Toro ProCore Processor Service Manual
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Toro ProCore Processor Service Manual

Toro ProCore Processor Service Manual

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Preface
The purpose of this publication is to provide the service
technician with information for troubleshooting, testing
and repair of major systems and components on the
ProCore Processor.
REFER TO THE OPERATOR'S MANUAL FOR OPER-
ATING,
MAINTENANCE
INSTRUCTIONS. Space is provided in Chapter 2 of this
book to insert the Operator's Manual and Parts Catalog
for your machine. A replacement Operator's Manual is
available on the internet at www.toro.com or by sending
complete Model and Serial Number to:
The Toro Company
Attn. Technical Publications
8111 Lyndale Avenue South
Minneapolis, MN 55420
The Toro Company reserves the right to change product
specifications or this publication without notice.
AND
ADJUSTMENT
E The Toro Company - - 2008
Service Manual
ProCore
R
This safety symbol means DANGER, WARNING,
or CAUTION, PERSONAL SAFETY INSTRUC-
TION. When you see this symbol, carefully read
the instructions that follow. Failure to obey the
instructions may result in personal injury.
NOTE: A NOTE will give general information about the
correct operation, maintenance, service, testing or re-
pair of the machine.
IMPORTANT: The IMPORTANT notice will give im-
portant instructions which must be followed to pre-
vent damage to systems or components on the
machine.
Part No. 08156SL
Processor

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  • Page 1 Operator’s Manual and Parts Catalog for your machine. A replacement Operator’s Manual is available on the internet at www.toro.com or by sending complete Model and Serial Number to: NOTE: A NOTE will give general information about the...
  • Page 2 This page is intentionally blank. ProCore Processor...

  • Page 3: Table Of Contents

    ........4 -- 17 Service and Repairs ..... . . 4 -- 20 ProCore Processor...
  • Page 4 This page is intentionally blank. ProCore Processor...

  • Page 5: Safety Instructions 1

    JACKING INSTRUCTIONS ..... SECURING PROCORE PROCESSOR TO TOW VEHICLE ......

  • Page 6: Safety Instructions

    4. Make sure that the operator is familiar with tow ve- 8111 Lyndale Avenue South hicle operation. Bloomington, Minnesota 55420--1196 5. Make sure that the ProCore Processor is properly at- tached to tow vehicle before operating. While Operating 1. Operator should be in the tow vehicle operators posi- 5.

  • Page 7: Jacking Instructions 1

    Maintenance and Service 1. Before servicing or making adjustments, position 10.Shut ProCore Processor engine off before checking ProCore Processor on a level surface and stop engine. or adding oil to the crankcase. Chock wheels to prevent it from moving. If machine is 11.

  • Page 8: Jacking Instructions

    If the machine is not properly supported by jack stands, the machine may move or fall, which may result in personal injury. 1. Position ProCore Processor on a level surface with machine attached to tow vehicle. Engage vehicle park- Figure 1 ing brake, stop engine and remove key from the ignition 1.

  • Page 9: Product Records

    Operator’s Manuals and Parts Catalogs for those options at the end of this chapter. Maintenance Maintenance procedures and recommended service in- tervals for the ProCore Processor are covered in the Op- erator’s Manual. Refer to that publication when performing regular equipment maintenance. ProCore Processor...

  • Page 10: Equivalents And Conversions

    Equivalents and Conversions 0.09375 Page 2 - - 2 Product Records and Maintenance ProCore Processor...

  • Page 11: Torque Specifications

    For critical applications, as determined reduced by 25% for lubricated fasteners to achieve by Toro, either the recommended torque or a torque that the similar stress as a dry fastener. Torque values may is unique to the application is clearly identified and spe- also have to be reduced when the fastener is threaded cified in this Service Manual.
  • Page 12 The specific torque value should be determined based on the fastener size, the aluminum or base material strength, length of thread engagement, etc. Page 2 - - 4 Product Records and Maintenance ProCore Processor...

  • Page 13: Standard Torque For Dry, Zinc Plated And Steel Fasteners (Metric Fasteners)

    The specific torque value should be determined based on the fastener size, the aluminum or base material strength, length of thread engagement, etc. ProCore Processor Page 2 - - 5 Product Records and Maintenance...
  • Page 14 Conversion Factors in- -lb X 11.2985 = N- -cm N- -cm X 0.08851 = in- -lb ft- -lb X 1.3558 = N- -m N- -m X 0.7376 = ft- -lb Page 2 - - 6 Product Records and Maintenance ProCore Processor...

  • Page 15: General Information 3

    ......BRIGGS & STRATTON VANGUARD V-TWIN, OHV RE- PAIR MANUAL ProCore Processor Page 3 - - 1 Engine...

  • Page 16: Specifications

    Flywheel magneto, twin electronic armatures with ignition advance Spark Plug Champion RC12YC Spark Plug Gap 0.030” (0.76 mm) Starter 12 VDC, solenoid shift Alternator 12 VDC / 20 Amps Dry Weight 132 lbs (60 kg) Engine Page 3 - - 2 ProCore Processor...

  • Page 17: General Information

    Toro distributor. Be pre- GUARD V-TWIN, OHV REPAIR MANUAL that is in- pared to provide your distributor with the Toro model and cluded at the end of this Chapter. The use of some serial number.

  • Page 18: Special Tools

    Special Tools Order special tools from your Toro Distributor. Centrifugal Clutch Puller The centrifugal clutch puller should be used to remove the clutch from the engine crankshaft. Toro Part Number: 114- -7730 To use the clutch puller (Fig. 1): 1. To protect the engine crankshaft, place thick washer on end of crankshaft and lightly grease the end of the ro- tator pin.

  • Page 19: Service And Repairs

    Service and Repairs Cooling System IMPORTANT: The engine that powers the ProCore Processor is air- -cooled. Operating the engine with dirty or plugged cooling fins or a plugged or dirty blower housing will result in engine overheating and damage. 1. Park machine on a level surface. Make sure engine is OFF.
  • Page 20 3. Tinnerman nut (2 used) 8. Air cleaner cap 13. Hose clamp (2 used) 4. Air cleaner assembly 9. Clamp 14. Cap screw (5/16”) (2 used) 5. Flat washer (4 used) 10. Service indicator Engine Page 3 - - 6 ProCore Processor...
  • Page 21 B. Make sure that vacuator valve is pointed down af- ter assembly. 2. Install air intake hose to intake manifold on engine and air cleaner assembly. Secure intake hose with hose clamps (item 11). ProCore Processor Page 3 - - 7 Engine...
  • Page 22 Store fuel in a clean, safety- -approved container and keep cap in place. Use gasoline for the engine only; not for any other purpose. Engine Page 3 - - 8 ProCore Processor...
  • Page 23 3. Secure straps and fuel tank with four (4) cap screws and flat washers. 4. Connect fuel hose to the stand pipe fitting on top of tank. Secure hose with worm clamp. 5. Connect spark plug wires to spark plugs. ProCore Processor Page 3 - - 9 Engine...
  • Page 24 (see Drive Belt Covers in the Service and Repairs sec- tion of Chapter 6 -- Chassis). Engine Page 3 - - 10 ProCore Processor...
  • Page 25 IMPORTANT: When securing lift cylinder pivot pin to frame, there should be clearance between the Figure 10 shoulder bolt head and pivot pin. Do not overtighten 1. Lift cylinder 3. Shoulder bolt shoulder bolt. 2. Pivot pin ProCore Processor Page 3 - - 11 Engine...
  • Page 26 41. Nut 13. Flat washer (2 used) 28. Flat washer (4 used) 42. Lock washer 14. Negative battery cable 15. Positive battery cable 29. Muffler mount 43. Cap screw (5/16”) (2 used) Engine Page 3 - - 12 ProCore Processor...
  • Page 27 12.If necessary, remove centrifugal clutch from engine crankshaft (see Centrifugal Clutch Removal in this sec- tion). Figure 13 1. Positive battery cable 4. Wire harness 2. Fusible link 5. Harness clamp 3. Engine connector ProCore Processor Page 3 - - 13 Engine...
  • Page 28 (see Jack Figure 14 Shaft Assembly in the Service and Repairs section 1. Jack shaft 3. Idler pulley of Chapter 6 - - Chassis). 2. Centrifugal clutch Engine Page 3 - - 14 ProCore Processor...

  • Page 29: General Information

    ........Securing ProCore Processor to Tow Vehicle .

  • Page 30: Operator's Manual

    Installation Instructions for the correct procedure for at- taching the ProCore Processor to the tow vehicle. Hydraulic Supply Hydraulic flow and relief pressure for the ProCore Proc- IMPORTANT: When changing tow vehicles or trac- essor are determined by the tow vehicle. Refer to your tors, make sure that the tow vehicle hydraulic fluid Operator’s Manual for recommendations concerning...

  • Page 31: Hydraulic Hoses

    Tube Installation in this section). If the hose has an el- bow at one end, tighten the swivel nut on that end before tightening the nut on the straight end of the hose. For additional hydraulic hose information, refer to Toro Service Training Book, Hydraulic Hose Servicing (Part Number 94813SL).

  • Page 32: Hydraulic Hose And Tube Installation

    85 to 105 ft--lb (116 to 142 N--m) 1 7/16 -- 12 110 to 136 ft--lb (150 to 184 N--m) 1 11/16 -- 12 140 to 172 ft--lb (190 to 233 N--m) Figure 4 Hydraulic System Page 4 - - 4 ProCore Processor...

  • Page 33: Hydraulic Fitting Installation (Sae Straight Thread O--Ring Face Seal Fitting Into Component Port)

    202 to 248 ft--lb (274 to 336 N--m) 121 to 149 ft--lb (165 to 202 N--m) 1 5/8 -- 12 247 to 303 ft--lb (335 to 410 N--m) 149 to 183 ft--lb (202 to 248 N--m) Figure 6 ProCore Processor Page 4 - - 5 Hydraulic System...
  • Page 34 1.00 + 0.25 6 (3/8 in.) 1.50 + 0.25 8 (1/2 in.) 1.50 + 0.25 10 (5/8 in.) 1.50 + 0.25 12 (3/4 in.) 1.50 + 0.25 16 (1 in.) 1.50 + 0.25 Hydraulic System Page 4 - - 6 ProCore Processor...

  • Page 35: Special Tools

    Part Number: TOR4079 TORO TEST FITTING KIT (NO. TOR4079) This kit includes a variety of O--ring Face Seal fittings to enable connection of test gauges to the ProCore Proc- essor hydraulic system. The kit includes: tee’s, unions, reducers, plugs, caps and male test fittings.

  • Page 36: Hydraulic Schematics

    LIFT RELIEF MANIFOLD NOTE: For identification purposes, the hydraulic hose to lift relief manifold port A is equipped with a cable tie at the Core Processor quick coupler. ProCore Processor Hydraulic Schematic Hydraulic System Page 4 - - 8 ProCore Processor...

  • Page 37: Hydraulic Schematic (With Tow Hitch Kit)

    LIFT RELIEF MANIFOLD OFFSET CYLINDER TOW HITCH MANIFOLD ProCore Processor Hydraulic Schematic NOTE: For identification purposes, the hydraulic hose With Tow Hitch Kit to lift relief manifold port A is equipped with a cable tie at the Core Processor quick coupler.

  • Page 38: Hydraulic Flow Diagrams 4

    A is equipped with a cable tie at the Core Processor quick coupler. LOWER LIFT CYLINDER (RETRACTING) LIFT RELIEF MANIFOLD Raise and Lower Circuits Working Pressure Return Flow Figure 11 Hydraulic System Page 4 - - 10 ProCore Processor...
  • Page 39 Raise (Fig. 11) When the tow vehicle control is positioned to raise the ProCore Processor, oil flows from the tow vehicle hy- draulic system, to the ProCore Processor lift relief man- ifold port A, through the CB cartridge check valve, out manifold port C1 and then to the barrel end of the Proc- essor lift cylinder.

  • Page 40: Tow Hitch Circuits

    NOTE: For identification purposes, the hydraulic hose Working Pressure to lift relief manifold port A is equipped with a cable tie Return at the Core Processor quick coupler. Flow Figure 13 Hydraulic System Page 4 - - 12 ProCore Processor...
  • Page 41 ProCore Processor raise and lower circuits via solenoid ProCore Processor hitch offset function via solenoid valves S1 and S2. Hydraulic flow to the tow hitch offset valves S3 and S4.

  • Page 42: Troubleshooting

    The successful operation of the ProCore Processor de- A hydraulic system with an excessive increase in heat pends on the hydraulic system of the tow vehicle. When or noise has a potential for failure.
  • Page 43 Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Hydraulic system on tow vehicle is malfunctioning (ProCore Proc- Á Á Á Á Á Á Á Á Á Á Á Á Á...
  • Page 44 This page is intentionally blank. Hydraulic System Page 4 - - 16 ProCore Processor...

  • Page 45: Testing

    Failure to use gauges with recommended pres- 3. Hydraulic flow and relief pressure for the ProCore sure (PSI/bar) rating as listed in test procedures Processor are determined by the tow vehicle. Make sure...

  • Page 46: Raise/Lower Relief Valve Pressure Test

    A is equipped with a cable tie at the Core Processor quick coupler. LOWER LIFT CYLINDER (RETRACTING) LIFT RELIEF MANIFOLD Raise and Lower Relief Valve Pressure Test PRESSURE Working Pressure GAUGE Return Flow Hydraulic System Page 4 - - 18 ProCore Processor...
  • Page 47 Manifold in the Service and Repairs section of this chap- ter). Also, if relief pressure is low, consider a problem 2. Have ProCore Processor attached to tow vehicle with the tow vehicle hydraulic system. Internal lift cylin- and park machines on a level surface. Engage tow ve- der leakage could also cause low circuit pressure.

  • Page 48: Service And Repairs

    Chock machine wheels to prevent machine from mov- Drain and flush all hoses and components. Also, drain ing. Make sure that ProCore Processor engine is off. Re- and refill tow vehicle hydraulic system reservoir and move key from ignition switch. If ProCore Processor is change oil filter.

  • Page 49: Check Hydraulic Lines And Hoses

    Check hydraulic lines and hoses daily for leaks, kinked WARNING lines, loose mounting supports, wear, loose fittings, weather deterioration and/or chemical deterioration. Make all necessary repairs before operating ProCore Keep body and hands away from pin hole leaks Processor. or nozzles that eject hydraulic fluid under high pressure.

  • Page 50: Lift Relief Manifold

    (2 used) Manifold Removal (Fig. 17) CAUTION 1. Have ProCore Processor attached to tow vehicle and park both machines on a level surface. Secure lift axle to frame with hitch pin and lynch pin to prevent lift Before opening hydraulic system, operate all hy- axle from shifting.
  • Page 51 3. Lower relief valve 7. Counterbalance valve and backup rings must be arranged properly on the car- 4. O- -ring 8. Plug with O- -ring tridge valves for proper operation and sealing. ProCore Processor Page 4 - - 23 Hydraulic System...
  • Page 52 12. Lock nut (4 used) 3. Wheel assembly 8. Shoulder bolt 13. Bushing 4. Grease fitting 9. Axle block (4 used) 14. Screw (2 used) 5. Lift cylinder 10. Flat washer (8 used) Hydraulic System Page 4 - - 24 ProCore Processor...
  • Page 53 Removal (Fig. 19) Installation (Fig. 19) 1. Have ProCore Processor attached to tow vehicle 1. If removed, install fittings with new O--rings into lift and park both machines on a level surface. Secure lift cylinder ports (see Hydraulic Fitting Installation in the axle to frame with hitch pin and lynch pin to prevent lift General Information section of this chapter).
  • Page 54 6. Hydraulic fitting (2 used) 9. Hose (from manifold port C4) 3. Flat washer (2 used) 7. O- -ring (2 used) 10. Hose (from manifold port C3) 4. Cap screw (2 used) Hydraulic System Page 4 - - 26 ProCore Processor...
  • Page 55 Removal (Fig. 21) Installation (Fig. 21) 1. Park ProCore Processor on a level surface. Secure 1. If removed, install fittings with new O--rings into offset machine lift axle to frame with hitch pin and lynch pin to cylinder ports (see Hydraulic Fitting Installation in the prevent lift axle from shifting.

  • Page 56: Hydraulic Lift Cylinder

    15. Grease fitting 5. Rod 11. Seal 16. Spacer (offset cylinder) 6. O- -ring NOTE: The service procedure for the ProCore Proces- Spanner sor lift cylinder and offset cylinder is the same. wrench Disassembly (Fig. 22) 1. Remove oil from the lift cylinder into a drain pan by slowly pumping the cylinder rod.
  • Page 57 C. Fill retaining ring slot in cylinder tube with silicone 2. Install backup ring (item 7), O--ring (item 6), seal sealant after retaining ring is installed. (item 11) and wiper (item 10) to the head. ProCore Processor Page 4 - - 29 Hydraulic System...

  • Page 58: Tow Hitch Manifold (Tow Hitch Kit)

    3. O- -ring 8. Flat washer (4 used) 12. Hydraulic hose (to tow vehicle) 4. Hydraulic fitting (5 used) 9. Cap screw (2 used) 13. Hydraulic hose (to offset cylinder) 5. O- -ring Hydraulic System Page 4 - - 30 ProCore Processor...
  • Page 59 Manifold Removal (Fig. 24) Manifold Installation (Fig. 24) 1. Park ProCore Processor on a level surface. Secure 1. If fittings were removed from manifold, lubricate and machine lift axle to frame with hitch pin and lynch pin to place new O--rings to fittings. Install fittings into manifold prevent lift axle from shifting.

  • Page 60: Tow Hitch Manifold Service (Tow Hitch Kit)

    25 ft- -lb (33.9 N- -m). 8. If solenoid coil was removed, slide coil onto solenoid valve. Secure coil with nut. Torque nut 60 in- -lb (6.8 N- -m). Hydraulic System Page 4 - - 32 ProCore Processor...

  • Page 61: Electrical Diagrams 5

    ... Electrical Diagrams The electrical schematic and wire harness drawings for the ProCore Processor are located in Chapter 7 -- Elec- trical Diagrams. ProCore Processor Page 5 - - 1...

  • Page 62: Special Tools

    The multimeter can test electrical components and cir- cuits for current (amps), resistance (ohms) or voltage. Obtain this tool locally. NOTE: Toro recommends the use of a DIGITAL Volt-- Ohm--Amp multimeter when testing electrical circuits. The high impedance (internal resistance) of a digital me- ter in the voltage mode will make sure that excess cur- rent is not allowed through the meter.
  • Page 63 Battery Hydrometer Use the Battery Hydrometer when measuring specific gravity of battery electrolyte. Obtain this tool locally. Figure 4 ProCore Processor Page 5 - - 3 Electrical System...

  • Page 64: Troubleshooting

    Engine cranks, but does not start. The ignition switch is faulty. Remote control engine stop switch is faulty. Engine or fuel system is malfunctioning (see Chapter 3 -- Engine). Engine and fuel may be too cold. Page 5 - - 4 Electrical System ProCore Processor...

  • Page 65: General Run Problems

    Remote control engine stop switch is faulty. Wiring to the run circuit components is broken or disconnected (see Wiring Schematic in Chapter 7 -- Electrical Diagrams). Engine or fuel system is malfunctioning (see Chapter 3 -- Engine). ProCore Processor Page 5 - - 5 Electrical System...

  • Page 66: Electrical System Quick Checks

    = 12.85 v NOTE: Depending upon the condition of the battery Difference = +0.55 v charge and battery temperature, the battery voltage will increase at different rates as the battery charges. Page 5 - - 6 Electrical System ProCore Processor...

  • Page 67: Component Testing

    3. Reconnect the harness connectors to the switch af- ter testing. POSITION CIRCUIT G + M + A B + L + A Figure 6 START B + L + S HEX NUT SWITCH LOCK WASHER Figure 7 ProCore Processor Page 5 - - 7 Electrical System...

  • Page 68: Remote Control Handle Switches

    (Fig. 8). The engine stop switch is a momentary switch that al- lows the operator to shut the ProCore Processor engine off from the tow vehicle. When this switch is depressed and held, the engine magneto ignition system is grounded to cause the engine to stop running.

  • Page 69: Hour Meter

    6. Replace the hour meter if necessary. 7. Connect wire harness connector to hour meter. Fuses The ProCore Processor uses two (2) fuses for circuit protection. The fuse holders for these fuses are located next to the engine (Fig. 12).

  • Page 70: Service And Repairs 5

    Fusible Link The ProCore Processor uses a fusible link for circuit protection. This fusible link connects the main wire har- ness to the starter B+ terminal and positive battery cable (Fig. 13). If the link should fail, current to the machine will cease.

  • Page 71: Solenoid Valve Coil (Tow Hitch Kit)

    Solenoid Valve Coil (Tow Hitch Kit) The ProCore Processor tow hitch kit uses four (4) sole- noid valve coils on the hydraulic tow hitch manifold (Fig. 15). When the solenoid valve coils are energized, tow vehicle hydraulic flow can be directed to the tow hitch hy- draulic offset cylinder to change the position of the Pro- Core Processor behind the tow vehicle.

  • Page 72: Service And Repairs

    Battery Terminal sparks away from the battery; do not smoke. Protector (Toro Part No. 107--0392) or petroleum jelly to Nausea may result if the gases are inhaled. Un- prevent corrosion.

  • Page 73: Specifications 6

    (+) cable first. Coat battery posts and cable connectors with Battery Terminal Protector 2. Loosen and remove negative cable from battery. Af- (Toro Part No. 107--0392) or petroleum jelly to pre- ter negative cable has been removed, loosen and re- vent corrosion.
  • Page 74 Follow the battery load tester manufacturer’s the battery. If the test voltage is at or above the mini- instructions when using a battery load tester. mum, return the battery to service. Page 5 - - 14 Electrical System ProCore Processor...
  • Page 75 11.5 hrs 17.3 hrs 23 hrs 6 amps 6 amps 6 amps 6 amps above 6 hrs 12 hrs 18 hrs 24 hrs 10 amps 10 amps 10 amps 10 amps ProCore Processor Page 5 - - 15 Electrical System...
  • Page 76 60 in- -lb (6.8 N- -m) Figure 17 1. Solenoid coil S1 5. Offset manifold 2. Solenoid coil S2 6. Nut 3. Solenoid coil S3 7. Nut 4. Solenoid coil S4 Page 5 - - 16 Electrical System ProCore Processor...

  • Page 77: General Information 6

    Operator’s Manual ......Securing ProCore Processor to Tow Vehicle ..SERVICE AND REPAIRS .

  • Page 78: Specifications

    70 to 90 ft--lb (95 to 122 N--m) Brush (Fig. 1) Bristle Length: New 4.500” (114.3 mm) Bristle Length: Replace 3.500” (88.9 mm) Figure 1 1. Brush hub 3. Bristle length 2. Brush bristle Chassis Page 6 - - 2 ProCore Processor...

  • Page 79: General Information

    General Information Operator’s Manual The Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your ProCore Processor. Refer to the Oper- ator’s Manual for additional information when servicing the machine. Securing ProCore Processor to Tow Vehicle...

  • Page 80: Service And Repairs

    70 to 90 ft- -lb (95 to 122 N- -m) Figure 2 1. Main frame 3. Wheel and tire assembly 5. Hitch pin 2. Lug nut (5 used per wheel) 4. Lift axle 6. Lynch pin Chassis Page 6 - - 4 ProCore Processor...
  • Page 81 1. Have ProCore Processor attached to tow vehicle 1. Position wheel to wheel hub on raised machine. and park machines on a level surface. Engage vehicle 2. Secure wheel to ProCore Processor with five (5) lug parking brake, stop engine and remove key from the nuts.

  • Page 82: Wheel Hubs And Bearings

    2. Grease seal 6. Lug screw (5 used) 10. Cotter pin 3. Inner bearing cone 7. Outer bearing cup 11. Slotted hex nut 4. Inner bearing cup 8. Outer bearing cone 12. Dust cup Chassis Page 6 - - 6 ProCore Processor...
  • Page 83 Removal (Fig. 3) Installation (Fig. 3) 1. Have ProCore Processor attached to tow vehicle 1. Thoroughly clean all parts before assembly. and park machines on a level surface. Engage vehicle 2. Assemble wheel hub: parking brake, stop engine and remove key from the ignition switch.

  • Page 84: Drive Belt Covers

    9. Cap screw (12 used) 14. Belt set 4. Jack shaft 10. Flat washer (12 used) 15. Flange head screw (2 used) 5. Idler pulley 11. Flange nut (3 used) 16. Heat shield 6. Belt cover Chassis Page 6 - - 8 ProCore Processor...
  • Page 85 Removal (Figs. 4, 5 and 6) 1. Park ProCore Processor on a level surface with the FRONT Processor fully lowered. Make sure that Processor en- gine is off. Remove key from the ignition switch. Chock RIGHT wheels to prevent movement of the machine.

  • Page 86: Pulley Assembly Service

    2. Pulley 6. Lock washer (3 used) 10. Taper lock bushing 3. Square key 7. Set screw (if equipped) 11. Square key 4. Taper lock bushing 8. Cap screw (3 used) 12. Pulley Chassis Page 6 - - 10 ProCore Processor...
  • Page 87 The ProCore Processor uses several pulley assemblies 3. Slide pulley and taper lock bushing onto shaft. The to drive the jack shaft, chopper axle, brush shaft and ro- pulley should be positioned to the inside of the taper lock tating corner shaft. Service of these pulley assemblies bushing.

  • Page 88: Flange Bearing Service

    4. Pulley 8. Screw (4 used per bearing) 12. Idler pulley The ProCore Processor jack shaft, chopper axle and brush shaft all use two (2) of the same flange bearings for support. Removal and installation of these bearings requires the same procedure.
  • Page 89 7. Install pulley and drive belt to shaft (refer to service information for specific drive assembly that exists later in this section). ProCore Processor Page 6 - - 13 Chassis...

  • Page 90: Jack Shaft Assembly

    A matched set of three (3) B--section belts drives the jack shaft. The jack shaft drives the chopper axle with a matched set of two (2) B--section drive belts. Adjustable idler pulleys maintain belt tension. Chassis Page 6 - - 14 ProCore Processor...
  • Page 91 Removal (Fig. 10) 1. Park ProCore Processor on a level surface with the Processor fully lowered. Make sure that Processor en- gine is off. Remove key from the ignition switch. Chock wheels to prevent movement of the machine. 2. Remove belt covers from both sides of jack shaft (see Drive Belt Covers in this section).
  • Page 92 -adjust positions of drive and driven pulleys to allow correct distance. 9. Secure jack shaft cover (item 22) to machine. 10.Install belt covers (see Drive Belt Covers in this sec- tion). Chassis Page 6 - - 16 ProCore Processor...
  • Page 93 This page is intentionally blank. ProCore Processor Page 6 - - 17 Chassis...

  • Page 94: Chopper Axle Service

    Chopper Axle Service RIGHT FRONT Figure 16 1. Cap screw (62 used) 3. Lock nut (62 used) 5. Chopper axle 2. LH blade assembly (31 used) 4. RH blade assembly (31 used) Chassis Page 6 - - 18 ProCore Processor...
  • Page 95 270 to 330 in- -lb (31 to 37 N- -m) Disassembly (Figs. 16 and 17) 1. Park ProCore Processor on a level surface with the Processor fully lowered. Make sure that Processor en- gine is off. Remove key from the ignition switch. Chock wheels to prevent movement of the machine.

  • Page 96: Chopper Axle Assembly

    (2) B--section drive belts. The right end of the chopper Chassis Page 6 - - 20 ProCore Processor...
  • Page 97 10.Label right and left side of the chopper assembly for installation purposes. Remove chopper assembly from 1. Park ProCore Processor on a level surface with the machine by lifting it up and toward the rear of the ma- Processor fully lowered. Make sure that Processor en- chine.
  • Page 98 BRUSH ORIENTATION corner shaft Figure 23 B. Slide sprocket onto chopper axle. Do not tighten set screws in sprocket. 1. Chopper axle 3. Rotating corner shaft 2. Brush shaft Chassis Page 6 - - 22 ProCore Processor...
  • Page 99 9. Install rear cover to machine (see Rear Cover Instal- lation in this section). 0.050” (1.3 mm) Idler Face to Sheave Face Figure 25 1. Brush shaft 3. Idler pulley 2. Chopper axle ProCore Processor Page 6 - - 23 Chassis...

  • Page 100: Brush Assembly

    Engage vehicle parking brake, stop en- leys maintain belt tension. gine and remove key from the ignition switch. Make sure that ProCore Processor engine is off. Chock wheels to prevent movement of either machine. Chassis Page 6 - - 24...
  • Page 101 6. Align bearing flanges to brush housing and secure 2. Brush drive (4 used) 5. Brush axle with four (4) carriage screws (item 19), flat washers 3. Washer (4 used) (item 20) and lock nuts (item 18). ProCore Processor Page 6 - - 25 Chassis...
  • Page 102 (item 9) to each side of machine with two in Alignment (2) flange nuts and carriage screws. Figure 32 14.Install belt covers (see Drive Belt Covers in this sec- 1. Brush shaft 3. Idler pulley tion). 2. Rotating corner shaft Chassis Page 6 - - 26 ProCore Processor...
  • Page 103 This page is intentionally blank. ProCore Processor Page 6 - - 27 Chassis...

  • Page 104: Rotating Corner Shaft Assembly

    Position idler pulley away from drive belt. Removal (Fig. 33) B. Carefully remove drive belt from pulley on rotat- 1. Park ProCore Processor on a level surface with the ing corner shaft. Processor fully lowered. Make sure that Processor en- 4.
  • Page 105 Figure 36 1. Brush shaft 3. Idler pulley 8. Install drive belt to drive and driven pulleys. 2. Rotating corner shaft ProCore Processor Page 6 - - 29 Chassis...
  • Page 106 6.0 mm) across the entire corner shaft (Fig. 37). If nec- essary, loosen fasteners that secure scraper plate to machine and adjust scraper plate location. 14.Install belt covers to machine (see Drive Belt Covers in this section). Chassis Page 6 - - 30 ProCore Processor...
  • Page 107 This page is intentionally blank. ProCore Processor Page 6 - - 31 Chassis...

  • Page 108: Roller

    10. Flange mount bearing (2 used) 16. Flat washer (7 used) 5. Carriage screw (4 used) 11. Carriage bolt (4 used) 17. Carriage screw (4 used) 6. Connector strap 12. Carriage screw (2 used) Chassis Page 6 - - 32 ProCore Processor...
  • Page 109 Removal (Fig. 38) Installation (Fig. 38) 1. Have ProCore Processor attached to tow vehicle 1. If adjustment plates and adjuster keys were removed and park machines on a level surface with the Processor from frame, secure them to frame with carriage screws, fully lowered.

  • Page 110: Lift Axle

    17. Bearing tube (2 used) 5. Lift cylinder 12. Lock nut 18. Lynch pin (2 used) 6. Pivot pin 13. Bushing (2 used) 19. Hitch pin (2 used) 7. Grease fitting (2 used) Chassis Page 6 - - 34 ProCore Processor...
  • Page 111 Make sure ing tube to lift axle with hitch pin and lynch pin. that ProCore Processor engine is off. Chock wheels to prevent movement of either machine. 2. Position lift axle under machine.

  • Page 112: Rear Cover

    3. Subframe pivot 8. Cap screw (47 used) 13. Flat washer (33 used) 4. Curtain 9. Pivot (2 used) 14. Backing plate hook (2 used) 5. Flange nut (36 used) 10. Pivot (2 used) Chassis Page 6 - - 36 ProCore Processor...
  • Page 113 Removal (Fig. 38) 1. Park ProCore Processor on a level surface with the Processor fully lowered. Make sure that Processor en- gine is off. Remove key from the ignition switch. Chock wheels to prevent movement of machine. 2. On both sides of machine, remove two (2) cap screws and flange nuts that secure pivot (item 9) to ma- chine frame.
  • Page 114 This page is intentionally blank. Chassis Page 6 - - 38 ProCore Processor...

  • Page 115: Circuit Drawings 7

    ..... . . Tow Hitch Kit Wire Harness ....ProCore Processor Page 7 - - 1 Electrical Diagrams...
  • Page 116 This page is intentionally blank. Electrical Diagrams Page 7 - - 2 ProCore Processor...

  • Page 117: Electrical Schematic

    BROWN ENGINE STOP SWITCH SOLENOID S1 HOUR METER SOLENOID S2 BLACK GRAY BLUE LIFT SOLENOID S3 OFFSET SWITCH BLACK SOLENOID S4 PROCESSOR TOW HITCH BATTERY (OPTIONAL) ProCore Processor Electrical Schematic All ground wires are black. Page 7 - - 3...

  • Page 118: Crank Circuits

    ENGINE STOP SWITCH SOLENOID S1 HOUR METER SOLENOID S2 BLACK GRAY BLUE SOLENOID S3 LIFT OFFSET SWITCH BLACK SOLENOID S4 PROCESSOR TOW HITCH BATTERY (OPTIONAL) ProCore Processor Crank Circuits Power Current Control Current Indicator Current Page 7 - - 4...

  • Page 119: Run Circuits

    ENGINE STOP SWITCH SOLENOID S1 HOUR METER SOLENOID S2 BLACK GRAY BLUE SOLENOID S3 LIFT OFFSET SWITCH BLACK SOLENOID S4 PROCESSOR TOW HITCH BATTERY (OPTIONAL) ProCore Processor Run Circuits Power Current Control Current Indicator Current Page 7 - - 5...

  • Page 120: Wire Harness Drawing

    ProCore Processor Wire Harness Drawing Page 7 - - 6...

  • Page 121: Wire Harness Diagram

    YELLOW GRAY GRAY BLACK BLUE BROWN BROWN YELLOW BROWN GREEN BLACK PINK ORANGE BLACK ProCore Processor Wire Harness Diagram Page 7 - - 7...

  • Page 122: Tow Hitch Kit Wire Harness

    BLUE BLACK BLUE BLACK BLUE BLACK BLUE BLACK BLUE BLACK ProCore Processor Tow Hitch Kit Wire Harness Page 7 - - 8...

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