FFFT 12 (3/4 inch) 1.25 to 1.75 16 (1 inch) 1.25 to 1.75 Hydraulic System: General Information Page 5–12 ProCore® 648s Aerator 20255SL Rev D...
Page 149 Hydraulic Schematics The hydraulic schematic for the ProCore 648s machine is located in 9 Appendix A, page 9–1. Traction Circuit The hydraulic traction circuit is a closed loop system consisting of an electro- hydraulic servo controlled variable displacement piston (traction) pump and a series of hydraulic wheel motors.
Page 150 Traction Circuit (continued) Primary controller uses the sensor signal to send a corresponding PWM output to the REV (top) solenoid valve on the traction pump servo piston assembly, which moves the pump swash plate to create a flow of oil. The oil flow exits the traction pump B port and flows to the rear wheel motors and then to the front wheel motor to drive the wheels in the reverse direction.
Page 151 Coring Head Lift Circuit The gear pump supplies oil flow for the coring head lift circuit and provides a constant supply of charge oil to the closed loop traction circuit. Coring Head Idle When the coring head lift system is not actively raising, or lowering, check valves in the de-energized proportional solenoid valves SP1 (raise) and SP2 (lower) hold the coring head lift cylinder stationary.
Page 152 Hydraulic Flow Diagrams Traction Circuit Schematic Figure 41 Traction Circuit Diagram (Forward) G386410S Hydraulic System: Hydraulic Schematics Page 5–16 ProCore® 648s Aerator 20255SL Rev D...
Page 153 Hydraulic Flow Diagrams (continued) Coring Head Lift Circuit Schematic Figure 42 Lift Circuit Diagram G386409S ProCore® 648s Aerator Page 5–17 Hydraulic System: Hydraulic Schematics 20255SL Rev D...
Page 154 Testing the Hydraulic System The most effective procedure to isolate the problems in the hydraulic system is to use hydraulic test equipment, such as pressure gauges and flow meters in the circuits during different operational checks; refer to Special Tools, page 2–14.
Page 155 IMPORTANT Use 2 people to perform all the tests, with 1 person in the Operator’s position and the other to read and record the test results. • Use the following resources to assist with hydraulic system troubleshooting: – The Hydraulic Schematic in 9 Appendix A, page 9–1.
Page 156 • Position any test hoses away from parts that may move during the test procedure. • After you connect the test equipment, check the hydraulic-fluid level in the hydraulic reservoir and ensure that the fluid level is correct. • Perform all the hydraulic tests with the hydraulic fluid at normal operating temperature.
Page 157 Traction Circuit—Charge Pressure (continued) 3. Remove the storage bin. 4. Clean the fittings and the hydraulic tube ends at the traction pump and at the wheel bypass manifold. Figure 43 Traction pump Hydraulic tube Lift manifold G2 port test fitting G385611S 5.
Page 158 Traction Circuit—Charge Pressure (continued) B. The gear pump is faulty (reduced coring head lift circuit performance will also be affected. Test the gear pump flow; refer to Testing the Lift Circuit — Gear Pump Flow, page 5–33. 15. Ensure the machine is set to Transport mode and apply a load to the traction pump by slowly moving the traction control in the F direction until 6200 to ORWARD...
Page 159 Traction Circuit—Charge Pressure (continued) Hydraulic Schematic Figure 44 Traction Circuit — Charge Pressure Test G386777S ProCore® 648s Aerator Page 5–23 Hydraulic System: Testing the Hydraulic System 20255SL Rev D...
Page 160 Traction Circuit—Wheel Motor Efficiency Wheel motor efficiency is the second in a series of tests recommended to determine traction circuit performance. Too much hydraulic fluid flow through a single stationary wheel motor under load indicates an internal leak in the wheel motor. A worn wheel motor is less efficient.
Page 161 Traction Circuit—Wheel Motor Efficiency (continued) Figure 45 Traction pump Hydraulic tube Lift manifold G388994S 6. Disconnect both ends of the hydraulic tube and remove the tube from the machine. 7. Install one hydraulic test hose to the exposed fitting at the traction pump, and a second test hose to the exposed fitting at the wheel bypass manifold.
Page 162 Traction Circuit—Wheel Motor Efficiency (continued) tested is not rotating and record the flow meter reading. Wheel motor internal leakage is measured by the flow meter in GPM. 8. Release the traction pedal, shut off the engine and rotate the front wheel being tested 90°.
Page 163 Traction Circuit—Wheel Motor Efficiency (continued) CAUTION Use extreme caution when performing test. The front wheel will be trying to move the machine forward. 8. Slowly press the traction control in the forward direction until 6,900 kPa (1,000 psi) is displayed on the tester pressure gauge. Ensure that the wheel being tested is not rotating and record the flow meter reading.
Page 164 Traction Circuit—Wheel Motor Efficiency (continued) Hydraulic Schematic Figure 46 Traction Circuit — Wheel Motor Efficiency G386821S Hydraulic System: Testing the Hydraulic System Page 5–28 ProCore® 648s Aerator 20255SL Rev D...
Page 165 Traction Circuit—Piston (Traction) Pump Flow and Relief Pressure The piston (traction) pump flow test is the third in a series of tests recommended to determine the traction circuit performance. This test compares fluid flow at No Load with fluid flow Under Load. A drop in flow under load of more than 12% indicates an internal leak or malfunctioning relief valve in the hydraulic pump.
Page 166 Traction Circuit—Piston (Traction) Pump Flow and Relief Pressure (continued) Figure 47 Traction pump Hydraulic tube Lift manifold G388994S 6. Disconnect both ends of the hydraulic tube and remove the tube from the machine. 7. Install one hydraulic test hose to the exposed fitting at the traction pump, and a second test hose to the exposed fitting at the wheel bypass manifold.
Page 167 Traction Circuit—Piston (Traction) Pump Flow and Relief Pressure (continued) 14. Verify the pump flow Under Load as follows: A. Slowly move the traction pedal to the fully F position. ORWARD B. Apply an additional load of 8,274 to 12,410 kPa (1,200 to 1,800 psi) by slowly closing the flow meter.
Page 168 Traction Circuit—Piston (Traction) Pump Flow and Relief Pressure (continued) Hydraulic Schematic Figure 48 Traction Circuit — Piston (Traction) Pump Flow and Relief Pressure G386848S Hydraulic System: Testing the Hydraulic System Page 5–32 ProCore® 648s Aerator 20255SL Rev D...
Page 169 Traction Circuit—Gear Pump Flow The gear pump is designed to satisfy the traction charge circuit and lift cylinder needs. The Gear Pump Flow Test compares fluid flow at No Load with fluid flow Under Load. A drop in flow under load of more than 15% indicates the gears and wear plates in the pump have worn.
Page 170 Traction Circuit—Gear Pump Flow (continued) 6. Install one hydraulic test hose to the exposed fitting at the gear pump, and a second test hose to the exposed fitting at the lift manifold. 7. Install a hydraulic tester to the exposed ends of the test hoses. Make sure the tester is installed in the correct flow direction (toward the lift manifold) and the tester flow control valve is fully open.
Page 171 Traction Circuit—Gear Pump Flow (continued) E. Repair hydraulic leaks if necessary before returning the machine to service. ProCore® 648s Aerator Page 5–35 Hydraulic System: Testing the Hydraulic System 20255SL Rev D...
Page 172 Traction Circuit—Gear Pump Flow (continued) Hydraulic Schematic Figure 50 Lift Circuit — Gear Pump Flow G386888S Hydraulic System: Testing the Hydraulic System Page 5–36 ProCore® 648s Aerator 20255SL Rev D...
Page 173 Lift Circuit—Relief Valve (RV) Pressure The relief valve for the lift circuit (RV) is located in the lift manifold. If both charge circuit pressure and lift operations perform poorly, perform the gear pump flow test; refer to Testing the Lift Circuit — Gear Pump Flow, page 5–33.
Page 174 Lift Circuit—Relief Valve (RV) Pressure (continued) 10. Move the throttle to low speed and set the key switch to the O position. 11. The circuit relief valve pressure should be approximately 6900 kPa (1000 PSI). If the relief pressure cannot be met or is greater than specified, the relief valve is damaged and should be repaired or replaced;...
Page 175 Adjustments Piston (traction) Pump Drive Belt Tension The piston (traction) pump is driven by the engine via a V-belt. V-belt tension is controlled by a spring-loaded idler that must be set manually; refer to the aerator Operator’s Manual. ProCore® 648s Aerator Page 5–39 Hydraulic System: Adjustments 20255SL Rev D...
Page 176 Service and Repairs General Precautions for Removing and Installing the Hydraulic System Components Repairing or Replacing the Components (Before) • Before removing any parts from the hydraulic system, park the machine on a level surface, raise the coring head and engage the service latch, set the key switch to the O position, and remove the key from the key switch.
Page 177 General Precautions for Removing and Installing the Hydraulic System Components (continued) IMPORTANT Drain and fill the hydraulic reservoir and change the oil filters if the component failure is severe or the system is contaminated; refer to the aerator Operator’s Manual. •...
Page 178 Checking the Hydraulic Lines and Hoses (continued) IMPORTANT Check the hydraulic lines and hoses daily for leaks, kinked lines, loose mounting supports, wear, loose fittings, and hose deterioration. Repair the damaged hydraulic lines and hoses before operating the machine. Flushing the Hydraulic System IMPORTANT If a component failure occurs in the traction circuit;...
Page 179 To effectively remove contamination from the closed−loop traction circuit, use of a Toro bidirectional high flow hydraulic filter and hydraulic hose kit is recommended; refer to Bidirectional High Flow Hydraulic Filter Kit, page 2–16.
Page 180 6. Disconnect both ends of the hydraulic tube and remove the tube from the machine. 7. Connect the Toro high flow hydraulic filter in series between the disconnected fittings. Use the hydraulic hose kit to connect the filter to the machine if necessary;...
Page 181 IMPORTANT If you are using a filter that is not the Toro high flow filter that is bi-directional, do not press the traction control in the opposite direction. If the flow is reversed when using a filter that is not bi-directional, unwanted material from the filter will again enter the traction circuit.
Page 182 Priming the Hydraulic Pumps (continued) IMPORTANT If the piston (traction) pump was rebuilt or replaced, make sure the pump housing is at least half full of clean hydraulic fluid after installation. 1. Make sure all hydraulic connections are properly tightened. 2.
Page 183 Charging the Hydraulic System (continued) 6. Make sure the traction control is in neutral, then start the engine and let it idle at low speed. The hydraulic pumps should pick up hydraulic fluid and fill the hydraulic system. If there is no indication of the system filling within 30 seconds, set the key switch to the O position and determine the cause.
Page 184 Hydraulic Reservoir Figure 54 G387552S Cap screw Lift manifold Hydraulic Reservoir Return filter Washer Dipstick Straight fitting Mounting strap Straight fitting Shoulder bolt Removing and Installing the Hydraulic Reservoir Refer to Figure 54 for this procedure. 1. Park the machine on a level surface, raise the coring head and engage the service latch, set the key switch to the O position, and remove the key from the key switch.
Page 185 Hydraulic Reservoir (continued) 7. Remove the fastener securing the mounting strap to the frame, then remove the hydraulic reservoir and mounting strap. 8. Clean hydraulic reservoir with solvent. 9. Inspect reservoir for leaks, cracks, or other damage. 10. Install the hydraulic reservoir. 11.
Page 186 Hydraulic Pump Drive Belt (continued) Removing the Hydraulic Pump Drive Belt Refer to Figure 55 for this procedure. 1. Remove the primary drive belt; refer to Removing the Primary Drive Belt, page 4– 2. Loosen the fasteners securing the hydraulic pump drive belt idler pulley to the bracket.
Page 187 Piston (Traction) Pump Figure 56 G390506S Cap screw (2 each) Elbow fitting Elbow fitting Gar pump Cap screw (2 each) Woodruff key O-Ring Pump pulley Elbow fitting Set screw (2 each) Flange nut (2 each) Elbow fitting (2 each) The following procedures describe removing the piston (traction) pump and gear pump from the machine as an assembly, then separating the pumps if necessary.
Page 188 Piston (Traction) Pump (continued) 4. Record the connector location and disconnect the main wire harness from the piston pump control valves (Traction Coil FWD-bottom and Traction Coil REV- top). 5. Remove the hydraulic return filter from the lift manifold to drain the hydraulic reservoir.
Page 189 Piston (Traction) Pump (continued) CAUTION Use a suitable lift or hoist to install the hydraulic pump assembly in the machine. The hydraulic pumps assembly (piston pump and gear pump combined) weighs approximately 25 kg (55 lbs). 3. Carefully lower the pump assembly into the frame and secure the pump to the frame with the previously removed fasteners.
Page 190 Piston (Traction) Pump (continued) Calibrating the Piston (Traction) Pump If the piston (traction) pump is replaced in part or in whole, the electro-hydraulic control aspect of the pump assembly requires calibration before returning the machine to service. If the traction system drives inconsistently or with abrupt wheel motion, check the traction pump-drive system for the following: •...
Page 191 Piston (Traction) Pump (continued) Figure 57 G494073 4. Navigate to the Service>Traction Pump screen and select the Start Teach option. Figure 58 G494074 5. Follow the on-screen calibration instructions. ProCore® 648s Aerator Page 5–55 Hydraulic System: Service and Repairs 20255SL Rev D...
Page 192 Piston (Traction) Pump (continued) Note: If the calibration procedure fails, try calibrating the item again. Ensure the traction system is operating properly before continuing to troubleshoot the system. Figure 59 G494130 6. When the traction pump calibration completes, shut off the engine. 7.
Page 193 Servicing the Piston (Traction) Pump Figure 60 G390519S Driveshaft Plug Shaft seal kit Control valve (2 each) Driveshaft Woodruff key Forward/ bearing kit Reverse relief Coil, control Seal kit valve kit (2 valve (2 each) Charge relief each) valve Rotating group Plug (5 each) Coupling Valve plate...
Page 194 Servicing the Piston (Traction) Pump (continued) Refer to the Poclain PM10 Hydraulic Pump Repair Manual for additional information. IMPORTANT If a piston (traction) pump failure occurred, refer to Traction Circuit Component Failure, page 5–5 for information regarding the importance of removing contamination from the traction circuit.
Page 195 Gear Pump (continued) Removing the Gear Pump Refer to Figure 61 for this procedure. 1. Park the machine on a level surface, raise the coring head and engage the service latch, set the key switch to the O position, and remove the key from the key switch.
Page 196 Gear Pump (continued) 8. Charge the hydraulic system; refer to Charging the Hydraulic System, page 5–46. Servicing the Gear Pump Figure 62 G387564S Uni-ring (2 each) Rear cover Retaining ring Cap screw (4 each) Shaft seal Thrust plate (2 each) Front cover Washer (4 each) Drive shaft/gear...
Page 197 Servicing the Gear Pump (continued) Figure 63 Marker line G320241S IMPORTANT Avoid distorting any pump components when clamping gear pump in a vise. Use a vise with soft jaws. 3. Secure the front cover of the pump in a vise with the drive shaft pointing down. 4.
Page 198 Servicing the Gear Pump (continued) 9. Clean all parts. Check all components for burrs, scoring, nicks, and other damage. 10. Replace the entire pump assembly if any pump components are excessively worn or scored. Inspecting the Gear Pump If internal pump parts are found to be worn or damaged, gear pump replacement is necessary.
Page 199 Servicing the Gear Pump (continued) B. The face of the thrust plate that contacts the gears should be free of wear, roughness, or scoring. C. The thickness of each set of thrust plates should be equal. 5. Inspect the front cover and the rear cover for damage or wear. Assembling the Gear Pump Refer to Figure 62...
Page 200 Servicing the Gear Pump (continued) 16. Place a small amount of clean hydraulic oil in the pump inlet and rotate the drive shaft clockwise one revolution. If any binding is noted, disassemble the pump and check for assembly problems. Front Wheel Motor Figure 65 G388905S Woodruff key...
Page 201 Front Wheel Motor (continued) 5. Use a torque multiplier and remove the wheel hub nut. Discard the wheel hub nut. IMPORTANT To prevent damage to hydraulic motor, DO NOT hit wheel hub or motor with a hammer during wheel hub removal or installation. 6.
Page 202 Rear Wheel Motors Figure 66 Left , rear wheel motor shown. G388906S Linkage rod Parking latch support Hex nut (4 each) Parking latch bar Wheel motor Woodruff key Cap screw (4 each) Elbow fitting (2 each) Wheel hub Hair pin Hub nut Drive stud (4 each) Removing the Rear Wheel Motor...
Page 203 Rear Wheel Motors (continued) 4. Clean the area around the hydraulic tube and fitting connections then disconnect or remove the hydraulic tubes from the wheel motor. Cap or plug the disconnected hydraulic tubes and fittings to prevent hydraulic system contamination. 5.
Page 204 Rear Wheel Motors (continued) 8. Install the rear wheel and tighten the lug nuts from 61 to 75 N·m (45 to 55 ft-lb). 9. Charge the hydraulic system; refer to Charging the Hydraulic System, page 5–46. Servicing the Wheel Motor Figure 67 G388890S O-ring...
Page 205 Servicing the Wheel Motor (continued) The ProCore 648s wheel motors are similar in construction, but different in displacement and primary rotation direction (forward) from each other; refer to Hydraulic System Specifications, page 2–3. Displacement and primary rotation direction are identified on the motor name plate.
Page 206 Lift Manifold Figure 68 G387919S Elbow fitting (2 Straight fitting Return filter Cap screw (3 each) each) Charge filter Flange nut (3 each) Lift manifold Straight fitting Removing the Lift Manifold Refer to Figure 68 for this procedure. 1. Park the machine on a level surface, raise the coring head and engage the service latch, set the key switch to the O position, and remove the key from the key switch.
Page 207 Lift Manifold (continued) 7. Label and disconnect the wire harness connectors from the solenoid valves. 8. Remove the fasteners securing the lift manifold to the frame and remove the lift manifold assembly from the machine. 9. If necessary, remove the hydraulic fittings from the lift manifold. Record the locations and orientations of the fittings for assembly purposes.
Page 208 Servicing the Lift Manifold Figure 69 G388194S Plug Relief valve (RV) Manifold block Orifice (OR) Check valve (CV3) Proportional solenoid valve (SP1) Plug Check valve (CV2) Priority valve (EC) Check valve (CV4) Seal kit 110–8337 Seal kit Logic valve (LC) Coil nut (2 each) Filter nipple, return Check valve (CV1)
Page 209 Servicing the Lift Manifold (continued) IMPORTANT A removable control orifice exists under the plug in the OR port of the hydraulic manifold. If the plug is removed, remove the orifice for cleaning and label its position for assembly purposes. If the hydraulic fittings are to be removed from the manifold: Mark the fitting orientation for assembly purposes.
Page 210 Wheel Bypass Manifold (continued) The wheel bypass manifold is located in front of the right rear wheel. Removing and Installing the Wheel Bypass Manifold Refer to Figure 70 for this procedure. 1. Park the machine on a level surface, raise the coring head and engage the service latch, set the key switch to the O position, and remove the key from the key switch.
Page 211 Servicing the Wheel Bypass Manifold Figure 71 G388283S Coil nut Seal kit Solenoid coil Manifold Cartridge valve (S1) For cartridge valve service procedures, refer to Servicing the Cartridge Valves, page 5–75. 1. If hydraulic fittings are to be removed from the manifold, mark the fitting orientation to allow for correct assembly.
Page 212 Servicing the Cartridge Valves (continued) 1. Park the machine on a level surface, raise the coring head and engage the service latch, set the key switch to the O position, and remove the key from the key switch. 2. Remove the storage bin. 3.
Page 213 Servicing the Cartridge Valves (continued) B. For solenoid operated valves: Temporarily install the solenoid on the cartridge valve and connect a 12-volt power source to the solenoid. While energized, flush out any contamination with a nonflammable aerosol brake cleaner. De-energize the solenoid. Repeat the flush while energized procedure 5 or 6 times.
Page 214 Spring tension plate (2 each) Thrust washer (2 each) Cylinder spacer (2 each) Cylinder pin (2 each) The hydraulic lift cylinder used on the ProCore 648s aerator is non-repairable and must be replaced if necessary. Removing the Lift Cylinder Refer to Figure 73 for this procedure.
Page 215 Lift Cylinder (continued) 4. Remove the coring head cover; refer to the Operator’s Manual. 5. Remove the drive belt cover; refer to the Operator’s Manual. 6. Record the position of the weight transfer tension plates and remove the weight transfer springs as follows: CAUTION The extension springs are under load and may cause personal injury during removal.
Page 216 Lift Cylinder (continued) Hydraulic System: Service and Repairs Page 5–80 ProCore® 648s Aerator 20255SL Rev D...
Page 217 Lift Cylinder (continued) Installing the Lift Cylinder Refer to Figure 73 for this procedure. 1. Lubricate new O-rings and place them onto the fitting. If previously removed, install the fitting into the lift cylinder; refer to Installing the Hydraulic Fittings (SAE Straight Thread O-Ring Fittings), page 5–8.
Page 218 Hydraulic System: Service and Repairs Page 5–82 ProCore® 648s Aerator 20255SL Rev D...
Page 219 Chapter 6 Electrical System Table of Contents General Information............................. 6–2 Operator’s Manual ........................... 6–2 Kohler Engine Electrical Components ....................6–2 InfoCenter Display ........................... 6–2 T: Primary Controller..........................6–4 CAN-bus Communications ........................6–5 Electrical Schematics and Wire Harness Drawings/Diagrams ............. 6–6 Electrical System Quick Checks.......................
Page 220 (-) cable from the engine when welding on the chassis. Operator’s Manual The Operator’s Manual provides information regarding the operation, general maintenance, and maintenance intervals for your ProCore 648s aerator. Refer to Operator’s Manual for additional information when servicing the machine. Kohler Engine Electrical Components When servicing or troubleshooting the engine electrical components, use the correct engine service manual.
Page 221 InfoCenter Display (continued) Figure 75 InfoCenter Display Screens G386847S ProCore® 648s Aerator Page 6–3 Electrical System: General Information 20255SL Rev D...
Page 222 Toro DIAG connector Socket head screw The ProCore 648s aerator uses a primary controller (T) to manage machine electrical functions. The primary controller is a TEC 5004 series micro-controller that monitors the condition of various machine switches and sensors (inputs) and directs electrical power to control appropriate machine functions (outputs) based on the state of the inputs.
Page 223 The Toro DIAG electronic control diagnostics service system is available to Authorized Toro Distributors to support machine fault diagnosis and maintenance services of the machine electrical control devices. The Toro DIAG connector is located in the machine console (battery and electronics enclosure).
Page 224 CAN-bus Communications (continued) Figure 77 G392061S T: Primary Controller Battery Toro DIAG Connector Socket head screw Electrical Schematics and Wire Harness Drawings/ Diagrams Refer to the Electrical Schematics and Wire Harness Drawings/Diagrams in Appendix A, page 9–1. Electrical System: General Information Page 6–6...
Page 225 Electrical System Quick Checks Testing the Charging System This is a simple test that determines if a charging system is functioning. It tells you if the charging system has an output, but not its capacity. 1. Use a digital multimeter to set DC volts and connect the positive (+) multimeter lead to the positive battery post and negative (-) multimeter lead to the negative battery post.
Page 226 Checking the Operation of the Interlock Switches (continued) 3. Try to start the engine with the aeration (coring head) bail engaged; the engine should not start. 4. Operate the machine in the forward direction and depress the bump-stop: the machine should stop moving forward. If in Aeration mode, the coring should raise and stop.
Page 227 Fusible link harness G392092S The ProCore 648s aerator uses a fusible link for circuit protection. The fusible link is located in a harness that connects the battery positive cable (at the starter B+ terminal) to the machine wire harness. If the link fails, current to the main relay is interrupted.
Page 228 Fusible Link Harness (continued) fusible link ring terminal with battery terminal protector; refer to Battery Terminal Protector, page 2–17. Fuses The individual control circuits are protected by a variety of fuses (A1/A2 – C5/C6) found in the fuse block located in the machine console (battery and electronics enclosure) on the left side of the machine frame.
Page 229 Fuses (continued) Testing the Fuses 1. Turn the key switch to the O position. Do not start the engine. 2. With the fuse installed in the fuse holder/block, use a multimeter to check that 12 VDC exists at both terminal test points on the fuse. If 12 VDC exists at 1 of the fuse test points but not at the other, the fuse is damaged.
Page 230 1. Set the key switch to the O position and remove the key from the switch. 2. The Toro DIAG connector is part of the CAN bus and is located in the machine console (battery and electronics enclosure). 3. Remove the connector from the cover anchored to the enclosure and use a multimeter (ohms setting) to check the Toro DIAG connector.
Page 231 InfoCenter display. Note: If the InfoCenter display is replaced for any reason, the machine software must be updated; contact an Authorized Toro Distributor for assistance. ProCore® 648s Aerator Page 6–13 Electrical System: Testing the Electrical Components...
Page 232 Toro DIAG Connector Socket head screw The ProCore 648s aerator uses a primary controller (T) to manage machine electrical functions. The primary controller is a TEC 5004 series microcontroller that monitors the condition of various machine switches and sensors (inputs) and directs electrical power to control appropriate machine functions (outputs) based on the state of the inputs.
Page 233 T: Primary Controller (continued) The T: primary controller communicates with the InfoCenter, on a Controller Area Network (CAN) bus system; refer to CAN-bus Communications, page 6–5 additional information. The machine electrical schematic and wire harness drawings in 9 Appendix A, page 9–1 can be used to identify possible circuit problems between the controller and the input or output devices (e.g.
Page 234 Testing Devices (Nodes) on the CAN Bus, page 6–13. Note: If the T: Primary controller is replaced for any reason, the machine software must be updated; contact an Authorized Toro Distributor for assistance. T: Primary Controller Inputs INPUT NUMBER DESCRIPTION...
Page 235 T: Primary Controller (continued) OUTPUT NUMBER DESCRIPTION OUTPUT DESCRIPTION NUMBER OUT 5 Not Used OUT 14 Traction Coil REV (top) OUT 6 Not Used OUT 15 Lift solenoid (SP1) OUT 7 Not Used OUT 16 Lower solenoid (SP2) OUT 8 Fan Relay coil OUT LS (ground) Main Power Relay...
Page 236 Key Switch (continued) 8. Connect the battery negative (-) cable at the battery. Immediate Raise/Lower (Drop-Control) Switch The Immediate Raise/Lower or Drop-Control switch is located on the control arm (handlebar) and has 2 positions: I and D . The switch MMEDIATE ELAYED illuminates when the I...
Page 237 Cruise Control (Speed Lock) Switch The Cruise Control switch is located on the control arm (handlebar) and has 3 positions: O , and E NABLE NGAGE Position Closed Circuits Component Contact Graphic 2 + 3, 5 + 6 NGAGE 2 + 3 NABLE 2 + 1 Testing the Cruise Control Switch...
Page 238 Aeration/Transport Mode Switch The Aeration/Transport Mode switch is located on the control arm (handlebar) and has 2 positions: A , and T ERATION RANSPORT Position Closed Circuits Component Contact Graphic 2 + 1, 5 + 4 ERATION 2 + 3, 5 + 6 RANSPORT Testing the Aeration/Transport Mode Switch The aeration/transport mode switch and its circuit wiring can be tested using the...
Page 239 Operator Presence Switch Figure 84 G392850S Lower console cover Dash panel Operator presence bail The operator presence switch is a normally closed proximity switch that is located on the control arm. The sensing plate that triggers the switch is attached to the operator presence bail.
Page 240 Operator Presence Switch (continued) Adjusting the Operator Presence Switch Figure 85 G392871S Operator presence switch Jam nut (2 each) Sensing plate 1. Park the machine on a level surface and set the key switch to the O position. 2. Remove the lower console cover and the dash panel from the control arm. Note: Disconnect the items on the dash panel from the console wire harness if necessary.
Page 241 Operator Presence Switch (continued) D. Recheck switch to sensing plate clearance. 5. Connect any disconnected items to the console wire harness and install the dash panel and lower console cover. 6. Test the operator presence switch operation before returning the machine to service.
Page 242 Bump-Stop Switch Figure 86 G392692S Bump-stop switch Switch cover The bump-stop switch is a normally closed proximity switch that is located on the control arm. The sensing plate that triggers the switch is located behind the switch cover. When the switch cover is depressed, the sensing plate is positioned near the target end of the bump-stop switch so the switch is opened.
Page 243 Bump-Stop Switch (continued) Adjusting the Bump-Stop Switch Figure 87 G392716S Switch cover Sensing plate Jam nut (2 each) Bump-stop switch 1. Park the machine on a level surface and set the key switch to the O position. 2. Remove the switch cover. IMPORTANT Be careful not to scratch the face of the sensor when measuring or adjusting the sensor clearance.
Page 244 Bump-Stop Switch (continued) 5. Install the switch cover and test bump-stop switch operation before returning the machine to service. Testing the Bump-Stop Switch The bump-stop switch and its circuit wiring can be tested using the InfoCenter Display; refer to Using the InfoCenter Display Screens for Troubleshooting, page 3– 63.
Page 245 Aeration Enable Switch Figure 88 G392849S Lower console cover Dash panel Aeration ball The aeration enable switch is a normally closed proximity switch that is located on the control arm. The sensing plate that triggers the switch is attached to the aeration bail. When the aeration bail is depressed, the sensing plate moves away from the target end of the aeration enable switch so the switch closes.
Page 246 Aeration Enable Switch (continued) Adjusting the Aeration Enable Switch Figure 89 G392924S Aeration enable switch Sensing plate Jam nut (2 each) 1. Park the machine on a level surface and set the key switch to the O position. 2. Remove the lower console cover and the dash panel from the control arm. Note: Disconnect the items on the dash panel from the console wire harness if necessary.
Page 247 Aeration Enable Switch (continued) Testing the Aeration Enable Switch The aeration enable switch and its circuit wiring can be tested using the InfoCenter Display; refer to Using the InfoCenter Display Screens for Troubleshooting, page 3– 63. If testing determines that the switch or the circuit wiring are not functioning correctly, proceed with the following test procedure: 1.
Page 248 Light Switch (Optional) Position Closed Circuits Component Contact Graphic 2 + 1, 5 + 4 2 + 3, 5 + 6 The optional light switch is located on the control arm (handlebar) and has 2 positions: O , and O Testing the Light Switch 1.
Page 249 Note: A 0.13 mm (0.005 inch) shim (Toro part number 139–8694) is available to move the sensor away from the wheel hub if necessary. ProCore® 648s Aerator Page 6–31...
Page 250 Wheel Speed Sensor (continued) Testing the Wheel Speed Sensor 1. Park the machine on a level surface and set the key switch to the O position. 2. Carefully remove any dirt or debris from the area around the sensor face and the front wheel hub teeth.
Page 251 Coring Head Speed Sensor Figure 91 Shown with the coring-head cover removed for clarity. G393295S Coring head speed sensor Crank arm/pulley Sensor bracket The coring head speed sensor is a normally closed proximity switch that is located behind the coring head crank arm/pulley. The spokes of the crank arm/pulley trigger the switch as they pass by the sensor.
Page 252 Coring Head Speed Sensor (continued) Adjusting the Coring Head Speed Sensor Figure 92 G393294S Coring head speed sensor Jam nut (2 each) Crank arm/pulley spoke 1. Park the machine on a level surface and set the key switch to the O position.
Page 253 Coring Head Speed Sensor (continued) A. Loosen the jam nuts that secure the sensor to the bracket and position the sensor to allow correct clearance between sensor and the crank arm/pulley spoke. B. Tighten the sensor jam nuts from 19 to 21 N·m (168 to 192 in-lb). C.
Page 254 Coring Head Position Sensor Figure 93 Shown with the coring-head cover removed for clarity. G394069S Control rod (short) Coring head position sensor, body The coring head position sensor is a paired two-piece assembly attached to the left side of the coring head frame. The sensor body includes 2 analog hall effect sensors. Only one of the hall effect sensor signals is used in this application.
Page 255 Coring Head Position Sensor (continued) Adjusting the Coring Head Position Sensor 1. Park the machine on a level surface, engage the service latch, use the InfoCenter Service>Service Lower function to lower the coring head onto the service latch, set the key switch to the O position and remove the key from the switch.
Page 256 Coring Head Position Sensor (continued) Figure 95 G394008S Index mark Magnetic headed bolt Jam Nut Sensor body Lever arm 4. Rotate the magnetic headed bolt clockwise into the lever arm just until the index mark on the bolt head points 60° (one flat) rearward. 5.
Page 257 Coring Head Position Sensor (continued) 4. In the InfoCenter navigate to the Settings>Protected Menus screen, select the Enter PIN screen, and enter the machine PIN. Figure 96 5. Navigate to the Service>Ground Height screen and select the Start Teach option. Figure 97 G494645 ProCore®...
Page 258 Coring Head Position Sensor (continued) 6. Follow the on-screen calibration instructions. Note: If the calibration procedure fails, try calibrating the item again. Ensure the coring head lift/lower system is operating properly before continuing to troubleshoot the system. Figure 98 G494746 7.
Page 259 Coring Head Position Sensor (continued) Expec- Loca- Connec- Wire Connector Graphic Harness tion Color Reading Main Brown Less than 2 Frame Ground ohms Main 5 VDC with key switch in the R position Frame Ground (do not start engine) Main Yellow Open Frame Ground...
Page 260 Coring Head Position Sensor (continued) Removing and Installing the Coring Head Position Sensor Figure 99 G394188S Lever arm Coring head position sensor, body Coring head position sensor control rod Magnetic headed bolt Ground following sensor control rod Jam nut Sensor bracket Note: The coring head position sensor and the magnetic headed bolt are paired with each other and cannot be interchanged.
Page 261 Coring Head Position Sensor (continued) 5. Loosen the jam nut on the magnetic headed bolt and remove the bolt and jam not from the machine. 6. Thread the jam nut all the way onto the magnetic headed bolt. 7. Thread the magnetic headed bolt and jam nut all the way into the lever arm. 8.
Page 262 Ground Following Sensor (continued) The sensor operates on 5VDC supplied by the T:Primary controller. When the automatic ground following feature is enabled, the T: Primary controller adjusts the coring head height by raising and lowering the coring head based on information from the ground following sensor to maintain consistent aeration depth.
Page 263 Ground Following Sensor (continued) Figure 102 G394007S Sensor body Lever arm Magnetic headed bolt Index mark Jam Nut 4. Rotate the magnetic headed bolt clockwise into the lever arm just until the index mark on the bolt head points straight upward (aligns with sensor body wires). 5.
Page 264 Ground Following Sensor (continued) ground following sensor; refer to Adjusting the Ground Following Sensor, page 6– 7. Disconnect the wire harness connector from the sensor. Check the sensor and the harness connector for damage or corrosion and clean or repair if necessary. 8.
Page 265 Ground Following Sensor (continued) Removing and Installing the Ground Following Sensor Figure 103 G394276S Coring head position sensor control rod Sensor bracket Ground following sensor, body Magnetic headed bolt Ground following sensor control rod Jam nut Lever arm Note: The ground following sensor and the magnetic headed bolt are paired with each other and cannot be interchanged.
Page 266 Ground Following Sensor (continued) 8. With the sensor wires oriented upward, secure the sensor body to the sensor bracket with the previously removed fasteners. 9. Connect the coring head position sensor to the main wire harness. 10. With the ground following sensor control rod (long) pointing forward, and the coring head position sensor control rod (short) pointing rearward, secure the sensor bracket assembly to the coring head frame with the previously removed fasteners.
Page 267 Traction Input Sensor (continued) a stop. A traction input sensor fault will disable the traction system until the key switch is cycled O and O . The InfoCenter Display can be used to monitor the traction input sensor during machine operation by viewing the Traction>Inputs screen; refer Using the InfoCenter Display Screens for Troubleshooting, page 3–63.
Page 268 Traction Input Sensor (continued) Figure 106 G394377S Jam Nut Magnetic headed bolt Index mark Sensor shaft Sensor body 8. Rotate the magnetic headed bolt clockwise into the sensor shaft just until the index mark on the bolt head points straight upward (aligns with sensor body wires).
Page 269 Traction Input Sensor (continued) Calibrating the Traction Input Sensor If the traction input sensor is removed, adjusted, or replaced, the traction input sensor requires calibration before returning the machine to service. 1. Jack the machine up and support it so that the tires can turn unobstructed; refer Jacking Instructions, page 1–6.
Page 270 Traction Input Sensor (continued) Figure 108 5. Follow the on-screen calibration instructions. Note: If the calibration procedure fails, try calibrating the item again. Ensure the traction control assembly is operating properly before continuing to troubleshoot the system. Figure 109 G494745 6.
Page 271 Traction Input Sensor (continued) Testing the Traction Input Sensor 1. Set the key switch to the R position. 2. Access the InfoCenter Diagnostics>Traction>Inputs screen. 3. Move the traction control to the full F position and record the Traction ORWARD Input 1 and Traction Input 2 voltages. 4.
Page 272 Traction Input Sensor (continued) Expec- Loca- Connec- Wire Connector Graphic Harness tion Color Reading Frame Ground Console White Less than 2 Main White ohms Console Green Open Frame Ground Console Green Less than 2 Main Green ohms 10. If the harness wires test correctly, replace the sensor. Removing and Installing the Traction Input Sensor Figure 110 G394515S...
Page 273 Traction Input Sensor (continued) 1. Park the machine on a level surface, set the key switch to the O position and remove the key from the switch. 2. Disconnect the battery negative (-) cable at the battery; refer to Removing and Installing the Battery, page 6–71.
Page 274 Electric Clutch Figure 111 Shown with the muffler and exhaust elbow removed for clarity. G392493S Main wire harness connector Electric clutch An electric clutch is used to engage the coring head (PTO). The electric clutch is mounted on the engine crankshaft and engages when current is applied to the clutch coil.
Page 275 Start relay Ok to Run relay The ProCore 648s aerator uses several electrical relays. The relays are located in the console (battery and electronics enclosure) on the left of the machine frame. One of the relays has four (4) terminals and four of the relays have five (5) terminals. The number of terminals the relay has determines how the relay should be tested.
Page 276 Relays (continued) Identifying the Relays and their Functions • The Main relay (4 terminal) supplies power to the machine control circuits. The main relay is energized by the key switch when in the R or S position. The T: TART Primary controller Low Side (LS) output provides a path to ground for the main relay coil.
Page 277 Relays (continued) Figure 113 5-terminal relay G256780S 6. Connect multimeter (ohms setting) leads to relay terminals 30 and 87. Ground terminal 86 and apply +12 VDC to terminal 85. The relay should make and break continuity between terminals 30 and 87 as +12 VDC is applied and removed from terminal 85.
Page 278 Diode Assemblies Figure 114 Shown with the heat shield assembly removed for clarity. G392385S Diode Electric clutch A diode plugs into the main wire harness near the electric coring head (PTO) clutch. The diode provides circuit protection form the load of the electric clutch coil. The diode can be identified by its black color and diode symbol on the end of the diode body.
Page 279 Diode Assemblies (continued) Component Multimeter Red (+) Multimeter Black (-) Resistance Graphic Lead Lead DIODE TERMINAL DIODE TERMINAL VERY LOW DIODE TERMINAL DIODE TERMINAL VERY HIGH 4. If testing determines the diode is faulty, replace the diode. 5. If the diode tests correctly and a circuit problem still exists, check the wire harnesses;...
Page 280 CAN bus Terminator Resistors (continued) • One of the termination resistors is located near the top of the operator control arm. This resistor is secured to the console wire harness at connector P11. Testing the CAN bus Terminator Resistor Refer to Figure 115 for this procedure.
Page 281 Hydraulic Solenoid Valve Coils Figure 117 G394861S Wheel bypass manifold Coil nut Valve SP1 coil (lift) Valve SP2 coil (lower) Valve S1 coil (wheel bypass) Lift manifold Electric coil actuated hydraulic valves are used on the lift manifold and the wheel bypass manifold.
Page 282 Hydraulic Solenoid Valve Coils (continued) Testing the Hydraulic Solenoid Valve Coils Typically, a failed solenoid coil will either be shorted (very low or no resistance) or open (infinite resistance). 1. Locate the hydraulic solenoid valve coil to be tested and disconnect the wire harness connector from the coil.
Page 283 Piston (Traction) Pump Control Solenoid Coils Figure 118 G394875S Coil nut Traction Coil FWD (bottom) Traction Coil REV (top) Piston (Traction Pump) The piston (traction) pump uses an electro–hydraulic servo piston assembly to change the position of the swash plate and the pump displacement. PWM (pulse width modulation) outputs from the T: Primary controller are provided to two (2) solenoid coils for pump control.
Page 284 Piston (Traction) Pump Control Solenoid Coils (continued) Testing the Piston (Traction) Pump Control Solenoid Coils Typically, a failed solenoid coil will either be shorted (very low or no resistance) or open (infinite resistance). 1. Locate the hydraulic solenoid valve coil to be tested and disconnect the wire harness connector from the coil.
Page 285 A. Clean battery by washing entire case with a solution of baking soda and water. Rinse with clear water. B. Coat battery posts and cable connectors with Toro Part No. 107-0392 battery terminal protector or petroleum jelly to prevent corrosion.
Page 286 (-) cable first. Clean the cable clamps and terminals separately. Connect the battery cables. Always connect the positive (+) cable first. Apply a coating of Toro Part No. 107-0392 battery terminal protector or a light coat of petroleum jelly to the terminals to reduce corrosion after you make the connections.
Page 287 Battery Figure 119 G394778S Battery Main wire harness Battery positive (+) cable Battery negative (-) cable Engine and chassis ground Battery Specifications The battery is the heart of the electrical system. With the regular and correct service, the battery life can be extended. Additionally, the battery and electrical component failure can be prevented.
Page 288 Battery (continued) Battery Specifications Battery-electrolyte specific gravity Fully Charged: 1.25 to 1.28 at 27°C (80°F) (maintainable battery) Discharged: less than 1.24 Battery specifications BCI Group UI300 CCA at -18°C (0°F) Reserve Capacity of 28 minutes at 27°C (80°F) Battery dimensions (including terminal posts Length 19.8 cm (7.8 inches) and caps) Width 13.2 cm (5.2 inches)
Page 289 Removing and Installing the Battery Figure 120 G394570S Battery Battery positive (+) cable Battery tray Battery negative (-) cable Wing nut (2 each) Hold-down post (2 each) Nut (2 each) Flat washer (2 each) Bolt (2 each) Hold-down rod IMPORTANT Be careful when removing the battery cables and ensure that you do not damage the terminal posts or cable connectors.
Page 290 Removing and Installing the Battery (continued) 9. Connect and tighten the positive (+) cable to the battery before connecting negative (-) cable. Tighten the battery terminal nuts from 14 to 20 N·m (10 to 15 ft-lb). 10. Apply a thin coating of battery terminal protector to the battery cable terminals; refer to Battery Terminal Protector, page 2–17.
Page 291 Inspecting, Maintaining, and Testing the Battery (continued) A. Use a hydrometer to measure the specific gravity of each cell. Pull the electrolyte in and out of the hydrometer barrel before taking a reading to warm-up the hydrometer. At the same time, take the temperature of the cell. B.
Page 292 Charging the Battery To minimize damage to the battery and allow the battery to charge fully, use the following slow charging procedure. You can accomplish this charging procedure with a constant current battery charger that is available locally. IMPORTANT Follow the manufacturer's instructions when using a battery charger. Note: When using a maintainable battery, using the specific gravity of the battery cells is the most accurate procedure of determining the battery condition.
Page 293 Charging the Battery (continued) Battery Charge Level Battery Charge Level Specific Gravity Open Circuit Voltage 100% 1.265 12.68 1.225 12.45 1.190 12.24 1.155 12.06 1.120 11.89 Battery Charge Rate Battery Battery Charge Level (Percent of Fully Charged) Reserve Capacity (Minutes) 80 or less 3.8 hrs @ 3 A 7.5 hrs @ 3 A...
Page 294 Electrical System: Service and Repairs Page 6–76 ProCore® 648s Aerator 20255SL Rev D...
Page 295 Chapter 7 Chassis Table of Contents General Information............................. 7–2 Service and Repairs ............................ 7–3 Wheels................................ 7–3 Parking Brake ............................7–5 Parking Brake Cable ..........................7–7 Steering Arm Assembly.......................... 7–9 Rear Roller Kit (Optional) ........................7–12 ProCore® 648s Aerator Page 7–1 Chassis 20255SL Rev D...
Page 296 The Operator’s Manual for the machine and optional kit Installation Instructions provide information regarding the operation, general maintenance, and maintenance intervals for your ProCore 648s Aerator and its accessories. Refer to the Operator’s Manual and Installation Instructions for additional information when servicing the machine.
Page 297 Service and Repairs Wheels Figure 121 G389007S Lock nut (2 each) Front wheel Wheel weight Weight adapter (2 each) Rear wheel Flat washer (2 each) Stud (2 each) Lug nut (4 each wheel) Removing and Installing the Front Wheel 1. Raise the front of the machine; refer to Jacking Instructions, page 1–6.
Page 298 Wheels (continued) Note: Ensure that the wheel weight adapters are installed with the 60° tapered end toward the wheel; refer to Figure 122. Figure 122 Wheel Weight Adapter Wheel end (fine thread) Weight end (course thread) G389004S 4. Install the front wheel, and tighten the lug nuts and wheel weight adapters from 61 to 75 N·m (45 to 55 ft-lb).
Page 299 Parking Brake Figure 123 G436187 Linkage rod (2 each) Woodruff key (2 each) Compression spring (2 each) Roll pin (2 each) Hex nut (2 each) Parking latch clevis (2 Parking latch bar (2 Eye bolt each) each) Extension spring Shoulder bolt (2 each) Drive stud (4 each hub) Flange nut (2 each) Retaining ring (2 each)
Page 300 Parking Brake (continued) Removing and Installing the Parking Brake Refer to Figure 123 for this procedure. 1. Remove the rear wheel; refer to Removing and Installing the Rear Wheels, page 7–4. 2. Ensure that the parking brake is disengaged (handlebar lowered). CAUTION Be careful when removing the extension spring from the parking latch pivot.
Page 301 Parking Brake Cable Removing and Installing the Parking Brake Cable Refer to Removing and Installing the Parking Brake, page 7–6 for additional information. 1. Park the machine on a level surface, raise the coring head and engage the service latch, set the key switch to the O position, and remove the key from the key switch.
Page 302 Parking Brake Cable (continued) Figure 125 G389346S Parking brake cable Retaining ring Parking latch pivot 8. Remove the retaining ring that secures the brake cable to the frame near the rear cross tube and remove the parking brake cable from the machine. 9.
Page 303 Steering Arm Assembly Figure 126 G389389S Slotted nut Flange nut (3 each) Handlebar assembly Cotter pin Main wire harness Lower handlebar cover connectors assembly Guide Parking brake cable Cap screw (6 each) Cap screw (4 each) Bearing cup (2 each) Steering spindle Bearing cone (2 each) Steering arm...
Page 304 Steering Arm Assembly (continued) CAUTION Removing the handlebar assembly requires a hoist or a two-person lift. The handlebar assembly weighs approximately 25 kg (55 lbs). C. Support the handlebar assembly and remove the fasteners securing the handlebar mounting studs to the steering arm. D.
Page 305 Steering Arm Assembly (continued) A. Tighten the slotted nut completely to seat the bearings, then back the nut off slightly. B. Retighten the slotted nut until drag is felt while rotating the steering arm. C. Back-off the nut if necessary to align the first available slot in the nut with the hole in the spindle shaft.
Page 306 Rear Roller Kit (Optional) Figure 127 G389402S Flat washer Roller tube Side plate Cap screw Roller shaft Lock nut Inner seal (face toward Jam nut Spring trunnion (2 each) roller) Hardened washer Spring bracket Bearing (seal outward) Roller shaft screw Threaded rod Wave washer Roller scraper...
Page 307 Chapter 8 Coring Head Table of Contents General Information............................. 8–2 Coring Head Operation........................... 8–2 Service and Repairs ............................ 8–5 Rotolink Dampers ............................ 8–5 Stomper Arms............................8–7 Coring Head Crankshaft Bearing Housings ..................8–9 Secondary Drive (Jackshaft) ....................... 8–12 Removing the Secondary Drive......................8–16 Installing the Secondary Drive ......................
Page 308 Operator’s Manual for additional information when servicing the machine. Coring Head Operation The coring head of the ProCore 648s consists of a frame that pivots to control aeration depth, a coring crankshaft, stomper arms with rotolinks to convert rotary drive motion into vertical tine motion, turf guards, tine holders, and a variety of aerating tines.
Page 309 Coring Head Operation (continued) Figure 128 G389596S The crankshaft assembly is supported with three identical bearing housing assemblies. The six stomper arms and rotolink dampers used on the ProCore 648 are the same for all positions. Coring Head Service Latch •...
Page 310 Coring Head Operation (continued) Figure 129 G494170 klink pin Pin (eft side plate) Service latch (in raised, locked position) Left coring head arm Most service operations recommend the coring head be fully raised and secured with the service latch; refer to the aerator Operator’s Manual. Return the service latch to its storage position before returning the machine to service.
Page 311 Service and Repairs Rotolink Dampers Figure 130 G389868S Hardened washer (2 Cap screw (2 each) Flange nut (2 each) each) Flange nut (2 each) Standoff (4 each) Cap screw (2 each) “D” washer (2 each) Stud (2 each) Lock nut (2 each) Bumper (2 each) Stomper arm Bearing (4 each)
Page 312 A complete coring head bearing kit that includes rotolink arm bearings, stomper arm bearings, retaining rings, and spacers, and crank arm bearings is available for the ProCore 648s. Contact your Authorized Toro Distributor for more information. 6. Assemble all components before fully tightening any fasteners so there is no preload on the rotolink damper components.
Page 313 Stomper Arms Figure 131 G389796S Cap screw Cap screw (4 each) Bearing (2 each arm) Iso-mount (2 each) Spacer (1 each arm) Coupling plate Retaining ring (1 each Coupling, inner arm) Cap screw (2 each) Snubbing washer (2 each) Stomper arm Coupling, outer Lock nut (2 each) Hardened washer...
Page 314 A complete coring head bearing kit that includes rotolink arm bearings, stomper arm bearings, retaining rings, and spacers, and crank arm bearings is available for the ProCore 648s. Contact your Authorized Toro Distributor for more information. 7. Remove the tines and tine holders from the stomper arm if necessary.
Page 315 Stomper Arms (continued) D. Install the hardened washer and cap screw securing the coupling and stomper arm to the crank arm and tighten from 265 to 278 N·m (195 to 205 ft-lb). E. Install the coupling plate assembly. Tighten the fasteners securing the coupling plate assembly to the inner coupling from 95 to 108 N·m (70 to 80 ft-lb).
Page 316 Coring Head Crankshaft Bearing Housings (continued) Note: All bearing housing assemblies are identical. Coring head crank arm positions are identified as #1 through #6 with the #1 position on the right side of the coring head (crank arm/pulley). Removing a Coring Head Crankshaft Bearing Housing Refer to Figure 132 for this procedure.
Page 317 A complete coring head bearing kit that includes rotolink arm bearings, stomper arm bearings, retaining rings, and spacers, and crank arm bearings is available for the ProCore 648s. Contact your Authorized Toro Distributor for more information. Installing a Coring Head Crankshaft Bearing Housing...
Page 318 Coring Head Crankshaft Bearing Housings (continued) 9. After assembly, rotate the coring head crankshaft by hand to make sure that no binding occurs. 10. Test the coring head operation before returning the machine to service. Secondary Drive (Jackshaft) Figure 134 G390164S Set screw (1 each Jackshaft...
Page 319 Secondary Drive (Jackshaft) (continued) The primary drive transfers power from the engine to the hydraulic pump assembly and to the coring head jackshaft. The primary drive includes the electric clutch, the hydraulic pump drive belt tensioner, and the coring head primary drive belt tensioner; refer to Primary Drive, page 4–15.
Page 320 Secondary Drive (Jackshaft) (continued) Removing the Secondary Drive Belt Refer to Figure 134 for this procedure. 1. Park the machine on a level surface, raise the coring head and engage the service latch, set the key switch to the O position, and remove the key from the key switch.
Page 321 Secondary Drive (Jackshaft) (continued) #1 rotolink damper assembly Installing the Secondary Drive Belt Refer to Figure 134 for this procedure. 1. Guide the secondary drive belt over the disconnected rotolink damper assembly and up through the coring head base plate; refer to Removing the Secondary Drive Belt, page 8–14.
Page 322 Secondary Drive (Jackshaft) (continued) 1. Use a 1/2-inch drive breaker bar inserted into the square hole in the spring arm to align the first slot in the spring arm with the hole in the coring head frame. 2. Install the upper fasteners securing the spring arm to the coring head frame in the location shown in Figure 136.
Page 323 Removing the Secondary Drive (continued) 1. Loosen the set screw that secures the bearing locking collar to the jackshaft. Note: The jackshaft rotates counterclockwise when viewed from the right side of the machine. 2. Using the blind (not threaded) hole in the bearing locking collar (Figure 137), unlock the collar from the jackshaft by rotating the collar in the opposite direction...
Page 324 Installing the Secondary Drive (continued) Installing the Outer Pulley Small Pulley Refer to Figure 134 for this procedure. Position the face of the taper lock bushing flush with the end of the jackshaft and tighten the bushing set screw. IMPORTANT Excessive or unequal pressure on the cap screws can damage the taper lock bushing.
Page 325 Installing the Secondary Drive (continued) 4. Install the secondary drive belt; refer to Installing the Secondary Drive Belt, page 8–15 5. Check that the inner and outer pulley alignment is still correct. Adjust the pulley location on the jackshaft if necessary. 6.
Page 326 Turf Guard Brackets (continued) The primary drive transfers power from the engine to the hydraulic pump assembly and to the coring head jackshaft. The primary drive includes the electric clutch, the hydraulic pump drive belt tensioner, and the coring head primary drive belt tensioner; refer to Ground Following Sensor, page 6–43.
Page 327 Turf Guard Brackets (continued) Removing the Turf Guard Brackets Refer to Figure 138 for this procedure. 1. Remove the rear wheels; refer to Removing and Installing the Rear Wheels, page 7–4. 2. Remove the coring head cover. 3. Remove the extension springs from the turf guard brackets. Note: Only 2 springs are installed at the factory at the center and left turf guard brackets.
Page 328 Turf Guard Brackets (continued) Figure 139 G390258S Jam nut (2 each) 6. Secure the control rod eye to the left turf guard bracket with the spacer and the previously removed fasteners. 7. Install the extension springs to the turf guard brackets. 8.
Page 329 Chapter 9 Appendix A Table of Contents Electrical Drawing Designations....................... 9–2 Electrical Schematic............................3 Main Harness Drawing ............................ 4 Main Harness Diagram............................ 5 Console Harness Drawing ..........................6 Console Harness Diagram..........................7 Light Kit Harness Drawing (Optional)......................8 Hydraulic Schematic ............................9 ProCore®...
Page 330 Y or YE YELLOW Numerous harness wires used on the Toro machines include a line with an alternate color. These wires are identified with the wire color and line color with either a / or _ separating the color abbreviations listed above (e.g., R/BK is a red wire with a black line, OR_BK is an orange wire with a black line).
Page 331 Electrical Schematic G385614S ProCore® 648s Aerator Electrical Schematic 20255SL Rev D...
Page 332 Main Harness Drawing G385862S Main Harness Drawing ProCore® 648s Aerator 20255SL Rev D...
Page 333 Main Harness Diagram G385861S ProCore® 648s Aerator Main Harness Diagram 20255SL Rev D...
Page 334 Console Harness Drawing G385860S Console Harness Drawing ProCore® 648s Aerator 20255SL Rev D...
Page 335 Console Harness Diagram G385859S ProCore® 648s Aerator Console Harness Diagram 20255SL Rev D...
Page 336 Light Kit Harness Drawing (Optional) G385863S Light Kit Harness Drawing (Optional) ProCore® 648s Aerator 20255SL Rev D...
Page 337 Hydraulic Schematic G385612S ProCore® 648s Aerator Hydraulic Schematic 20255SL Rev D...
Page 338 Appendix A: Hydraulic Schematic Page 9–10 ProCore® 648s Aerator 20255SL Rev D...

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Toro ProCore 648s Service Manual

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