Part No. 04129SL (Rev. C)
Service Manual
R
ProCore 648
Preface
The purpose of this publication is to provide the service
technician with information for troubleshooting, testing
and repair of major systems and components on the
ProCore 648.
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.
REFER TO THE OPERATOR’S MANUALS FOR OP-
ERATING, MAINTENANCE AND ADJUSTMENT
INSTRUCTIONS. Space is provided in Chapter 2 of this
book to insert the Operator’s Manuals and Parts Cata-
logs for your machine. Replacement Operator’s Manu-
als and Parts Catalogs are available on the internet at
www.toro.com.
NOTE: A NOTE will give general information about the
correct operation, maintenance, service, testing or re-
pair of the machine.
The Toro Company reserves the right to change product
specifications or this publication without notice.
IMPORTANT: The IMPORTANT notice will give im-
portant instructions which must be followed to pre-
vent damage to systems or components on the
machine.
E The Toro Company - 2004, 2006, 2009
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Table Of Contents
Chapter 1 – Safety
Chapter 5 – Electrical System
Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . 1 – 2
Jacking Instructions . . . . . . . . . . . . . . . . . . . . . . . . . 1 – 4
Safety and Instruction Decals . . . . . . . . . . . . . . . . 1 – 5
Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 1
Circuit Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 7
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 8
Electrical System Quick Checks . . . . . . . . . . . . . 5 – 11
Component Testing . . . . . . . . . . . . . . . . . . . . . . . . 5 – 13
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . 5 – 28
Chapter 2 – Product Records and Maintenance
Product Records . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 – 1
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 – 1
Equivalents and Conversions . . . . . . . . . . . . . . . . 2 – 2
Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . 2 – 3
Chapter 6 – Chassis
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 3
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . . 6 – 4
Chapter 3 – Kohler Engine
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 2
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 3
General Information . . . . . . . . . . . . . . . . . . . . . . . . 3 – 4
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 5
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . . 3 – 7
KOHLER ENGINE SERVICE MANUAL
Chapter 7 – Coring Head
General Information . . . . . . . . . . . . . . . . . . . . . . . . 7 – 2
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . . 7 – 4
Chapter 8 – Electrical Diagrams
Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . 8 – 3
Electrical Circuit Drawings . . . . . . . . . . . . . . . . . . . 8 – 4
Wire Harness Drawings . . . . . . . . . . . . . . . . . . . . 8 – 11
Chapter 4 – Hydraulic System
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 – 2
General Information . . . . . . . . . . . . . . . . . . . . . . . . 4 – 4
Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . 4 – 7
Hydraulic Flow Diagrams . . . . . . . . . . . . . . . . . . . . 4 – 8
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 – 12
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 – 14
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 – 17
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . 4 – 30
HYDRO–GEAR BDP–10A/16A/21L HYDROSTATIC
PUMPS SERVICE AND REPAIR MANUAL
SAUER DANFOSS GROUP 2 GEAR PUMPS AND
MOTORS SERVICE MANUAL
SAUER DANFOSS OMEW HYDRAULIC MOTOR
SERVICE MANUAL
ProCore 648
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ProCore 648
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Chapter 1
Safety
Table of Contents
SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . 2
Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
While Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Maintenance and Service . . . . . . . . . . . . . . . . . . . . 3
JACKING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . 4
SAFETY AND INSTRUCTION DECALS . . . . . . . . . . 5
ProCore 648
Safety
Page 1 – 1
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Safety Instructions
The ProCore 648 is designed and tested to offer safe
service when operated and maintained properly. Al-
though hazard control and accident prevention partially
are dependent upon the design and configuration of the
machine, these factors are also dependent upon the
awareness, concern and proper training of the person-
nel involved in the operation, transport, maintenance
and storage of the machine. Improper use or mainte-
nance of the machine can result in injury or death. To re-
duce the potential for injury or death, comply with the
following safety instructions.
WARNING
To reduce the potential for injury or death,
comply with the following safety instructions.
Before Operating
1. Read and understand the contents of the Operator’s
Manual before starting and operating the machine. Be-
come familiar with the controls and know how to stop the
machine and engine quickly. Additional copies of the
Operator’s Manual are available on the internet at
www.Toro.com.
4. Since gasoline is highly flammable, handle it careful-
ly:
A. Store fuel in containers specifically designed for
this purpose.
B. Do not remove machine fuel tank cap while en-
gine is hot or running.
2. Keep all shields, safety devices and decals in place.
If a shield, safety device or decal is defective, illegible
or damaged, repair or replace it before operating the
machine. Also tighten any loose nuts, bolts or screws to
ensure machine is in safe operating condition.
C. Do not smoke while handling fuel.
D. Fill fuel tank outdoors and only to within an inch of
the top of the tank, not the filler neck. Do not overfill
the fuel tank.
3. Assure interlock switches are adjusted correctly so
engine cannot be started unless traction lever is in NEU-
TRAL and coring head is DISENGAGED.
E. Wipe up any spilled fuel.
While Operating
1. Operator should be standing at the side console
when starting the engine and at the handle when operat-
ing the machine. Stay away from the coring head when
it is engaged.
5. Do not touch engine, muffler or exhaust pipe while
engine is running or soon after it is stopped. These
areas could be hot enough to cause burns.
6. Before leaving the operator’s position:
A. Ensure that traction lever is in neutral.
2. Before starting the engine:
A. Engage the parking brake.
B. Raise coring head and wait for coring head to
stop.
B. Make sure traction lever is in neutral.
3. After engine is started, release parking brake and
apply no pressure to traction lever. Machine must not
move. If movement is evident, the traction linkage is ad-
justed incorrectly. Shut engine off and adjust traction
linkage until machine does not move when traction lever
is released (see Operator’s Manual).
C. Set parking brake. Stop engine and remove key
from ignition switch.
7. Anytime the machine is parked (short or long term),
install the service latch to secure the coring head in the
raised position. This eliminates the risk of the coring
head accidentally lowering to the ground.
4. Do not run engine in a confined area without ade-
quate ventilation. Exhaust fumes are hazardous and
could possibly be deadly.
8. Do not park on slopes unless wheels are chocked or
blocked.
Safety
ProCore 648
Rev. C
Page 1 -- 2
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7. Anytime the machine is parked (short or long term),
install the service latch to secure the coring head in the
raised position. This eliminates the risk of the coring
head accidentally lowering to the ground.
8. Do not park on slopes unless wheels are chocked or
blocked.
Maintenance and Service
1. Before servicing or making adjustments, position
machine on level surface, raise coring head, set parking
brake, stop engine and remove key from the ignition
switch. Install the service latch to secure the coring head
in the raised position.
11.Do not overspeed the engine by changing governor
setting. To assure safety and accuracy, check maximum
engine speed with a tachometer.
12.Shut engine off before checking or adding oil to the
engine crankcase.
2. Make sure machine is in safe operating condition by
keeping all nuts, bolts and screws tight.
13.Disconnect battery before servicing the machine.
Disconnect negative battery cable first and positive batꢀ
tery cable last. If battery voltage is required for troubleꢀ
shooting or test procedures, temporarily connect the
battery. Reconnect positive battery cable first and negaꢀ
tive battery cable last.
3. Never store the machine or fuel container inside
where there is an open flame, such as near a water heatꢀ
er or furnace.
4. Make sure all hydraulic line connectors are tight and
all hydraulic hoses and lines are in good condition beꢀ
fore applying pressure to the hydraulic system.
14.Battery acid is poisonous and can cause burns.
Avoid contact with skin, eyes and clothing. Protect your
face, eyes and clothing when working with a battery.
5. Keep body and hands away from pin hole leaks in hyꢀ
draulic lines that eject high pressure hydraulic fluid. Use
cardboard or paper to find hydraulic leaks. Hydraulic
fluid escaping under pressure can penetrate skin and
cause injury. Hydraulic fluid accidentally injected into
the skin must be surgically removed within a few hours
by a doctor familiar with this form of injury or gangrene
may result.
15.Battery gases can explode. Keep cigarettes, sparks
and flames away from the battery.
16.At the time of manufacture, the machine conformed
to all applicable safety standards. To assure optimum
performance and continued safety certification of the
machine, use genuine Toro replacement parts and acꢀ
cessories. Replacement parts and accessories made
by other manufacturers may result in non-conformance
with the safety standards, and the warranty may be
voided.
6. Before disconnecting any hydraulic component or
performing any work on the hydraulic system, all presꢀ
sure in system must be relieved. See Relieving Hydrauꢀ
lic System Pressure in the General Information section
of Chapter 4 – Hydraulic System.
17.When changing tires or performing other service,
use correct blocks, hoists and jacks. Make sure maꢀ
chine is parked on a solid level floor such as a concrete
floor. Prior to raising the machine, remove any attachꢀ
ments that may interfere with the safe and proper raising
of the machine. Always chock or block wheels. Use jack
stands or solid wood blocks to support the raised maꢀ
chine. If the machine is not properly supported by blocks
or jack stands, the machine may move or fall, which may
result in personal injury (see Jacking Instructions).
7. If major repairs are ever needed or assistance is deꢀ
sired, contact an Authorized Toro Distributor.
8. Use care when checking or servicing the coring
head: wear gloves and use caution.
9. To reduce potential fire hazard, keep engine area
free of excessive grease, grass, leaves and dirt.
10.If engine must be running to perform maintenance or
make an adjustment, keep hands, feet, clothing and othꢀ
er parts of the body away from all moving machine parts.
Keep bystanders away.
ProCore 648
Safety
Page 1 – 3
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Jacking Instructions
CAUTION
1
When changing attachments, tires or perform-
ing other service, use correct blocks, hoists
and jacks. Make sure machine is parked on a
solid level surface such as a concrete floor.
Prior to raising machine, remove any attach-
ments that may interfere with the safe and prop-
er raising of the machine. Always chock or
block wheels. Use jack stands or solid wood
blocks to support the raised machine. If the ma-
chine is not properly supported by blocks or
jack stands, the machine may move or fall,
which may result in personal injury.
Figure 1
1. Front wheel
2. Frame jacking point
Jacking the Front End
1. Set parking brake and chock rear tires to prevent the
machine from moving. Install service latch to secure
coring head.
IMPORTANT: To prevent wheel motor damage, DO
NOT use front wheel motor as a jacking point.
2
2. Position jack securely under the front of the frame
(Fig. 1).
3. Jack front of machine off the ground.
4. Position jack stands or hardwood blocks under the
front of the frame to support the machine.
1
Figure 2
Jacking the Rear End
1. Rear wheel
2. Frame jacking point
1. Chock front tire to prevent the machine from moving.
Install service latch to secure coring head.
2
IMPORTANT: To prevent wheel motor damage, DO
NOT use rear wheel motor as a jacking point.
2. Place jack securely under the frame plate just inside
of the rear wheel (Fig. 2).
NOTE: If available, a hoist can be used to lift the rear
of the ProCore 648. Use eyelets in coring head bearing
housings as hoist attachment points (Fig. 3).
1
3. Jack (or lift) rear of machine off the ground.
4. Position jack stands or hardwood blocks under the
frame to support the machine.
Figure 3
1. Bearing housing
2. Lifting eyelet
Safety
ProCore 648
Page 1 – 4
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Safety and Instruction Decals
Numerous safety and instruction decals are affixed to
the ProCore 648. If any decal becomes illegible or damꢀ
aged, install a new decal. Part numbers for replacement
decals are listed in your Parts Catalog. Order replaceꢀ
ment decals from your Authorized Toro Distributor.
ProCore 648
Safety
Page 1 – 5
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Safety
ProCore 648
Page 1 – 6
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Chapter 2
Product Records and Maintenance
Table of Contents
PRODUCT RECORDS . . . . . . . . . . . . . . . . . . . . . . . . . 1
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
EQUIVALENTS AND CONVERSIONS . . . . . . . . . . . 2
Decimal and Millimeter Equivalents . . . . . . . . . . . . 2
U.S. to Metric Conversions . . . . . . . . . . . . . . . . . . . 2
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . 3
Fastener Identification . . . . . . . . . . . . . . . . . . . . . . . 3
Standard Torque for Dry, Zinc Plated and
Steel Fasteners (Inch Series) . . . . . . . . . . . . . . . 4
Standard Torque for Dry, Zinc Plated and
Steel Fasteners (Metric Fasteners) . . . . . . . . . . 5
Other Torque Specifications . . . . . . . . . . . . . . . . . . 6
Conversion Factors . . . . . . . . . . . . . . . . . . . . . . . . . 6
Product Records
Insert Operator’s Manual and Parts Catalog for your
ProCore 648 at the end of this chapter. Additionally, if
any optional equipment or accessories have been
installed to your ProCore, insert the Installation Instrucꢀ
tions, Operator’s Manuals and Parts Catalogs for those
options at the end of this chapter.
Maintenance
Maintenance procedures and recommended service inꢀ
tervals for the ProCore 648 are covered in the Opera-
tor’s Manual. Refer to that publication when performing
regular equipment maintenance. Refer to the Engine
Operator’s Manual for additional engine specific mainꢀ
tenance procedures.
ProCore 648
Product Records and Maintenance
Page 2 – 1
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Equivalents and Conversions
0.09375
Product Records and Maintenance
ProCore 648
Rev. C
Page 2 -- 2
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Torque Specifications
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 speꢀ
cified in this Service Manual.
As noted in the following tables, torque values should be
reduced by 25% for lubricated fasteners to achieve
the similar stress as a dry fastener. Torque values may
also have to be reduced when the fastener is threaded
into aluminum or brass. The specific torque value
should be determined based on the aluminum or brass
material strength, fastener size, length of thread enꢀ
gagement, etc.
These Torque Specifications for the installation and
tightening of fasteners shall apply to all fasteners which
do not have a specific requirement identified in this Serꢀ
vice Manual. The following factors shall be considered
when applying torque: cleanliness of the fastener, use
of a thread sealant (e.g. Loctite), degree of lubrication
on the fastener, presence of a prevailing torque feature,
hardness of the surface underneath the fastener’s head
or similar condition which affects the installation.
The standard method of verifying torque shall be perꢀ
formed by marking a line on the fastener (head or nut)
and mating part, then back off fastener 1/4 of a turn.
Measure the torque required to tighten the fastener until
the lines match up.
Fastener Identification
Grade 1
Grade 5
Grade 8
Class 8.8
Class 10.9
Inch Series Bolts and Screws
Figure 1
Metric Bolts and Screws
Figure 2
ProCore 648
Product Records and Maintenance
Page 2 – 3
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Standard Torque for Dry, Zinc Plated and Steel Fasteners (Inch Series)
Grade 1, 5 &
8 with Thin
Height Nuts
SAE Grade 1 Bolts, Screws, Studs &
Sems with Regular Height Nuts
(SAE J995 Grade 2 or Stronger Nuts)
SAE Grade 5 Bolts, Screws, Studs &
Sems with Regular Height Nuts
(SAE J995 Grade 2 or Stronger Nuts)
SAE Grade 8 Bolts, Screws, Studs &
Sems with Regular Height Nuts
(SAE J995 Grade 5 or Stronger Nuts)
Thread Size
in–lb
in–lb
N–cm
in–lb
15 + 2
N–cm
170 + 20
190 + 20
330 + 30
350 + 30
475 + 45
540 + 45
1125 + 100
1300 + 100
2250 + 280
2540 + 280
N–m
in–lb
23 + 2
N–cm
260 + 20
280 + 20
460 + 45
485 + 45
675 + 70
765 + 70
1580 + 170
1800 + 170
3390 + 340
3670 + 340
N–m
# 6 – 32 UNC
# 6 – 40 UNF
# 8 – 32 UNC
# 8 – 36 UNF
# 10 – 24 UNC
# 10 – 32 UNF
1/4 – 20 UNC
1/4 – 28 UNF
5/16 – 18 UNC
5/16 – 24 UNF
10 + 2
13 + 2
147 + 23
17 + 2
25 + 2
29 + 3
41 + 4
13 + 2
18 + 2
25 + 5
30 + 5
282 + 30
339 + 56
31 + 3
43 + 4
42 + 4
60 + 6
48 + 4
68 + 6
48 + 7
53 + 7
53 + 7
65 + 10
105 + 17
128 + 17
ft–lb
599 + 79
734 + 113
1186 + 169
1446 + 192
N–m
100 + 10
115 + 10
200 + 25
225 + 25
ft–lb
140 + 15
160 + 15
300 + 30
325 + 30
ft–lb
115 + 15
138 + 17
ft–lb
3/8 – 16 UNC
3/8 – 24 UNF
7/16 – 14 UNC
7/16 – 20 UNF
1/2 – 13 UNC
1/2 – 20 UNF
5/8 – 11 UNC
5/8 – 18 UNF
3/4 – 10 UNC
3/4 – 16 UNF
7/8 – 9 UNC
16 + 2
16 + 2
22 + 3
30 + 3
41 + 4
43 + 4
58 + 5
17 + 2
18 + 2
24 + 3
35 + 3
47 + 4
50 + 4
68 + 5
27 + 3
27 + 3
37 + 4
50 + 5
68 + 7
70 + 7
95 + 9
29 + 3
29 + 3
39 + 4
55 + 5
75 + 7
77 + 7
104 + 9
30 + 3
48 + 7
65 + 9
75 + 8
102 + 11
115 + 11
203 + 20
230 + 20
359 + 34
407 + 34
583 + 61
644 + 61
105 + 10
120 + 10
210 + 20
240 + 20
375 + 35
420 + 35
600 + 60
660 + 60
142 + 14
163 + 14
285 + 27
325 + 27
508 + 47
569 + 47
813 + 81
895 + 81
32 + 3
53 + 7
72 + 9
85 + 8
65 + 10
75 + 10
93 + 12
115 + 15
140 + 20
155 + 25
88 + 12
95 + 15
140 + 20
165 + 25
225 + 25
260 + 30
119 + 16
129 + 20
190 + 27
224 + 34
305 + 34
353 + 41
150 + 15
170 + 15
265 + 25
300 + 25
430 + 45
475 + 45
7/8 – 14 UNF
NOTE: Reduce torque values listed in the table above
by 25% for lubricated fasteners. Lubricated fasteners
are defined as threads coated with a lubricant such as
oil, graphite or thread sealant such as Loctite.
NOTE: The nominal torque values listed above for
Grade 5 and 8 fasteners are based on 75% of the miniꢀ
mum proof load specified in SAE J429. The tolerance is
approximately + 10% of the nominal torque value. Thin
height nuts include jam nuts.
NOTE: Torque values may have to be reduced when
installing fasteners into threaded aluminum or brass.
The specific torque value should be determined based
on the fastener size, the aluminum or base material
strength, length of thread engagement, etc.
Product Records and Maintenance
ProCore 648
Page 2 – 4
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Standard Torque for Dry, Zinc Plated and Steel Fasteners (Metric Fasteners)
Class 8.8 Bolts, Screws and Studs with
Regular Height Nuts
Class 10.9 Bolts, Screws and Studs with
Thread Size
Regular Height Nuts
(Class 8 or Stronger Nuts)
(Class 10 or Stronger Nuts)
M5 X 0.8
M6 X 1.0
57 + 5 in–lb
96 + 9 in–lb
19 + 2 ft–lb
38 + 4 ft–lb
66 + 7 ft–lb
166 + 15 ft–lb
325 + 33 ft–lb
640 + 60 N–cm
1018 + 100 N–cm
26 + 3 N–m
78 + 7 in–lb
885 + 80 N–cm
1500 + 150 N–cm
36 + 3 N–m
133 + 13 in–lb
27 + 2 ft–lb
M8 X 1.25
M10 X 1.5
M12 X 1.75
M16 X 2.0
M20 X 2.5
52 + 5 N–m
53 + 5 ft–lb
72 + 7 N–m
90 + 10 N–m
225 + 20 N–m
440 + 45 N–m
92 + 9 ft–lb
125 + 12 N–m
310 + 30 N–m
610 + 50 N–m
229 + 22 ft–lb
450 + 37 ft–lb
NOTE: Reduce torque values listed in the table above
by 25% for lubricated fasteners. Lubricated fasteners
are defined as threads coated with a lubricant such as
oil, graphite or thread sealant such as Loctite.
NOTE: The nominal torque values listed above are
based on 75% of the minimum proof load specified in
SAE J1199. The tolerance is approximately + 10% of the
nominal torque value.
NOTE: Torque values may have to be reduced when
installing fasteners into threaded aluminum or brass.
The specific torque value should be determined based
on the fastener size, the aluminum or base material
strength, length of thread engagement, etc.
ProCore 648
Product Records and Maintenance
Page 2 – 5
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Other Torque Specifications
SAE Grade 8 Steel Set Screws
Wheel Bolts and Lug Nuts
Thread Size Recommended Torque**
65 + 10 ft–lb 88 + 14 N–m
Recommended Torque
Thread Size
Square Head
140 + 20 in–lb
215 + 35 in–lb
35 + 10 ft–lb
75 + 15 ft–lb
Hex Socket
73 + 12 in–lb
145 + 20 in–lb
18 + 3 ft–lb
7/16 – 20 UNF
Grade 5
1/4 – 20 UNC
5/16 – 18 UNC
3/8 – 16 UNC
1/2 – 13 UNC
1/2 – 20 UNF
Grade 5
80 + 10 ft–lb 108 + 14 N–m
80 + 10 ft–lb 108 + 14 N–m
80 + 10 ft–lb 108 + 14 N–m
M12 X 1.25
Class 8.8
50 + 10 ft–lb
M12 X 1.5
Class 8.8
** For steel wheels and non–lubricated fasteners.
Thread Cutting Screws
(Zinc Plated Steel)
Thread Cutting Screws
(Zinc Plated Steel)
Type 1, Type 23 or Type F
Thread Threads per Inch
Size
Baseline Torque*
Thread Size
Baseline Torque*
20 + 5 in–lb
Type A Type B
No. 6 – 32 UNC
No. 8 – 32 UNC
No. 10 – 24 UNC
1/4 – 20 UNC
No. 6
No. 8
18
15
12
11
20
18
16
14
20 + 5 in–lb
30 + 5 in–lb
38 + 7 in–lb
85 + 15 in–lb
30 + 5 in–lb
38 + 7 in–lb
No. 10
No. 12
85 + 15 in–lb
110 + 20 in–lb
200 + 100 in–lb
5/16 – 18 UNC
3/8 – 16 UNC
* Hole size, material strength, material thickness & finish
must be considered when determining specific torque
values. All torque values are based on non–lubricated
fasteners.
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
Product Records and Maintenance
ProCore 648
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Chapter 3
Kohler Engine
Table of Contents
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 4
Fuel Shutoff Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Adjust Choke Control . . . . . . . . . . . . . . . . . . . . . . . . 5
Adjust Engine Speed . . . . . . . . . . . . . . . . . . . . . . . . 5
SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 7
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Belt Tensioners . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
KOHLER ENGINE SERVICE MANUAL
ProCore 648
Page 3 – 1
Kohler Engine
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Introduction
This Chapter gives information about specifications and
repair of the Kohler engine used in the ProCore 648.
Most repairs and adjustments require tools which are
commonly available in many service shops. Special
tools are described in the Kohler Engine Service Manuꢀ
al. The use of some specialized test equipment is exꢀ
plained. However, the cost of the test equipment and the
specialized nature of some repairs may dictate that the
work be done at an engine repair facility.
General engine maintenance procedures are described
in your Operator’s Manual. Information on engine trouꢀ
bleshooting, testing, disassembly, and reassembly is
identified in the Kohler Engine Service Manual that is inꢀ
cluded at the end of this section.
Service and repair parts for Kohler engines are supplied
through your local Kohler dealer or distributor.
Kohler Engine
ProCore 648
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Specifications
Item
Description
Make / Designation
Kohler, CH23S, 4–stroke, V–Twin
Air Cooled, OHV
Number of Cylinders
Bore x Stroke
2
3.15” x 2.64” (80 mm x 67 mm)
41.1 Cubic Inches (674 cc)
8.5:1
Total Displacement
Compression Ratio
Dry Weight (approximate)
Fuel
90 Pounds (41 Kilograms)
Unleaded, Regular Gasoline (Minimum 87 Octane)
7.5 U.S. Gallons (28.4 Liters)
Mechanical
Fuel Tank Capacity
Governor
Idle Speed (no load)
High Idle (no load)
Engine Oil
1400 + 50 RPM
3400 + 50 RPM
See Operator’s Manual
Gear driven trochoid type
2 U.S. Quart (1.9 Liters) with filter
12 VDC
Oil Pump
Crankcase Oil Capacity
Starter
ProCore 648
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General Information
Fuel Shutoff Valve
The fuel shutoff valve located under the fuel tank (Fig.
1) should be closed when removing the fuel tank or enꢀ
gine from the machine. Additionally, close the shutoff
valve if the machine is being transported on a trailer or
when placing the machine in long term storage.
1
Figure 1
1. Fuel shutoff valve (under the fuel tank)
Kohler Engine
ProCore 648
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Adjustments
Adjust Choke Control
Proper choke operation is dependent upon proper adꢀ
justment of choke control cable.
1
1. Park machine on a level surface, fully raise coring
head, engage parking brake, stop engine and remove
key from the ignition switch.
2. Remove air cleaner cover from engine to view choke
plate in carburetor.
2
3. Move choke control lever to RUN position. Check
that choke plate in carburetor is fully open.
4. Move choke control lever to CHOKE position. Check
that choke plate in carburetor is fully closed.
Figure 2
5. If needed, choke cable can be adjusted by loosening
cable clamp screw and repositioning control cable until
choke plate operates correctly.
1. Choke cable
2. Cable clamp
6. Install air cleaner cover to engine.
Adjust Engine Speed
1. Allow engine to reach operating temperature before
checking or adjusting engine speed. Park machine on
a level surface, fully raise coring head and apply parking
brake.
2. With engine running, move throttle control lever to
FAST (high idle) position.
1
3. Using a tachometer, check that engine is operating
at 3400 + 50 RPM.
4. If high idle speed is incorrect, adjust high speed
screw on governor assembly until high idle is 3400 + 50
RPM (Fig. 3).
Figure 3
1. High speed screw
5. Move throttle control lever to SLOW (idle speed)
position.
6. Using a tachometer, check that engine is operating
at 1400 + 50 RPM.
7. For additional information, refer to the Kohler Engine
Service Manual that is included at the end of this Chapꢀ
ter.
ProCore 648
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ProCore 648
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Service and Repairs
Cooling System
To ensure proper engine cooling, make sure the grass
screen, cooling fins and other external surfaces of the
engine are kept clean at all times.
1
1
NOTE: Perform this maintenance procedure at the in-
terval specified in the Operator’s Manual.
IMPORTANT: The engine that powers the ProCore
648 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 en-
gine overheating and engine damage.
3
1. Park machine on a level surface, fully raise coring
head, engage parking brake, stop engine and remove
key from the ignition switch.
2
Figure 4
IMPORTANT: Never clean engine with pressurized
water. Water could enter and contaminate the fuel
system.
1. Cylinder head
2. Grass screen
3. Blower housing
2. Clean cooling fins on both cylinder heads.
3. Clean grass screen and blower housing of dirt and
debris (Fig. 4).
4. If blower housing removal is necessary for cooling
system cleaning, engine needs to be removed from ma-
chine (see Engine Removal and Installation in this sec-
tion).
IMPORTANT: Never operate engine without the
blower housing installed. Overheating and engine
damage will result.
5. Make sure grass screen and blower housing are re-
installed to the engine if removed.
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Fuel System
2
RIGHT
FRONT
1
12
Anti–seize
Lubricant
8
3
7
4
6
9
5
11
8
6
10
10
30 to 60 in–lb
(3.4 to 6.8 N–m)
Figure 5
1. Fuel tank
2. Fuel cap
3. Hose clamp
4. Fuel hose
5. Fuel shut–off valve
6. Hose clamp
9. Clamp
10. Cap screw (4 used)
7. Fuel hose
11. Flange bushing (4 used)
12. Machine frame
8. Flat washer (4 used)
Check Fuel Lines and Connections
DANGER
Check fuel lines and connections periodically as recom-
mended in the Operator’s Manual. Check fuel lines for
deterioration, damage or leaking connections. Replace
hoses, clamps and connections as necessary.
Because gasoline is highly flammable, use cau-
tion when storing or handling it. Do not smoke
while filling the fuel tank. Do not fill fuel tank
while engine is running, hot, or when machine is
in an enclosed area. Always fill fuel tank outside
and wipe up any spilled fuel before starting the
engine. Store fuel in a clean, safety–approved
container and keep cap in place. Use gasoline
for the engine only; not for any other purpose.
Drain and Clean Fuel Tank
Drain and clean the fuel tank periodically as recom-
mended in the Operator’s Manual. Also, drain and clean
the fuel tank if the fuel system becomes contaminated
or if the machine is to be stored for an extended period.
To clean fuel tank, flush tank out with clean solvent.
Make sure tank is free of contaminates and debris.
Kohler Engine
ProCore 648
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Fuel Tank Removal (Fig. 5)
2
1. Park machine on a level surface, fully raise coring
head, engage parking brake, stop engine and remove
key from the ignition switch. Secure coring head with
service latch.
3
2. Close tank fuel shut–off valve. Disconnect fuel hose
from the fuel filter (Fig. 6).
3. Use shut–off valve to empty fuel tank into a suitable
container.
1
4. Remove fuel tank using Figure 5 as a guide.
Fuel Tank Installation (Fig. 5)
Figure 6
1. Install fuel tank to frame using Figure 5 as a guide.
Apply anti–seize lubricant to fuel tank cap screws and
torque screws from 30 to 60 in–lb (3.4 to 6.8 N–m).
1. Fuel shut–off valve
2. Fuel filter
3. Fuel hose
2. Connect fuel hose to the fuel filter.
3. Fill fuel tank (see Operator’s Manual). Open fuel
shut–off valve.
4. Return coring head service latch to stored position
before using machine.
ProCore 648
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Exhaust System
17 to 21 ft–lb
(23.1 to 28.5 N–m)
1
FRONT
RIGHT
3
4
11
6
2
7
5
7
8
8
9
10
12
13
14
15
Figure 7
1. Engine
6. Muffler bracket
11. Heat shield
2. Exhaust manifold
3. Hex nut (4 used)
4. Frame
7. Flange head screw (3 used)
8. Muffler clamp (2 used)
9. Exhaust elbow
12. Lock washer (2 used)
13. Cap screw (2 used)
14. Flange nut (2 used)
15. Muffler
5. Flange nut (2 used)
10. Carriage screw (2 used)
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ProCore 648
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Removal (Fig. 7)
Installation (Fig. 7)
NOTE: Make sure exhaust manifold and engine sealꢀ
ing surfaces are free of debris or damage that may preꢀ
vent a tight, leak–free seal.
CAUTION
The muffler and exhaust pipe may be hot. To
avoid possible burns, allow the engine and exꢀ
haust system to cool before working on the exꢀ
haust system.
1. If exhaust manifold was removed, place exhaust
gaskets on the engine exhaust manifold studs. Secure
exhaust manifold to engine with four hex nuts. Torque
hex nuts from 17 to 21 ft–lb (23.1 to 28.5 N–m).
1. Park machine on a level surface, fully raise coring
head, engage parking brake, stop engine and remove
key from the ignition switch. Secure coring head with
service latch.
IMPORTANT: Finger tighten all exhaust system
fasteners before securing so there is no preload on
exhaust components.
2. Position muffler clamps over exhaust elbow and
muffler inlets.
2. Remove fasteners that secure exhaust heat shield
to machine (flange head screw and two (2) cap screws
with lock washers). Remove heat shield from machine.
3. Slide exhaust elbow onto exhaust manifold and then
slide muffler onto elbow.
3. Loosen muffler clamps that secure muffler and exꢀ
haust elbow.
4. Secure muffler to frame with two (2) carriage screws
and flange nuts.
4. Remove two (2) flange nuts that secure muffler to
frame. Retrieve two (2) carriage screws. Remove mufꢀ
fler and exhaust elbow from machine.
5. Tighten muffler clamps.
6. Position exhaust heat shield to machine and secure
with flange head screw and two (2) cap screws with lock
washers.
5. If exhaust manifold removal is required, remove four
(4) hex nuts from the exhaust manifold studs on engine.
Separate the exhaust manifold from the engine.
7. Return coring head service latch to stored position
before using machine.
6. Remove exhaust gaskets.
ProCore 648
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Engine
1
2
3
FRONT
RIGHT
4
5
6
7
9
11
12
16
12
8
19
10
13
13
14
21
15
17
18
19
19
20
8
Figure 8
1. Engine
8. Cap screw (4 used)
15. Carriage screw (2 used)
16. Heat shield
2. Negative battery cable
3. Wire harness ground
4. Flange screw
9. Frame
10. Flange nut (2 used)
11. Muffler bracket
12. Flange head screw (3 used)
13. Muffler clamp (2 used)
14. Exhaust elbow
17. Lock washer (2 used)
18. Cap screw (2 used)
19. Flange nut (6 used)
20. Muffler
5. Lock washer
6. Exhaust manifold
7. Hex nut (4 used)
21. Starter cable
Removal (Fig. 8)
4. Remove exhaust system (see Exhaust System Re-
moval in this section).
1. Park machine on a level surface, fully raise coring
head, engage parking brake, stop engine and remove
key from the ignition switch. Secure coring head with
service latch. Chock wheels to keep the machine from
moving.
5. Close fuel tank shut--off valve.
6. Loosen hose clamp and disconnect fuel hose from
the fuel filter on the front side of the engine. Plug fuel
hose to prevent leakage and contamination.
2. Disconnect negative (--) and then positive (+) battery
cables at the battery.
3. Remove pump belt cover from machine (see Opera-
tor’s Manual).
Kohler Engine
ProCore 648
Rev. C
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7. Disconnect electrical connections from engine.
NOTE: Label all electrical connections for reassembly
purposes.
2
1
A. Remove harness red wire and positive battery
cable from the starter motor solenoid stud (Fig. 9).
B. Disconnect negative battery cable and wire har-
ness ground wire from the front corner of engine
base (Fig. 10). Locate and retrieve starwasher from
between engine and wire connectors.
3
C. Unplug machine harness connector from electric
clutch.
Figure 9
1. Solenoid stud
2. Positive battery cable
3. Harness red wire
D. Remove cable tie that secures hourmeter wire to
spark plug wire. Position hourmeter wire clear of en-
gine.
E. Unplug machine wire harness connector from en-
gine connector. Position wiring harness away from
the engine.
2
8. Remove primary drive belt (coring head) (see Prima-
ry Drive Belt in the Service and Repairs section of Chap-
ter 7 – Coring Head).
9. Remove hydraulic pump drive belt (see Pump Drive
Belt in the Service and Repairs section of Chapter 4 –
Hydraulic System).
1
3
10.Remove engine from machine:
Figure 10
1. Flange head screw
2. Wire harness ground
3. Negative battery cable
A. Connect a hoist or chain fall to lift tabs located on
each of the cylinder heads.
B. Remove four (4) cap screws and flange nuts that
secure the engine to the machine frame.
1
Anti–seize
Lubricant
3
CAUTION
4
One person should operate lift or hoist while
another person guides the engine out of the ma-
chine.
IMPORTANT: Make sure not to damage the engine,
fuel hoses, hydraulic lines, electrical harness or
other parts while removing the engine.
2
50 to 55 ft–lb
(67.8 to 74.6 N–m)
C. Remove engine from the machine.
5
11.If needed, remove electric clutch (see Electric Clutch
in the Service and Repairs section of Chapter 5 – Electri-
cal System) and hydraulic pump drive pulley from en-
gine (Fig. 11).
Figure 11
1. Engine
2. Pump pulley
3. Electric clutch
4. Hardened washer
5. Cap screw
12.If needed, remove belt tensioning components from
engine (see Belt Tensioners in this section).
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Installation (Fig. 8)
B. Wrap hourmeter wire around spark plug wire and
secure with cable tie.
1. Locate machine on a level surface with key removed
from the ignition switch. Chock wheels to keep the maꢀ
chine from moving.
C. Position negative battery cable and wire harness
ground wire to the front corner of engine base (Fig.
10). Place starwasher between engine and wire conꢀ
nectors and secure with flange head screw.
2. Make sure that all parts removed from the engine
during maintenance or rebuilding are reinstalled to the
engine.
D. Plug machine harness connector to electric
clutch.
3. If electric clutch and hydraulic pump drive pulley
were removed from engine crankshaft (Fig. 11):
E. Connect red wire and positive battery cable to the
starter motor solenoid stud (Fig. 9).
A. Apply anti–seize lubricant to crankshaft.
7. After engine installation, verify pulley alignment
across engine and hydraulic pump pulley faces with a
straight edge. If necessary, loosen two (2) set screws on
hydraulic pump pulley and adjust location of pulley. Reꢀ
tighten pulley set screws after adjustment.
B. Install hydraulic pump drive pulley with the hub
away from engine.
C. Slide clutch onto crankshaft and secure to crankꢀ
shaft with screw and hardened washer. Hold hardꢀ
ened washer with pliers to prevent crankshaft from
turning and torque screw from 50 to 55 ft–lb (67.9 to
74.6 N–m).
8. Install hydraulic pump drive belt (see Pump Drive
Belt in the Service and Repairs section of Chapter 4 –
Hydraulic System).
4. If removed, install belt tensioner components to enꢀ
gine assembly (see Belt Tensioners in this section).
9. Adjust hydraulic pump drive belt tension (see Opera-
tor’s Manual).
5. Reinstall engine to machine.
10.Install primary drive belt (coring head) (see Primary
Drive Belt in the Service and Repairs section of Chapter
7 – Coring Head).
A. Connect a hoist or chain fall to lift tabs located on
each of the cylinder heads.
11.Remove plug installed in fuel hose during disassemꢀ
bly. Connect fuel hose to the fuel filter and secure with
hose clamp.
CAUTION
12.Install exhaust system (see Exhaust System Instalꢀ
lation in this section).
One person should operate lift or hoist while
another person guides the engine to the maꢀ
chine.
13.Check engine oil level (see Operator’s Manual).
IMPORTANT: Make sure not to damage the engine,
fuel hoses, hydraulic lines, electrical harness or
other parts while installing the engine.
14.Check all wires, control cables and hoses to make
sure that they are not contacted by rotating or moving
parts.
B. Reinstall engine to the machine. Make sure fasꢀ
tener holes of the engine are aligned with the holes in
the machine frame.
15.Connect positive (+) and then negative (–) battery
cables at the battery.
16.Install pump belt cover to machine (see Operator’s
Manual).
C. Secure engine to the frame with four (4) cap
screws and flange nuts. The front two (2) cap screws
should be positioned down through engine and
frame. The rear two (2) cap screws should be up
through frame and engine.
17.Open fuel shut–off valve under the fuel tank.
18.Return coring head service latch to stored position
before using machine.
6. Reconnect electrical connections to engine:
A. Plug engine wire harness connector into machine
harness connector.
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ProCore 648
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Belt Tensioners
26
27
41 to 49 ft–lb
(55.6 to 66.4 N–m)
25
26
4
28
23
29
21
20
30
31
19
18
16
15
23
14
32
34
24
4
23
33
12
22
41 to 49 ft–lb
(55.6 to 66.4 N–m)
17
1
13
Anti–seize
Lubricant
11
8
8
4
9
7
9
10
2
7
50 to 55 ft–lb
(67.8 to 74.6 N–m)
6
3
5
Figure 12
1. Engine
13. Flange nut
24. Spacer (.750” long)
2. Hydraulic pump drive pulley
3. Electric clutch
4. Flange nut
14. Flat washer
15. Idler arm assembly
16. Washer
25. Idler mounting bracket
26. Spacer (.560” long)
27. Lock nut
5. Hardened washer
6. Cap screw
7. Flat washer
8. Grommet
9. Spacer
10. Cap screw
11. Clutch strap
12. Cap screw
17. Idler spacer
18. Idler arm spacer
19. Torsion spring
20. Idler pulley
21. Hardened washer
22. Cap screw
23. Cap screw
28. Idler support
29. Flange head screw
30. Spring bracket
31. Spring
32. Flange head screw
33. Idler pulley
34. Bracket (fastens to machine frame)
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ProCore 648
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Removal (Fig. 12)
Installation (Fig. 12)
1. Release tension on idler torsion spring (item 19):
1. Install belt tensioner components to engine using
Figure 12 as a guide.
2. Install the hydraulic pump drive belt and primary
drive belt (coring head).
CAUTION
Be careful when removing or applying tension
from or to the torsion spring of the idler pulley.
The spring is under heavy load and may cause
personal injury.
3. Apply tension to idler torsion spring (item 19):
A. Insert nut driver or small piece of pipe onto the
end of the torsion spring.
B. Push down on the spring end and hook the spring
under the idler mounting bracket notch. Release the
spring slowly to lock it into place.
A. Insert nut driver or small piece of pipe onto the
end of the torsion spring.
B. Push down on the spring end and unhook the
spring from the idler mounting bracket.
4. Adjust the hydraulic pump drive belt (see Operator’s
Manual) and primary drive belt (coring head) (see Priꢀ
mary Drive Belt in the Service and Repairs section of
Chapter 7 – Coring Head).
2. Remove belt tensioner components from engine as
needed using Figure 12 as a guide.
ProCore 648
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Chapter 4
Hydraulic System
Table of Contents
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 4
Hydraulic Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Hydraulic Fitting Installation . . . . . . . . . . . . . . . . . . . 4
Pushing/Pulling Machine . . . . . . . . . . . . . . . . . . . . . 6
Check Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . 6
Relieving Hydraulic System Pressure . . . . . . . . . . 6
HYDRAULIC SCHEMATIC . . . . . . . . . . . . . . . . . . . . . 7
HYDRAULIC FLOW DIAGRAMS . . . . . . . . . . . . . . . . 8
Traction Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Coring Head Raise/Lower Circuits . . . . . . . . . . . . 10
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Hydraulic Pressure Test Kit . . . . . . . . . . . . . . . . . . 12
Hydraulic Tester (Pressure and Flow) . . . . . . . . . 12
Hydraulic Test Fitting Kit . . . . . . . . . . . . . . . . . . . . . 13
Wheel Hub Puller . . . . . . . . . . . . . . . . . . . . . . . . . . 13
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . 14
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Charge Pressure Test . . . . . . . . . . . . . . . . . . . . . . . 18
Coring Head Raise/Lower Relief (R1)
SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . 30
General Precautions for Removing and Installing
Hydraulic System Components . . . . . . . . . . . . . 30
Check Hydraulic Lines and Hoses . . . . . . . . . . . . 30
Flush Hydraulic System . . . . . . . . . . . . . . . . . . . . . 31
Hydraulic System Start--up . . . . . . . . . . . . . . . . . . 32
Hydraulic Pump Drive Belt . . . . . . . . . . . . . . . . . . . 34
Hydraulic Pump Control Assembly . . . . . . . . . . . . 36
Hydraulic (Traction/Charge) Pump . . . . . . . . . . . . 38
Hydraulic (Traction/Charge) Pump Service . . . . . 41
Wheel Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Wheel Motor Service . . . . . . . . . . . . . . . . . . . . . . . 44
Hydraulic Lift Control Manifold . . . . . . . . . . . . . . . 46
Hydraulic Lift Control Manifold Service . . . . . . . . 48
Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Lift Cylinder Service . . . . . . . . . . . . . . . . . . . . . . . . 52
Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . 54
HYDRO--GEAR BDP--10A/16A/21L HYDROSTATIC
PUMPS SERVICE AND REPAIR MANUAL
SAUERDANFOSSGROUP2GEARPUMPSANDMO-
TORS SERVICE MANUAL
SAUER DANFOSS OMEW HYDRAULIC MOTOR
SERVICE MANUAL
Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Traction (Piston) Pump (P1) Flow Test . . . . . . . . 22
Traction Circuit Relief Pressure Test . . . . . . . . . . 24
Gear Pump (P2) Flow Test . . . . . . . . . . . . . . . . . . 26
Wheel Motor Efficiency Test . . . . . . . . . . . . . . . . . 28
Rev. C
ProCore 648
Page 4 -- 1
Hydraulic System
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Specifications
Item
Description
Traction Pump (P1)
Displacement at full stroke (per revolution)
Forward relief pressure
Variable displacement piston pump
.976 Cubic Inches (16 cc)
2900 PSI (200 Bar)
Reverse relief pressure
2900 PSI (200 Bar)
Charge/Lift Pump (P2)
Displacement (per revolution)
Charge Pressure
Gear pump
.37 Cubic Inches (6.1 cc)
40 PSI (2.8 Bar)
Lift System Relief (R1) Pressure
1000 PSI (69 Bar)
Front Wheel Motor
Displacement
Orbital rotor motor
24 Cubic Inches (393 cc)
Rear Wheel Motors
Displacement
Orbital rotor motor
12 Cubic Inches (197 cc)
Hydraulic Filter
Spin–on cartridge type
See Operator’s Manual
Hydraulic Oil
Hydraulic Reservoir Capacity
Total Hydraulic System Capacity
1.75 U.S. Gal. (6.6 L)
3 U.S. Gal. (11.4 L) (Approximate)
Hydraulic System
Page 4 – 2
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ProCore 648
Page 4 – 3
Hydraulic System
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General Information
Hydraulic Hoses
Hydraulic hoses are subject to extreme conditions such
as pressure differentials during operation and exposure
to weather, sun, chemicals, very warm storage condiꢀ
tions, or mishandling during operation and mainteꢀ
nance. These conditions can cause damage or
premature deterioration. Some hoses are more suscepꢀ
tible to these conditions than others. Inspect the hoses
frequently for signs of deterioration or damage.
WARNING
Before disconnecting or performing any work
on hydraulic system, relieve all pressure in
system. See Relieving Hydraulic System Presꢀ
sure in this section.
Keep body and hands away from pin hole leaks
or nozzles that eject hydraulic fluid under high
pressure. Use paper or cardboard, not hands,
to search for leaks. Hydraulic fluid escaping
under pressure can have sufficient force to
penetrate the skin and cause serious injury. If
fluid is injected into the skin, it must be surgiꢀ
cally removed within a few hours by a doctor
familiar with this type of injury. Gangrene may
result from such an injury.
When replacing a hydraulic hose, be sure that the hose
is straight (not twisted) before tightening the fittings.
This can be done by observing the imprint on the hose.
Use two wrenches; hold the hose straight with one
wrench and tighten the hose swivel nut onto the fitting
with the other wrench.
Hydraulic Fitting Installation
O–Ring Face Seal
Nut
Body
1. Make sure both threads and sealing surfaces are
free of burrs, nicks, scratches, or any foreign material.
Sleeve
2. Make sure the O–ring is installed and properly
seated in the groove. It is recommended that the O–ring
be replaced any time the connection is opened.
Seal
3. Lubricate the O–ring with a light coating of oil.
4. Put the tube and nut squarely into position on the
face seal end of the fitting and tighten the nut until finger
tight.
Figure 1
5. Mark the nut and fitting body. Hold the body with a
wrench. Use another wrench to tighten the nut to the cor-
rect Flats From Finger Tight (F.F.F.T.). The markings on
the nut and fitting body will verify that the connection has
been tightened.
Final
Position
Mark Nut
and Body
Initial
Extend Line
Position
Size
F.F.F.T.
4 (1/4 in. nominal hose or tubing)
6 (3/8 in.)
8 (1/2 in.)
10 (5/8 in.)
12 (3/4 in.)
0.75 + 0.25
0.75 + 0.25
0.75 + 0.25
1.00 + 0.25
0.75 + 0.25
0.75 + 0.25
Finger Tight
After Proper Tightening
Figure 2
16 (1 in.)
Hydraulic System
Page 4 – 4
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SAE Straight Thread O–Ring Port – Non–adjustable
1. Make sure both threads and sealing surfaces are
free of burrs, nicks, scratches, or any foreign material.
2. Always replace the O–ring seal when this type of fitꢀ
ting shows signs of leakage.
O–Ring
3. Lubricate the O–ring with a light coating of oil.
4. Install the fitting into the port and tighten it down full
length until finger tight.
Figure 3
5. Tighten the fitting to the correct Flats From Finger
Tight (F.F.F.T.).
Fitting Size
Installation Torque
9–10 ft–lb (12–13 N–m)
20–21 ft–lb (27–28 N–m)
35–37 ft–lb (47–50 N–m)
60–66 ft–lb (81–89 N–m)
81–87 ft–lb (110–117 N–m)
121–131 ft–lb (164–177 N–m)
4
6
Size
F.F.F.T.
4 (1/4 in. nominal hose or tubing)
6 (3/8 in.)
8 (1/2 in.)
10 (5/8 in.)
12 (3/4 in.)
1.00 + 0.25
1.50 + 0.25
1.50 + 0.25
1.50 + 0.25
1.50 + 0.25
1.50 + 0.25
8
10
12
16
16 (1 in.)
NOTE: Installation torque values for non–adjustable fit-
tings are listed in Figure 4. These torque values should
only be used when a fitting can be accessed with a
socket. Use of an offset wrench (e.g. crowfoot wrench)
will affect torque wrench accuracy and should not be
used.
Figure 4
SAE Straight Thread O–Ring Port – Adjustable
1. Make sure both threads and sealing surfaces are
free of burrs, nicks, scratches, or any foreign material.
2. Always replace the O–ring seal when this type of fitꢀ
ting shows signs of leakage.
Lock Nut
3. Lubricate the O–ring with a light coating of oil.
4. Turn back the jam nut as far as possible. Make sure
the back up washer is not loose and is pushed up as far
as possible (Step 1).
Back–up Washer
O–Ring
5. Install the fitting into the port and tighten finger tight
until the washer contacts the face of the port (Step 2).
Figure 5
6. To put the fitting in the desired position, unscrew it by
the required amount, but no more than one full turn
(Step 3).
Step 1
Step 2
Step 3
Step 4
7. Hold the fitting in the desired position with a wrench
and turn the jam nut with another wrench to the correct
Flats From Finger Tight (F.F.F.T.) (Step 4).
Size
F.F.F.T.
4 (1/4 in. nominal hose or tubing)
6 (3/8 in.)
8 (1/2 in.)
10 (5/8 in.)
12 (3/4 in.)
1.00 + 0.25
1.50 + 0.25
1.50 + 0.25
1.50 + 0.25
1.50 + 0.25
1.50 + 0.25
16 (1 in.)
Figure 6
ProCore 648
Page 4 – 5
Hydraulic System
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Pushing/Pulling Machine
IMPORTANT: If push/pull limits are exceeded, seꢀ
vere damage to the piston (traction) pump may ocꢀ
cur.
If it becomes necessary to push/pull the machine, push/
pull at a speed below 1 mph (1.6 kph), and for a disꢀ
tance less than 100 feet (30.5 meters). The piston
(traction) pump is equipped with a by–pass valve that
needs to be rotated counterclockwise (loosened) one
turn for pushing/pulling. The by–pass valve should be
torqued from 95 to 120 in–lb (10.7 to 13.6 N–m) before
the machine is returned to operation.
1
See Operator’s Manual for pushing/pulling procedures.
Figure 7
1. By–pass valve location
Check Hydraulic Fluid
The ProCore 648 hydraulic system is designed to operꢀ
ate on anti–wear hydraulic fluid. The reservoir (Fig. 8)
holds about 1.75 gallons (6.6 liters) of hydraulic fluid.
Check level of hydraulic fluid daily.
1
2
See Operator’s Manual for fluid level checking proceꢀ
dure and hydraulic oil recommendations.
Figure 8
1. Hydraulic reservoir
2. Hydraulic reservoir cap
Relieving Hydraulic System Pressure
Before disconnecting or performing any work on the hyꢀ
draulic system, all pressure in the hydraulic system
must be relieved. With the coring head fully raised, turn
key switch to OFF and allow engine to stop. Secure corꢀ
ing head with service latch.
To relieve lift system pressure, turn key switch to ON
(engine not running). Move traction lever to forward diꢀ
rection and depress lower switch on handle to lower corꢀ
ing head onto service latch. Return key switch to OFF
when pressure has been relieved. Remove key from the
ignition switch.
To relieve hydraulic pressure in traction circuit, move
traction lever to both forward and reverse directions.
Hydraulic System
Page 4 – 6
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Hydraulic Schematic
LIFT
CYLINDER
ORF1
CYL
SVR
R2
SVL
R1
SVQ
G1
PV
CONTROL
MANIFOLD
P
CHG
G2
T
FRONT
WHEEL
’B’ PORT
FORWARD
(BOTTOM)
M1
’P’ PORT
’P’ PORT
M3
’P’ PORT
M2
P1
P2
’A’ PORT
(TOP)
CIR
PSI
GPM
COMPONENT
P1
.98
.37
--
10.5
2900
P2
4.1
--
--
40
1000
40
--
PV
R1
R2
M1
M2
M3
ORF1
--
--
--
--
23.8
12.1
12.1
.050
--
--
--
--
--
ProCore 648
Hydraulic Schematic
--
--
All solenoids are shown as
de--energized
Rev. C
ProCore 648
Page 4 -- 7
Hydraulic System
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Hydraulic Flow Diagrams
LIFT
CYLINDER
ORF1
CYL
SVR
SVL
(NOT ENERGIZED)
(NOT ENERGIZED)
R1
SVQ
(NOT ENERGIZED)
G1
R2
PV
CONTROL
MANIFOLD
P
CHG
G2
T
FRONT
WHEEL
’B’ PORT
FORWARD
(BOTTOM)
M1
’P’ PORT
’P’ PORT
M3
’P’ PORT
M2
P1
P2
’A’ PORT
(TOP)
Traction Circuit (Forward Shown)
Working Pressure
Low Pressure (Charge)
Return or Suction
Flow
Rev. C
Hydraulic System
Page 4 -- 8
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Traction Circuit
The traction (piston) pump (P1) is driven by the engine
through the pulleys and pump drive belt. The traction cir-
cuit of the hydraulic system acts essentially as a closed
loop. Taking its suction directly from the return side of the
wheel motors of the traction circuit, the traction (piston)
pump supplies oil flow to the wheel motors through the
supply side of the traction circuit.
Reverse Direction
The traction circuit operates essentially the same in re-
verse as it does in the forward direction. However, the
flow through the circuit is reversed. When the traction le-
ver is moved to the reverse position, the linkage from the
lever positions the swash plate in the traction motor so
oil flows out the upper port of the pump. Oil flow from the
pump goes to the wheel motors (rear motors first and
then front motor) and turns them in the reverse direction.
Maximum reverse traction pressure is limited by a 2900
PSI (200 Bar) relief valve located in the top of the pump
assembly.
The gear pump (P2) is attached to the traction pump and
is directly coupled to it. The gear pump provides charge
oil to replace small amounts of traction pump internal oil
leakage. Hydraulic charge oil is supplied to the traction
circuit from the gear pump, through the lift control man-
ifold (manifold port P, proportional valve PV and man-
ifold port CHG) and past the charge circuit check valve
in the return side of the traction circuit. Proportional
valve PV ensures that sufficient gear pump flow is al-
ways available for the charge oil needs of the traction cir-
cuit. Gear pump flow in excess of charge circuit needs
is available to raise/lower the coring head. After charge
and raise/lower requirements are met, excess P2 flow
is directed to the hydraulic reservoir through the hydrau-
lic oil filter.
Oil flowing from the wheel motors returns to the bottom
port of the traction pump and is continuously pumped
out the top port as long as the traction lever is held in the
reverse direction.
Forward Direction
With the engine running and the traction lever in the neu-
tral position, the traction pump supplies no flow to the
wheel motors. When the traction lever is moved to the
forward position, the linkage from the lever positions the
swash plate in the traction pump so oil flows out the low-
er port of the pump. Oil flow from the pump is directed
to the wheel motors (front motor first and then rear mo-
tors) and turns them in the forward direction. Maximum
forward traction pressure is limited by a 2900 PSI (200
Bar) relief valve located in the bottom of the pump as-
sembly.
Oil flowing from the rear wheel motors returns to the top
port of the traction pump and is continuously pumped
out the bottom port as long as the traction lever is held
in the forward direction.
ProCore 648
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Hydraulic System
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LIFT
ORF1
CYLINDER
(EXTENDING)
CYL
SVL
(NOT
ENERGIZED)
SVR
(ENERGIZED)
R1
CORING HEAD
RAISE
G1
SVQ
(ENERGIZED)
R2
CONTROL
MANIFOLD
PV
CHG G2
P
T
TO
TRACTION
PUMP
FROM
GEAR
PUMP
LIFT
ORF1
CYLINDER
(RETRACTING)
CYL
SVL
(ENERGIZED)
SVR
(NOT ENERGIZED)
R1
CORING HEAD
LOWER
G1
SVQ
(ENERGIZED)
R2
CONTROL
MANIFOLD
PV
CHG G2
P
T
Coring Head Raise/Lower Circuits
Working Pressure
TO
TRACTION
PUMP
FROM
GEAR
PUMP
Low Pressure (Charge)
Return or Suction
Flow
Hydraulic System
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Coring Head Raise/Lower Circuits
The gear pump (P2) is attached to the traction pump
(P1) and is directly coupled to it. The gear pump supplies
hydraulic flow for maintaining charge pressure of 40 PSI
(2.8 Bar) to the low pressure side of the traction circuit
and also for raising the aerator coring head. The gear
pump takes its suction from the hydraulic reservoir.
When the coring head reaches the aerating position, so-
lenoid valves SVQ and SVL in the hydraulic manifold are
de–energized. The valve shift of SVQ removes the by-
pass to orifice (ORF1). The valve shift of SVL prevents
oil flow from the lift cylinder. Without flow from the lift cyl-
inder, the cylinder and coring head are held in place.
Maximum lift/lower circuit pressure is limited to 1000
PSI (69 Bar) by relief valve R1 in the lift control manifold.
True CoreTM Ground Following System
When aerating with the ground follow switch in the ON
position, the True CoreTM Ground Following System hy-
draulically adjusts the coring head position to ensure
aerating depth consistency over undulating surfaces.
The head high limit and head low limit switches on the
depth actuator assembly are opened or closed depend-
ing on movement of the turf guards over ground irregu-
larities. These switches are used as inputs for the
aerator control module to energize or de–energize sole-
noid valves SVR and SVL in the hydraulic manifold. As
these solenoid valves are energized or de–energized,
the coring head is raised or lowered as described above.
Flow from gear pump (P2) goes to the lift control man-
ifold (port P) and is directed to pressure compensating
valve (PV). Valve PV ensures that sufficient hydraulic
flow is always available to the traction circuit for charge
oil. When not raising the coring head, gear pump flow in
excess of charge circuit needs is directed to the hydrau-
lic oil filter and then returns to the hydraulic reservoir.
Raise Coring Head
When the coring head is to be raised (e.g. traction lever
is released from forward or raise/lower switch is pressed
to raise), solenoid valves SVR and SVQ in the hydraulic
manifold are energized. The valve shift of SVR prevents
gear pump flow return to the reservoir. The valve shift of
SVQ allows oil flow to bypass the control manifold orifice
(ORF1) for more immediate cylinder movement. Oil
flows through the load holding check valve in solenoid
valve SVL to direct gear pump flow out of control man-
ifold port CYL to the lift cylinder. Hydraulic pressure
against the lift cylinder rod extends the cylinder and
raises the coring head.
The control manifold orifice (ORF1) restricts oil flow to
and from the lift cylinder to allow more accurate ground
following. Solenoid valve SVQ is always de–energized
when coring head is in the lowered, aerating position.
If the ground follow switch is turned to the OFF position,
the coring head lowers to the manual coring head stops
and the ground following operation is not functional. So-
lenoid valve SVL is always energized while aerating
when the ground follow switch is in the OFF position.
When the raise input ends (e.g. coring head is fully
raised or raise/lower switch is released), solenoid
valves SVR and SVQ in the hydraulic manifold are de–
energized. The valve shift of SVR allows flow return to
the reservoir. The valve shift of SVQ removes the by-
pass to orifice (ORF1). The load holding check valve in
solenoid valve SVL prevents oil flow from the lift cylinder.
Without flow to or from the lift cylinder, the cylinder and
coring head positions are held in place.
Lower Coring Head
When the coring head is to be lowered (e.g. raise/lower
switch is pressed to lower), solenoid valves SVQ and
SVL in the hydraulic manifold are energized. The valve
shift of SVQ allows oil flow to bypass the control man-
ifold orifice (ORF1) for more immediate cylinder move-
ment. The valve shift of SVL allows a path for oil flow
from the lift cylinder. The weight of the coring head and
tension of the weight transfer springs cause the lift cylin-
der to retract and the coring head to lower. Oil flowing
from the retracting lift cylinder returns to the reservoir.
ProCore 648
Page 4 – 11
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Special Tools
Order these special tools from your Toro Distributor.
Hydraulic Pressure Test Kit
Toro Part Number: TOR47009
Use to take various pressure readings for diagnostic
tests. Quick disconnect fittings provided attach directly
to mating fittings on machine test ports without tools. A
high pressure hose is provided for remote readings.
Contains one each: 1000 PSI (70 Bar), 5000 PSI (350
Bar) and 10000 PSI (700 Bar) gauges. Use gauges as
recommended in Testing section of this chapter.
Figure 9
Hydraulic Tester (Pressure and Flow)
Toro Part Number: TOR214678
This tester requires O--ring Face Seal (ORFS) adapter
fittings for use on this machine (see Hydraulic Test Fit-
ting Kit -- TOR4079 in this section).
1. INLET HOSE: Hose connected from the system cir-
cuit to the inlet side of the hydraulic tester.
2. LOAD VALVE: A simulated working load is created
in the circuit by turning the valve to restrict flow.
3. LOW PRESSUREGAUGE:Low range gauge to pro-
vide accurate reading at low pressure: 0 to 1000 PSI.
Figure 10
A protector valve cuts out when pressure is about to
exceed the normal range for the gauge. The cutout
pressure is adjustable.
4. HIGH PRESSURE GAUGE: High range gauge
which accommodates pressures beyond the capacity of
the low pressure gauge: 0 to 5,000 PSI.
5. FLOW METER: This meter measures actual oil flow
in the operating circuit with a gauge rated at 15 GPM.
6. OUTLET HOSE: A hose from the outlet side of the
hydraulic tester connects to the hydraulic system circuit.
Hydraulic System
Page 4 -- 12 Rev. C
ProCore 648
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Hydraulic Test Fitting Kit
Part Number: TOR4079
TORO TEST FITTING KIT (NO. TOR4079)
This kit includes a variety of O–ring Face Seal fittings to
enable connection of test gauges to the ProCore 648 hy-
draulic system.
The kit includes: tee’s, unions, reducers, plugs, caps,
and male test fittings.
Figure 11
Wheel Hub Puller
Part Number: TOR4097
The wheel hub puller allows safe removal of the wheel
hub from the shaft of wheel motors.
Figure 12
ProCore 648
Page 4 – 13
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Troubleshooting
The cause of an improperly functioning hydraulic sys-
tem is best diagnosed with the use of proper testing
equipment and a thorough understanding of the com-
plete hydraulic system.
Continued use of an improperly functioning hydraulic
system could lead to extensive hydraulic component
damage.
The charts that follow contain information to assist in
troubleshooting. There may possibly be more than one
cause for a machine malfunction.
A hydraulic system with an excessive increase in heat
or noise has a potential for failure. Should either of these
conditions be noticed, immediately stop the machine,
turn off the engine, locate the cause of the trouble, and
correct it before allowing the machine to be used again.
Refer to the Testing section of this Chapter for precau-
tions and specific test procedures.
Problem
Possible Cause
Fitting(s), hose(s), or tube(s) are loose or damaged.
Hydraulic oil leaks
O–ring(s) or seal(s) are missing or damaged.
Oil level in reservoir is low.
Foaming hydraulic fluid
Hydraulic system has wrong kind of oil.
Pump suction line(s) has an air leak.
Hydraulic system operates hot
Traction system pressure is high due to excessive load.
Oil level in reservoir is low.
Traction pump by–pass valve is open or defective.
Excessive dirt and debris on hydraulic components.
Oil is contaminated or too light.
Charge pressure is low.
Air trapped in traction circuit.
Wheel motor(s) are worn or damaged.
Traction pump is worn or damaged.
Neutral is difficult to find or unit oper-
ates in one direction only
External control linkage is misadjusted, disconnected, binding or
damaged.
Excess air in the traction lines.
Traction pump is worn or damaged.
Hydraulic oil is very cold.
Traction response is sluggish
Traction pump by–pass valve is open or worn.
Engine speed is too low.
Pump drive belt is loose or worn.
Charge pressure is low.
Traction pump or wheel motor(s) are worn or damaged.
Hydraulic System
Page 4 – 14
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Problem
Possible Cause
No traction in either direction
Parking brake is engaged.
Oil level in reservoir is low.
Traction pump by–pass valve is open.
Pump drive belt is loose, worn or broken.
Traction cable broken or damaged.
Charge pressure is low.
Hydraulic pump pulley not secure to pump shaft.
Traction pump or wheel motor(s) are worn or damaged.
Parking brake is engaged (rear wheel motors).
Wheel motor will not turn
Key on wheel motor shaft is sheared or missing.
Internal parts in wheel motor are damaged.
Wheel motor will not hold load in
neutral
Make up fluid from charge pump is not available.
Wheel motor(s) is/are worn or damaged.
System reset switch needs to be pressed.
Coring head will not lift or lifts slowly
Engine speed is too low.
Reservoir oil level is low.
Pump pulley drive belt is loose or worn.
Lift cylinder is binding.
Coring head is binding.
Lift control manifold relief valve (R1) is stuck open.
Lift control manifold orifice (ORF1) is damaged or plugged.
Lift control manifold SVQ cartridge valve solenoid is not being
energized.
Gear pump (P2) is worn or damaged.
Coring head raises, but will not stay
up
Lift control manifold SVL cartridge stuck open.
Lift control manifold SVL cartridge valve leaks.
ProCore 648
Page 4 – 15
Hydraulic System
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Hydraulic System
Page 4 – 16
ProCore 648
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Testing
The most effective method for isolating problems in the
hydraulic system is by using hydraulic test equipment
such as pressure gauges and flow meters in the circuits
during various operational checks (see Special Tools
section in this Chapter).
1. Thoroughly clean the machine before disconnecting
or disassembling any hydraulic components. Always
keep in mind the need for cleanliness when working on
hydraulic equipment. Hydraulic system contamination
will cause excessive wear of hydraulic components.
2. Put caps or plugs on any hydraulic lines left open or
exposed during testing or removal of components.
CAUTION
3. The engine must be in good operating condition. Use
a tachometer when making a hydraulic test. Engine
speed will affect the accuracy of hydraulic test results.
Failure to use gauges with recommended pres-
sure (PSI/Bar) rating as listed in test procedures
could result in damage to gauge and possible
personal injury from leaking hot oil.
4. Because the hydraulic pump is belt driven, check for
proper pump belt adjustment before performing any hy-
draulic test. Check pump speed with a phototac when
performing hydraulic pump flow tests.
Before Performing Hydraulic Tests
All obvious areas such as oil supply, filter, binding link-
age, loose fasteners, improper adjustments or improper
operation must be checked before assuming that a hy-
draulic component is the source of the problem being
experienced.
5. To prevent damage to tester or components, the inlet
and the outlet hoses must be properly connected, and
not reversed (when using tester with flow and pressure
capabilities).
6. When using hydraulic tester with flow and pressure
capabilities, completely open load valve in hydraulic
tester before starting engine. This will minimize the pos-
sibility of component damage.
Precautions For Hydraulic Testing
WARNING
7. Install fittings finger tight, far enough to insure that
they are not cross–threaded, before tightening with a
wrench.
Before disconnecting or performing any work
on the hydraulic system, all pressure in the
system must be relieved. See Relieving Hydrau-
lic System Pressure in the General Information
section of this chapter.
8. To prevent hose or tester damage, position the tester
hoses so that moving machine parts will not make con-
tact with them.
Keep body and hands away from pin hole leaks
or nozzles that eject hydraulic fluid under high
pressure. Use paper or cardboard, not hands, to
search for leaks. Hydraulic fluid escaping under
pressure can have sufficient force to penetrate
skin and cause serious injury. If fluid is injected
into the skin, it must be surgically removed
within a few hours by a doctor familiar with this
type of injury. Gangrene may result from such
an injury.
9. Check and adjust the oil level in the reservoir after
connecting hydraulic test equipment.
10.Check the control linkage for improper adjustment,
binding or broken parts. Make sure control linkage is
functioning properly before conducting hydraulic tests.
11.All hydraulic tests should be made with the hydraulic
oil at normal operating temperature.
ProCore 648
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Charge Pressure Test (Using Pressure Gauge)
LIFT
CYLINDER
ORF1
CYL
SVR
SVL
R1
SVQ
G1
R2
PV
CONTROL
MANIFOLD
P
CHG
G2
T
PRESSURE
GAUGE
FRONT
WHEEL
’B’ PORT
(BOTTOM)
FORWARD
M1
’P’ PORT
’P’ PORT
M3
’P’ PORT
M2
P1
P2
’A’ PORT
(TOP)
Working Pressure
Low Pressure (Charge)
Return or Suction
Flow Direction
Figure 13
Rev. C
Hydraulic System
Page 4 -- 18
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Procedure for Charge Pressure Test:
C. While machine is moving, monitor the charge
pressure reading on the pressure gauge (do not acti-
vate the lift control while monitoring pressure).
1. Make sure hydraulic oil is at normal operating tem-
perature by operating the machine for approximately 10
minutes.
D. The charge pressure should drop no more than
15% from initial test reading (Step 8 above). A pres-
sure drop of more than 15% indicates a traction cir-
cuit problem (e.g. damaged or leaking proportional
valve (PV), worn or damaged piston pump (P1)).
2. Park machine on a level surface with the coring head
fully raised. Make sure engine is off and the parking
brake is engaged. Secure coring head with service
latch.
11.Shut off engine.
3. Read Precautions For Hydraulic Testing in this sec-
tion.
12.Disconnect pressure gauge from hydraulic control
manifold port G2.
CAUTION
2
Operate all hydraulic controls to relieve system
pressure and avoid injury from pressurized hy-
draulic oil.
1
4. Connect pressure gauge to the hydraulic control
manifold G2 port quick fitting (Fig. 14).
CAUTION
If using pressure gauge with hose, make sure
that hose is free of the left, rear wheel after
installation.
Figure 14
1. Hydraulic manifold
2. G2 port quick fitting
5. Make sure that traction lever is in neutral and the
parking brake is engaged.
6. Start engine and operate engine at full speed (3400
+ 50 RPM).
7. Pressure gauge should read approximately 40 PSI
(2.8 Bar). Record pressure reading.
8. Turn off engine.
9. If specification is not met, inspect proportional valve
PV in control manifold.
10.A dynamic charge pressure test can be performed as
follows:
A. Leave pressure gauge connected to hydraulic
control manifold G2 port.
B. Disengage parking brake. Start engine and oper-
ate at full speed (3400 + 50 RPM). Move the traction
lever fully forward.
ProCore 648
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Coring Head Raise/Lower Relief (R1) Pressure Test (Using Pressure Gauge)
LIFT
CYLINDER
ORF1
CYL
SVR
SVL
(NOT
ENERGIZED)
PRESSURE
GAUGE
(ENERGIZED)
R1
G1
SVQ
(ENERGIZED)
R2
PV
CONTROL
MANIFOLD
P
CHG
G2
T
FRONT
WHEEL
’B’ PORT
(BOTTOM)
FORWARD
M1
’P’ PORT
’P’ PORT
M3
’P’ PORT
M2
P1
P2
’A’ PORT
(TOP)
Working Pressure
Low Pressure (Charge)
Return or Suction
Flow Direction
Figure 15
Rev. C
Hydraulic System
Page 4 -- 20
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Procedure for Coring Head Raise/Lower Relief (R1)
Pressure Test:
C. If measured relief pressure is too low, check for
restriction in gear pump intake line or leakage in lift
cylinder. If pump intake line is not restricted and lift
cylinder is not leaking, increase the relief valve pres-
sure setting. Use an allen wrench and turn adjust-
ment socket clockwise. A 1/8 turn on the socket will
make a measurable change in relief pressure.
1. Make sure hydraulic oil is at normal operating tem-
perature by operating the machine for approximately 10
minutes.
2. Park machine on a level surface with the coring head
fully raised. Make sure engine is off and the parking
brake is engaged.
D. Reinstall cap on relief valve after adjustment.
E. Repeat steps 9 through 11 above until the relief
valve pressure setting is correct.
3. Read Precautions For Hydraulic Testing in this sec-
tion.
F. If the relief valve pressure setting cannot be ad-
justed to specification, the relief valve (R1), gear
pump or lift cylinder should be suspected of wear or
damage.
CAUTION
13.When testing is complete, disconnect pressure
gauge from the hydraulic manifold G1 fitting. Reconnect
proximity switch #1. Install rear hood.
Operate all hydraulic controls to relieve system
pressure and avoid injury from pressurized hy-
draulic oil.
4. Connect pressure gauge to the hydraulic control
manifold G1 port quick fitting (Fig. 14).
1
5. Remove rear hood (see Operator’s Manual).
6. Locate and disconnect proximity switch #1. This
switch is secured to the switch mounting bracket located
on right rear frame plate.
2
7. Make sure that traction lever is in the neutral position
and the parking brake is engaged.
3
8. With proximity switch #1 disconnected, system pres-
sure will increase to relief (R1) pressure shortly after the
engine is started.
Figure 16
1. Hydraulic manifold
2. G1 port quick fitting
3. Relief valve (R1)
9. Start and run engine at full speed (3400 + 50 RPM).
Watch the pressure gauge and note pressure when the
relief valve (R1) opens.
2
10.Shut off engine. Record measured relief valve (R1)
pressure.
11.Pressure gauge should read approximately 1000
PSI (69 Bar).
1
12.If measured relief pressure is incorrect, adjust relief
valve (R1) as follows:
NOTE: Do not remove lift relief valve from the hydraulic
manifold for adjustment.
Figure 17
1. Relief valve cap
2. Adjustment socket
A. Remove the cap from the relief valve (Fig. 17).
B. If measured relief pressure is too high, decrease
relief valve pressure setting by using an allen wrench
to turn adjustment socket counterclockwise. A 1/8
turn on the socket will make a measurable change in
relief pressure.
ProCore 648
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Traction (Piston) Pump (P1) Flow Test (Using Tester With Flow Meter and Pressure
Gauge)
LIFT
CYLINDER
ORF1
CYL
SVR
R2
SVL
R1
G1
SVQ
PV
CONTROL
MANIFOLD
P
CHG
G2
T
FRONT
WHEEL
TESTER
’B’ PORT
(BOTTOM)
FORWARD
M1
’P’ PORT
’P’ PORT
M3
’P’ PORT
M2
P1
P2
’A’ PORT
(TOP)
Working Pressure
Low Pressure (Charge)
Return or Suction
Flow Direction
Figure 18
Procedure for Traction (Piston) Pump (P1) Flow
Test:
3. Read Precautions For Hydraulic Testing in this sec-
tion.
1. Make sure hydraulic oil is at normal operating tem-
perature by operating the machine for approximately 10
minutes.
4. Remove pump control assembly from traction pump
(see Hydraulic (Traction/Charge) Pump Removal in the
Service and Repairs section of this chapter). Position
pump control assembly away from pump.
2. Park machine on a level surface with the coring head
fully raised. Make sure engine is off and parking brake
is disengaged. Secure coring head with service latch.
5. Make sure that hydraulic pump drive belt is adjusted
properly (see Operator’s Manual).
Rev. C
Hydraulic System
Page 4 -- 22
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6. Lift or jack machine so all wheels are off the floor to
allow flow through the traction circuit. Support machine
with jackstands or blocking.
14.While holding trunnion shaft fully counter–clockwise,
close flow control valve on tester until pressure gauge
reads 1000 PSI. As flow control valve is being closed,
engine speed will drop to approximately 3200 RPM.
Verify that pump speed is approximately 2500 RPM with
a phototac. Observe flow gauge.
7. Attach a heavy chain to the rear of the machine frame
and something immovable in the shop to prevent the
machine from moving during testing.
TESTER READING: A pump in good condition
should have a flow of approximately 9.5 GPM
CAUTION
15.Open flow control valve on tester, return trunnion
shaft to the neutral position and turn off engine. Record
results of hydraulic flow test.
Operate all hydraulic controls to relieve system
pressure and avoid injury from pressurized hy-
draulic oil.
16.If flow is less than 7.6 GPM or a pressure of 1000 PSI
cannot be obtained, consider that a pump problem ex-
ists.
8. Clean hose fitting and disconnect hydraulic hose
from the lower 45 fitting on the rear side of the traction
o
NOTE: Forward traction circuit relief pressure can be
determined with the same tester connections as this
test. See TEST NO. 4: Traction Circuit Relief Pressure.
pump (Fig. 19).
NOTE: An alternate testing location would be at the hy-
draulic hose connection to the P1 port of the front wheel
motor.
17.When testing is complete, disconnect tester from
o
lower 45 fitting and hydraulic hose. Reconnect hose to
fitting. Secure pump control assembly to traction pump
(see Hydraulic (Traction/Charge) Pump Installation in
the Service and Repairs section of this chapter).
IMPORTANT: Make sure oil flow indicator arrow on
the flow meter is showing that the oil will flow from
the traction pump, through the tester and into the
disconnected hose.
2
9. Install hydraulic tester with flow meter and pressure
gauges in series with the traction pump and the discon-
nected hose. Make sure flow control valve on the
tester is fully open.
10.Check and adjust the oil level in the reservoir after
connecting hydraulic tester.
11.One person should operate the machine while
another person reads the tester.
1
12.Start and run engine at full speed (3400 + 50 RPM).
Figure 19
CAUTION
o
1. Lower 45 fitting
2. Hydraulic hose
Use extreme caution when conducting test. The
wheels of the machine will be trying to move the
machine forward.
IMPORTANT: Do not rotate the traction pump trun-
nion shaft clockwise (reverse) during testing.
13.Using a wrench, slowly rotate traction pump trunnion
shaft counter–clockwise to the fully forward position.
Rev. B
ProCore 648
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Traction Circuit Relief Pressure Test (Using Tester With Flow Meter and Pressure
Gauge)
LIFT
CYLINDER
ORF1
CYL
SVR
R2
SVL
R1
G1
SVQ
PV
CONTROL
MANIFOLD
P
CHG
G2
T
PRESSURE
GAUGE
FRONT
WHEEL
’B’ PORT
(BOTTOM)
FORWARD
M1
’P’ PORT
’P’ PORT
’P’ PORT
M2
M3
P1
P2
’A’ PORT
(TOP)
Working Pressure
Low Pressure (Charge)
Return or Suction
NOTE: FORWARD TRACTION CIRCUIT
RELIEF PRESSURE TEST IS SHOWN
Flow Direction
Figure 20
Rev. C
Hydraulic System
Page 4 -- 24
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Procedure for Traction Circuit Relief Pressure Test:
10.One person should operate the machine while
another person reads the gauge.
1. Make sure hydraulic oil is at normal operating tem-
perature by operating the machine for approximately 10
minutes. Make sure that traction lever is adjusted to the
neutral position (see Operator’s Manual).
11.Make sure that parking brake is engaged. Start and
run engine at full speed (3400 + 50 RPM).
2. Park machine on a level surface with the coring head
fully raised. Make sure engine is off and parking brake
is engaged. Secure coring head with service latch.
CAUTION
Use extreme caution when conducting test. The
front wheel of the machine will be trying to move
the machine.
3. Read Precautions For Hydraulic Testing in this sec-
tion.
4. Set the aerator spacing lever to the transport posi-
tion.
12.Slowly move traction lever fully in direction of relief
valve to be tested (forward or reverse).
5. Make sure that hydraulic pump drive belt is adjusted
properly (see Operator’s Manual).
IMPORTANT: DO NOT hold system at relief for more
than 4 seconds.
6. Lift or jack front of machine so front wheel is off the
floor. Support front of machine with jackstands or block-
ing.
13.Watch the pressure gauge and record pressure
when the traction circuit relief valve opens.
TESTER READING: pressure approximately 2900
PSI in both forward and reverse direction.
CAUTION
14.Release traction lever and turn off engine. Record re-
sults of hydraulic pressure test.
Operate all hydraulic controls to relieve system
pressure and avoid injury from pressurized hy-
draulic oil.
15.If traction pressure is too low, inspect relief valves in
piston (traction) pump (see the HYDRO–GEAR
BDP–10A/16A/21L HYDROSTATIC PUMPS SERVICE
AND REPAIR MANUAL at the end of this chapter).
Clean or replace relief valves as necessary as they are
not adjustable. If relief valves are in good condition, pis-
ton (traction) pump should be suspected of wear and in-
efficiency.
7. Clean hose fitting and disconnect appropriate hy-
draulic hose from fitting on the rear side of the traction
pump (Fig. 21):
A. For forward direction relief pressure test, discon-
o
nect hose from lower 45 fitting. NOTE: forward relief
NOTE: Forward and reverse relief valves are identical.
Relief valves can be switched in piston (traction) pump
to help in identifying a faulty relief valve.
pressure can also be measured with hydraulic tester
installed as described in TEST NO. 3: Traction (Pis-
ton) Pump Flow. Make sure flow control valve on the
tester is fully open.
16.Disconnect Tee–fitting with pressure gauge from
pump fitting and hydraulic hose. Reconnect hose to
pump fitting.
NOTE: An alternate testing location for forward di-
rection relief would be at the hydraulic hose connec-
tion to the front wheel motor P1 port.
2
B. For reverse direction relief pressure test, discon-
nect hose from upper 90 fitting.
o
NOTE: An alternate testing location for reverse di-
rection relief would be at the diagnostic port on the
hydraulic tube between the rear wheel motors.
8. Install Tee–fitting with pressure gauge between the
traction pump and the disconnected hose.
1
9. Check and adjust the oil level in the reservoir after
connecting pressure gauge.
Figure 21
o
o
1. Lower 45 fitting
2. Upper 90 fitting
ProCore 648
Page 4 – 25
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Gear Pump (P2) Flow Test (Using Tester With Flow Meter and Pressure Gauge)
LIFT
CYLINDER
ORF1
CYL
SVR
R2
SVL
R1
SVQ
G1
PV
CONTROL
MANIFOLD
P
CHG
G2
T
TESTER
FRONT
WHEEL
’B’ PORT
(BOTTOM)
FORWARD
M1
’P’ PORT
’P’ PORT
M3
’P’ PORT
M2
P1
P2
’A’ PORT
(TOP)
Working Pressure
Low Pressure (Charge)
Return or Suction
Flow Direction
Figure 22
Rev. C
Hydraulic System
Page 4 -- 26
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Procedure for Gear Pump (P2) Flow Test:
7. Start and operate engine at full speed (3400 + 50
RPM).
1. Make sure hydraulic oil is at normal operating tem-
perature by operating the machine for approximately 10
minutes.
8. Watch flow and pressure gauges carefully while
slowly closing the flow control valve until pressure
gauge reads 500 PSI.
2. Park machine on a level surface with the coring head
fully raised. Make sure engine is off and the parking
brake is engaged. Secure coring head with service
latch.
9. Flow gauge reading should be approximately 4
GPM.
10.Open flow control valve on tester and turn off engine.
Record results of hydraulic pressure test.
3. Read Precautions For Hydraulic Testing in this sec-
tion.
11.If specification is not met, repair or replace gear
pump.
CAUTION
12.Disconnect tester from the pump and control man-
ifold. Reconnect hydraulic tube to the pump and man-
ifold.
Operate all hydraulic controls to relieve system
pressure and avoid injury from pressurized hy-
draulic oil.
4. Remove hydraulic tube that connects the gear pump
(P2) outlet to port P of hydraulic manifold (Fig. 23).
1
IMPORTANT: Make sure oil flow indicator arrow on
the flow meter is showing that oil will flow from the
gear pump, through the tester and into hydraulic
manifold port P.
2
5. Install elbows to fittings on pump and manifold to al-
low connection of hydraulic tester with flow meter and
pressure gauges to fittings. Install hydraulic tester in
place of the removed hydraulic tube between the gear
pump (P2) outlet and port P in the hydraulic manifold.
Make sure flow control valve on the tester is fully
open.
Figure 23
1. Gear pump outlet
2. Manifold port P
6. Make sure that traction lever is in neutral and the
parking brake is engaged.
ProCore 648
Page 4 – 27
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Wheel Motor Efficiency Test (Using Tester With Flow Meter and Pressure Gauge)
LIFT
CYLINDER
ORF1
CYL
SVR
R2
SVL
R1
G1
SVQ
PV
CONTROL
MANIFOLD
P
CHG
G2
T
TEST CONNECTION FOR
REAR WHEEL MOTOR SHOWN
FRONT
WHEEL
’B’ PORT
(BOTTOM)
FORWARD
M1
’P’ PORT
CAP
’P’ PORT
’P’ PORT
M2
M3
P1
P2
CAP
TESTER
’A’ PORT
(TOP)
Working Pressure
Low Pressure (Charge)
Return or Suction
Flow Direction
Figure 24
NOTE: Over a period of time, a wheel motor can wear
internally. A worn motor will be less efficient and eventu-
ally, will allow the wheel motor to stall under heavy load
conditions. Continued operation with a worn, inefficient
motor can generate excessive heat, cause damage to
seals and other components in thehydraulic systemand
affect overall machine performance.
Rev. C
Hydraulic System
Page 4 -- 28
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Procedure for Wheel Motor Efficiency Test:
IMPORTANT: Make sure oil flow indicator arrow on
the flow gauge is showing that the oil will flow from
the wheel motor, through the tester and into the
traction pump fitting.
1. Make sure hydraulic oil is at normal operating temꢀ
perature by operating the machine for approximately 10
minutes. Make sure the hydraulic reservoir is full.
9. Install hydraulic tester with flow meter and pressure
gauges between the disconnected hose and traction
pump. Make sure flow control valve on the tester is fully
open.
2. Make sure that traction lever is adjusted to the neuꢀ
tral position (see Operator’s Manual).
3. Park machine on a level surface with the coring head
fully raised. Make sure engine is off and the parking
brake is engaged. Secure coring head with service
latch.
10.Start engine and move throttle to full speed (3400 +
50 RPM).
4. Read Precautions For Hydraulic Testing in this secꢀ
tion.
CAUTION
Use extreme caution when performing test. The
tire(s) on the ground will be trying to move the
machine forward.
CAUTION
Operate all hydraulic controls to relieve system
pressure and avoid injury from pressurized hyꢀ
draulic oil.
11.Slowly push traction lever in forward direction until
1000 PSI is displayed on the pressure gauge. Make sure
that wheel motor being tested does not rotate.
12.Wheel motor internal leakage will be shown on flow
meter in GPM. Flow should be less than 1.5 GPM for
the tested wheel motor.
5. Attach a heavy chain between the rear of the maꢀ
chine frame and an immovable object to prevent the maꢀ
chine from moving during testing.
13.Release traction lever and turn off engine. Record reꢀ
sults of hydraulic flow test.
6. If front wheel motor requires testing:
A. Both rear wheel motors should have hydraulic
lines connected. Block up both rear wheels off the
ground. Release parking brake so rear wheels can
turn.
14.If specifications are not met, the tested wheel motor
needs to be repaired or replaced as necessary.
15.Reconnect hydraulic lines to wheel motor.
B. Position front wheel on the ground. Immobilize
front wheel to prevent it from turning.
16.If additional wheel motor(s) require testing, complete
steps 6 to 14 for the remaining wheel motor(s).
7. If a rear wheel motor requires testing:
17.Disconnect tester from machine. Reconnect hose to
pump connection.
A. Disconnect both hydraulic lines from rear wheel
motor that is not being tested. Cap disconnected hyꢀ
draulic lines and plug wheel motor ports to prevent
contamination.
1
B. Front wheel motor should have hydraulic lines
connected. Block up front wheel off the ground.
C. Make sure parking brake is engaged to prevent
rear wheel rotation.
8. Clean hose fitting and disconnect hose from upper
90 fitting on traction pump (Fig. 25).
o
2
Figure 25
o
o
1. Upper 90 fitting
2. Lower 45 fitting
ProCore 648
Page 4 – 29
Hydraulic System
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Service and Repairs
General Precautions for Removing and Installing Hydraulic System Components
Before Repair or Replacement of Components
After Repair or Replacement of Components
1. Before removing any parts from the hydraulic sysꢀ
tem, park machine on a level surface, fully raise coring
head, engage parking brake, stop engine and remove
key from the ignition switch. Secure coring head with
service latch.
1. Check oil level in the hydraulic reservoir and add corꢀ
rect oil if necessary. Drain and refill hydraulic system
reservoir and change oil filter if component failure was
severe or system is contaminated (see Flush Hydraulic
System).
2. Clean machine before disconnecting, removing or
disassembling any hydraulic components. Make sure
hydraulic components, hoses connections and fittings
are cleaned thoroughly. Always keep in mind the need
for cleanliness when working on hydraulic equipment.
2. Lubricate O–rings and seals with clean hydraulic oil
before installing hydraulic components.
3. Make sure caps or plugs are removed from the hyꢀ
draulic tubes, hydraulic fittings and components before
reconnecting.
4. Use proper tightening methods when installing hyꢀ
draulic hoses and fittings (see Hydraulic Fitting Installaꢀ
tion in the General Information section of this chapter).
CAUTION
Operate all hydraulic controls to relieve system
pressure and avoid injury from pressurized hyꢀ
draulic oil. See Relieving Hydraulic System Presꢀ
sure in the General Information section of this
chapter.
5. After repairs, check control linkages and cables for
proper adjustment, binding and/or broken parts.
6. After disconnecting or replacing any hydraulic comꢀ
ponents, operate machine functions slowly until air is
out of system (see Hydraulic System Start Up in this secꢀ
tion).
3. Put caps or plugs on any hydraulic lines, hydraulic fitꢀ
tings or hydraulic components left open or exposed to
prevent hydraulic system contamination.
7. Check for hydraulic oil leaks. Shut off engine and corꢀ
rect leaks if necessary. Check oil level in hydraulic reserꢀ
voir and add correct oil if necessary.
4. Put labels on disconnected hydraulic lines and
hoses for proper installation after repairs are completed.
5. Note the position of hydraulic fittings (especially elꢀ
bow fittings) on hydraulic components before removal.
Mark parts if necessary to make sure they will be aligned
properly when reinstalling hydraulic hoses and tubes.
Check Hydraulic Lines and Hoses
Check hydraulic lines and hoses daily for leaks, kinked
lines, loose mounting supports, wear, loose fittings,
weather deterioration and/or chemical deterioration.
Make all necessary repairs before operating machine.
WARNING
Keep body and hands away from pin hole leaks
or nozzles that eject hydraulic fluid under high
pressure. Use paper or cardboard, not hands, to
search for leaks. Hydraulic fluid escaping under
pressure can have sufficient force to penetrate
the skin and cause serious injury. If fluid is in-
jected into the skin, it must be surgically re-
moved within a few hours by a doctor familiar
with this type of injury. Gangrene may result from
such an injury.
Hydraulic System
Page 4 – 30
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Flush Hydraulic System
IMPORTANT: Flush the hydraulic system any time
there is a severe component failure or the system is
contaminated (oil appears milky or black or conꢀ
tains metal particles).
9. Reattach both spark plug wires.
10.Start engine and let it idle at low speed for a minimum
of two (2) minutes.
11.Increase engine speed to high idle for minimum of
one (1) minute under no load.
IMPORTANT: Flush hydraulic system when chang-
Ing from petroleum base hydraulic fluid, such as
Mobil 424, to biodegradable fluid, such as Mobil
EAL Envirosyn H. Operate machine under normal
operating conditions for at least four (4) hours beꢀ
fore draining.
12.Lower and raise coring head several times.
13.Shut off engine and check for hydraulic oil leaks.
Check oil level in hydraulic reservoir and add correct oil
if necessary.
1. Park machine on a level surface, fully raise coring
head, engage parking brake, stop engine and remove
key from the ignition switch. Secure coring head with
service latch.
14.Install pump belt cover to machine (see Operator’s
Manual).
15.Operate the machine for two (2) hours under normal
operating conditions.
2. Remove pump belt cover from machine (see Opera-
tor’s Manual).
16.Check condition of hydraulic oil. If the fluid shows any
signs of contamination, or if you are changing to biodeꢀ
gradable fluid, repeat steps 1 through 13 again.
NOTE: The hydraulic reservoir will drain when the hyꢀ
draulic oil filter is removed from the hydraulic manifold.
3. Clean area around filter mounting area (Fig. 26). Reꢀ
move filter from hydraulic manifold and drain reservoir
into a suitable container. Drain hydraulic system. Drain
all hoses, tubes and components while the system is
warm. Discard filter.
17.Resume normal operation and follow recommended
maintenance intervals.
4. Inspect and clean reservoir (see Hydraulic Reservoir
in this section).
5. Make sure filter mounting surface is clean. Apply hyꢀ
draulic oil to gasket on the new filter. Screw filter on until
gasket contacts mounting surface of manifold, then
tighten filter half a turn.
1
NOTE: Use biodegradable fluid, such as Mobil EAL Enꢀ
virosyn H, for this step if you are changing to this type of
fluid. Use only hydraulic fluids specified in Operator’s
Manual. Other fluids could cause system damage.
2
6. Fill hydraulic reservoir.
Figure 26
1. Hydraulic filter
2. Hydraulic manifold
7. Disconnect and ground both spark plug wires to preꢀ
vent engine from starting.
8. Turn ignition key switch to start position; engage
starter for ten (10) seconds to prime hydraulic pumps.
Repeat this step again.
ProCore 648
Page 4 – 31
Hydraulic System
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Hydraulic System Start--up
NOTE: When initially starting the hydraulic system with
new or rebuilt components such as the hydraulic pump,
wheel motors or lift cylinder, it is important that this start--
up procedure be used. This procedure reduces the
chance of damaging the hydraulic system or its compo-
nents from not purging the system of air.
C. Attach a heavy chain between the rear of the ma-
chine frame and something immovable in the shop to
prevent the machine from moving during the bleed-
ing process.
IMPORTANT: Make sure oil flow indicator arrow
on the flow gauge is showing that oil will flow
from the test port of traction line and through the
tester.
1. After the hydraulic system components have been
properly installed and if the hydraulic pump was rebuilt
or replaced, make sure traction pump housing is at least
half full of clean hydraulic oil (see Operator’s Manual for
oil specifications).
D. Connect inletend ofhydraulic tester with flow me-
ter and pressure gauges to test port in upper traction
line (Fig. 27). Place outlet end of tester in a drain con-
tainer. Make sure that flow control valve on the tester
is fully closed.
2. Make sure allhydraulic connections andlines arese-
cured tightly.
3. Make sure hydraulic reservoir is full. Add correct oil
if necessary (see Operator’s Manual). Drain, flush and
refill hydraulic system reservoir and change oil filter if
component failure was severe or if system is contami-
nated.
E. Check hydraulic reservoir level and fill if neces-
sary.
F. Start engine and move traction lever to the for-
ward direction to allow the wheels to rotate slowly.
NOTE: Bleeding the traction circuit might require
approximately five (5) minutes of running.
4. After repairs, check control linkage for proper adjust-
ment, binding or broken parts. Correct any problems be-
fore proceeding.
IMPORTANT: When bleeding the traction circuit,
tester valve should be barely open which will al-
low a slow stream of oil from tester outlet.
5. Disconnect and ground both engine spark plug wires
to prevent engine from starting.
G. While traction lever is held in the forward direction
(wheels turning), have second person slowly open
valve on tester very slightly to allow air out of traction
circuit. Air in the traction circuit will be indicated by
foamy oil coming from the outlet end of the tester.
6. Make sure traction lever is in neutral. Turn ignition
key switch to start; engage starter for ten (10) seconds
to prime hydraulic pump. Repeat this step again.
7. Reattach both spark plug wires.
8. Apply parking brake and make sure traction lever is
in neutral. Start engine and run at low idle. The charge
pump should pick up oil and fill the hydraulic system.
H. While bleeding the traction circuit, if more than .5
gallon (1.9 liters) of oil is removed, close tester valve
and release traction lever. Check hydraulic oil reser-
voir level and fill if necessary. Continue with bleeding
procedure.
9. If traction circuit was repaired (e.g. hydrostat or
wheel motor was replaced), bleed the traction circuit to
evacuate air from the circuit:
I. When allevidence offoamy oilhas been evacuat-
ed from the traction circuit, close tester valve, re-
lease traction lever and stop engine.
NOTE: Before bleeding the traction circuit, review the
following procedure (steps A through L) completely.
J. Remove tester from traction circuit test port.
Check hydraulic reservoir level and fill if necessary.
A. Stop engine and relieve pressure in traction cir-
cuit by moving traction lever to both forward and re-
verse direction.
K. If the hydrostat or a wheel motor was replaced or
rebuilt, start engine and operate the traction system
so the wheels rotate slowly for 10 minutes.
B. Jack up machine from floor and support machine
with jack stands or blocking to allow wheels to turn
freely.
L. Lower machine to ground. Remove chain from
rear of machine.
Hydraulic System
Page 4 -- 32 Rev. A
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10.Start engine and operate the traction system at vary-
ing speeds for a 10 minute period.
1
11.Stop the machine. Check hydraulic reservoir level
and fill if necessary. Check hydraulic components for
leaks and tighten any loose connections.
2
Figure 27
1. Test port
2. Hydraulic manifold
ProCore 648
Page 4 -- 33 Rev. A
Hydraulic System
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Hydraulic Pump Drive Belt
4
FRONT
RIGHT
6
7
2
5
8
3
9
10
11
1
Anti–seize
lubricant
12
16
17
13
15
14
Figure 27
1. Flange nut (2 used)
2. Hydraulic (traction/charge) pump
3. Key
7. Spring bracket
8. Idler support bracket
9. Idler pulley
13. Hydraulic pump pulley
14. Pump drive belt
15. L bracket
4. Engine
10. Flange nut
16. Flange head screw
17. Flange head screw (2 used)
5. Engine pulley
6. Flange head screw
11. Tensioning spring
12. Set screw
Hydraulic System
Page 4 – 34
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Drive Belt Removal (Fig. 27)
Drive Belt Installation (Fig. 27)
1. Park machine on a level surface, fully raise coring
head, engage parking brake, stop engine and remove
key from the ignition switch. Secure coring head with
service latch.
1. Install pump drive belt to pulleys.
2. Lift idler pulley and insert pump drive belt under idler.
3. Allow tensioning spring to apply tension to idler
pulley. Tighten flange head screw (item 6) and flange nut
(item 10) to secure belt adjustment.
2. Remove pump belt cover from machine (see Opera-
tor’s Manual).
4. Install coring head primary drive belt to electric clutch
(see Primary Drive Belt Installation in Service and Reꢀ
pairs section of Chapter 7 – Coring Head).
3. Remove coring head primary drive belt from electric
clutch (see Primary Drive Belt Removal in Service and
Repairs section of Chapter 7 – Coring Head).
5. Install pump belt cover to machine (see Operator’s
Manual).
4. Loosen the flange head screw (item 6) and flange nut
(item 10) that secure the drive belt idler pulley (item 11).
Lift idler pulley to allow removal of drive belt from the pulꢀ
leys and the machine.
ProCore 648
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Hydraulic System
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Hydraulic Pump Control Assembly
13
17
18
16
12
11
15
14
21
19
19
22
23
3
20
24
10
28
7
Loctite #242
3
29
30
6
28
9
35
5
8
31
32
3
36
33
34
37
25
26
27
1
19
31
Loctite #242
29
4
3
RIGHT
FRONT
2
Figure 28
1. Hydraulic pump
14. Trunnion clamp
15. Socket head screw (2 used)
16. Pump lever
17. Cap screw
18. Jam nut
19. Traction lever spacer
20. Lock nut
21. Ball joint
22. Jam nut
23. Stroke control cable
24. Traction stud
25. Lock washer
26. Ball bearing
27. Cap screw
28. Cap screw
29. Spherical rod end
30. Thrust washer
31. Flange bushing
32. Damper
33. Neutral lever
34. Plug
35. Washer head screw
36. Cable clamp
37. Spacing control cable
2. Cap screw (2 used)
3. Flange nut
4. Lock nut
5. Flange nut (2 used)
6. Control bracket
7. Washer head screw
8. Lock nut
9. Extension spring
10. Speed selector pivot
11. Retaining ring
12. Swivel
13. Cap screw
Hydraulic System
Page 4 – 36
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Disassembly (Fig. 28)
7
11
10
1. Park machine on a level surface, fully raise coring
head, engage parking brake, stop engine and remove
key from the ignition switch. Secure coring head with
service latch.
10
8
9
6
5
4
2. Remove pump belt cover from machine (see Opera-
tor’s Manual).
3. Remove two (2) lock nuts that secure pump shield to
pump (Fig. 29). Remove shield from pump. Locate and
retrieve two (2) flat washers from tops of studs on pump
control assembly.
1
3
2
CAUTION
Figure 29
The extension spring is under tension and may
cause personal injury during removal. Use cau-
tion when removing spring from neutral lever.
1. Hydraulic pump
7. Trunnion clamp
2. Cap screw (2 used)
3. Control bracket
4. Flange nut (2 used)
5. Flat washer
8. Socket hd screw (2 used)
9. Washer head screw
10. Lock nut
11. Pump shield
6. Pump lever
4. Remove components from pump control assembly
as needed using Figures 28, 29 and 30 as guides.
Assembly (Fig. 28)
2
1. Install removed components to pump control assem-
bly using Figures 28, 29 and 30 as guides.
A. If rod ends were removed from damper, apply
Loctite #242 to threads of damper shaft before instal-
ling rod ends.
1
B. Damper should be secured to third hole from out-
er end of traction lever (Fig. 30).
2. Place two (2) flat washers to tops of studs on pump
control assembly. Position pump shield to pump and se-
cure with two (2) lock nuts.
Figure 30
1. Damper
2. Rod end location
3. Install pump belt cover to machine (see Operator’s
Manual).
4. Check traction drive for neutral and adjust if needed
(see Operator’s Manual).
5. Operate machine and verify hole spacing accuracy.
Adjust if needed (see Operator’s Manual).
ProCore 648
Page 4 – 37
Hydraulic System
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Hydraulic (Traction/Charge) Pump
5
FRONT
RIGHT
4
3
2
1
7
8
6
9
29
19
10
21
30
11
2
25
12
28
22
2
27
24
23
26
19
20
24
13
21
17
Anti–seize
lubricant
18
14
16
15
Figure 31
1. Hydraulic (traction/charge) pump
2. O–ring
11. Flange nut
12. Tensioning spring
13. Set screw
21. O–ring
22. Flange nut (2 used)
o
3. O–ring
23. 45 hydraulic fitting
o
4. 90 hydraulic fitting
14. Pump pulley
15. Pump drive belt
16. L bracket
24. O–ring
25. O–ring
5. Engine
6. Engine pulley
7. Flange head screw
8. Spring bracket
9. Idler support bracket
10. Idler pulley
26. Hydraulic adapter
27. O–ring
17. Flange head screw
o
18. Flange head screw (2 used)
19. O–ring
28. 90 hydraulic fitting
29. Hydraulic fitting
30. Key
o
20. 90 hydraulic fitting
Removal (Fig. 31)
CAUTION
1. Park machine on a level surface, fully raise coring
head, engage parking brake, stop engine and remove
key from the ignition switch. Secure coring head with
service latch.
Operate all hydraulic controls to relieve system
pressure and avoid injury from pressurized hy-
draulic oil. See Relieving Hydraulic System Pres-
sure in the General Information section of this
chapter.
Hydraulic System
Page 4 – 38
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2. Remove pump belt cover from machine (see Opera-
tor’s Manual).
8. Remove both flange head screws and flange nuts
securing the hydraulic pump to the pump support. Lift
pump assembly from the machine.
3. Loosen the flange head screw (item 7) and flange nut
(item 11) that secure the drive belt idler pulley (item 10).
Lift idler pulley to allow removal of drive belt from the hy-
draulic pump pulley.
NOTE: If hydraulic fittings are to be removed from hy-
draulic pump, note correct orientation of fittings before
loosening the fittings.
IMPORTANT: Before loosening pump pulley, mark
position of the pulley on the hydraulic pump shaft.
Pulley position is critical for proper alignment of the
hydraulic pump drive belt.
9. Remove hydraulic fittings and o–rings from the pump
as required.
10.Discard all removed o–rings.
4. Loosen two (2) set screws that secure pump pulley
to the hydraulic pump shaft. Slide pulley from the pump
shaft. Locate and remove key from pump shaft.
7
11
10
10
8
9
6
5
5. Remove two (2) lock nuts that secure pump shield to
pump (Fig. 32). Remove shield from pump. Locate and
retrieve two (2) flat washers from tops of studs on pump
control assembly.
4
6. Disconnect hydraulic pump controls (Fig. 32 and 33)
from the pump as follows:
1
3
CAUTION
2
The extension spring is under tension and may
cause personal injury during removal. Use cau-
tion when removing spring from neutral lever.
Figure 32
A. Remove extension spring from the neutral lever.
1. Hydraulic pump
2. Cap screw (2 used)
3. Control bracket
4. Flange nut (2 used)
5. Flat washer
7. Trunnion clamp
8. Socket hd screw (2 used)
9. Washer head screw
10. Lock nut
B. Loosen two (2) socket head screws (item 8, Fig.
32) that secure pump lever to pump trunnion shaft.
11. Pump shield
6. Pump lever
C. Remove two (2) cap screws with flange nuts
(items 2 and 4, Fig. 32) and washer head screw (item
9, Fig. 32) that secures control bracket to hydraulic
pump.
3
1
D. Carefully lift pump control assembly and position
away from pump.
7. Disconnect all hydraulic hoses and tubes connected
to the hydraulic fittings on the hydraulic pump assembly.
Allow hoses to drain into a suitable container. Plug or
cap openings of pump and hoses to prevent contamina-
tion.
4
3
2
CAUTION
Figure 33
Support hydraulic pump when removing it from
the pump support to prevent the pump from fal-
ling and causing personal injury.
1. Extension spring
2. Socket head screw
3. Flange nut/cap screw
4. Washer head screw
ProCore 648
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Hydraulic System
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Installation (Fig. 31)
7. Place two (2) flat washers to tops of studs on pump
control assembly. Position pump shield to pump and seꢀ
cure with two (2) lock nuts.
1. Install hydraulic fittings with new o–rings to the hyꢀ
draulic pump. Orientate the fittings as noted during disꢀ
assembly.
8. Lift idler pulley and install drive belt to the pump
pulley. Adjust drive belt tension (see Operator’s Manuꢀ
al).
CAUTION
9. Install pump belt cover to machine (see Operator’s
Manual).
Support hydraulic pump when installing it to the
pump support to prevent the pump from falling
and causing personal injury.
10.Follow Hydraulic System Start–up procedures.
11.Check traction drive for neutral and adjust if needed
(see Operator’s Manual).
2. Position hydraulic pump assembly to the frame
pump support. Secure pump to the pump support with
two (2) flange head screws and flange nuts.
12.Operate machine and check hole spacing. Adjust if
needed (see Operator’s Manual).
3. Make sure the bore of the pump pulley is clean. Apply
anti–seize lubricant to the hydraulic pump shaft. Posiꢀ
tion key to pump shaft and slide pulley onto pump shaft
with the pulley hub toward the pump. Position pulley to
the marked position on the pump shaft.
4. Apply Loctite 242 (or equivalent) to pulley set screws
and secure pulley to pump shaft with two (2) set screws.
5. Remove any caps or plugs that were placed in pump
openings, hydraulic hoses or hydraulic tubes during the
pump removal procedure. Connect hydraulic hoses and
tubes to hydraulic pump.
6. Install hydraulic pump controls (Fig. 32 and 33) to the
pump as follows:
A. Carefully position pump control assembly to
pump. Make sure pump lever with attached trunnion
clamp is placed over pump trunnion shaft.
B. Secure control bracket to hydraulic pump with
two (2) cap screws with flange nuts and washer head
screw.
C. Secure pump lever to pump trunnion shaft with
two (2) socket head screws.
CAUTION
The extension spring is under tension and may
cause personal injury during installation. Use
caution when installing the spring to the neutral
lever.
D. Install extension spring to the neutral lever.
Hydraulic System
Page 4 – 40
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Hydraulic (Traction/Charge) Pump Service
23
1
24
22
21
2
5
3
4
19
18
20
9
6
7
14
8
10
11
13
12
15
16
17
26
31
25
32
28
29
27
30
Figure 34
1. Retaining ring
2. Seal
12. Valve plate
23. Guide slot
13. Forward relief valve
14. By–pass valve
15. Endcap kit
16. Check ball (2 used)
17. Check spring (2 used)
18. Pin (2 used)
19. Reverse relief valve
20. Cylinder block kit
21. Thrust bearing
22. Swash plate
24. Trunnion arm
25. Ring
3. Spacer
4. Pump shaft kit
5. Pump housing
6. Thrust washer
7. Spring block
8. Nut (4 used)
9. Trunnion seal kit
10. Pin (2 used)
11. O–ring
26. Adapter plate
27. Flange head screw (4 used)
28. Coupler
29. O–ring
30. Gear pump (P2) (charge/lift)
31. Washer (2 used)
32. Cap screw (2 used)
NOTE: For repair of the hydraulic (traction/charge)
pump, see the HYDRO–GEAR BDP–10A/16A/21L HY-
DROSTATIC PUMPS SERVICE AND REPAIR MANU-
AL (hydrostat) and the SAUER DANFOSS GROUP 2
GEAR PUMPS AND MOTORS SERVICE MANUAL
(gear pump) at the end of this chapter.
ProCore 648
Page 4 – 41
Hydraulic System
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Wheel Motors
190 to 230 ft–lb
(258 to 312 N–m)
2
3
1
4
5
6
7
8
12
11
20
10
9
13
19
45 to 55 ft–lb
(61 to 75 N–m)
190 to 230 ft–lb
(258 to 312 N–m)
2
18
12
14
7
15
16
17
4
10
6
RIGHT
8
45 to 55 ft–lb
15
16
12
(61 to 75 N–m)
FRONT
9
17
Figure 35
8. Bearing plate
9. Lug nut
1. Rear wheel motor (LH shown)
2. Woodruff key
15. Wheel weight adapter
16. Stud
3. Parking latch support (2 used)
4. Stud (4 used per wheel)
5. Parking latch disc (2 used)
6. Wheel hub
10. Tire and wheel assembly
11. Cap screw (4 used per rear motor)
12. Lock nut (4 used per motor)
13. Frame
17. Thrust washer
18. Front wheel motor
19. Front fork
20. Cap screw (4 used)
7. Lock nut
14. Front wheel weight
Removal (Fig. 35)
CAUTION
1. Park machine on a level surface, fully raise coring
head, engage parking brake, stop engine and remove
key from the ignition switch. Secure coring head with
service latch.
Operate all hydraulic controls to relieve system
pressure and avoid injury from pressurized hy-
draulic oil. See Relieving Hydraulic System Pres-
sure in the General Information section of this
chapter.
Hydraulic System
Page 4 – 42
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2. Remove wheel from machine (see Wheel Removal
in Service and Repairs section of Chapter 6 – Chassis).
3. If rear wheel motor was removed, slide parking latch
link through parking latch bar and secure with hair pin
(Fig. 36).
IMPORTANT: To prevent damage to hydraulic motor,
DO NOT hit wheel hub or motor with a hammer dur-
ing wheel hub removal or installation.
4. Remove caps or plugs that were put on any hydraulic
lines or fittings during disassembly.
3. Loosen nut that secures wheel hub to motor shaft.
Use wheel hub puller (see Special Tools) to free wheel
hub assembly from motor shaft. Remove nut and hub
assembly from motor shaft. Locate and retrieve wood-
ruff key from motor shaft.
5. Install hydraulic lines to hydraulic fittings on wheel
motor. Tighten connections.
6. Make sure that wheel motor shaft and wheel hub ta-
per are thoroughly cleaned.
7. Install woodruff key into motor shaft keyslot. Slide
wheel hub assembly onto motor shaft. Secure wheel
hub to motor shaft with nut. Torque nut from 190 to 230
ft–lbs (258 to 312 N–m).
A. Front wheel hub assembly includes wheel hub,
bearing plate and wheel studs.
B. Rear wheel hub assembly includes wheel hub,
bearing plate, parking latch disc and wheel studs.
A. Front hub assembly includes wheel hub, bearing
plate and wheel studs.
4. Clean wheel motor and hydraulic connections. Label
hydraulic lines for assembly purposes.
B. Rear hub assembly includes wheel hub, bearing
plate, parking latch disc and wheel studs.
5. Disconnect hydraulic lines from hydraulic fittings on
motor to be removed. Allow hydraulic oil to drain from
lines into a suitable container. Put caps or plugs on open
hydraulic lines and fittings to prevent contamination.
8. Install wheel to machine (see Wheel Installation in
Service and Repairs section of Chapter 6 – Chassis).
Tighten lug nuts from 45 to 55 ft–lb (61 to 75 N–m).
6. If rear wheel motor is being removed, pull hair pin
that secures parking latch link to parking latch bar (Fig.
36). Slide link from bar and position link away from park-
ing latch support.
9. Follow Hydraulic System Start–up procedures.
7. Support wheel motor. Remove four (4) cap screws
and lock nuts that secure motor to frame. If rear wheel
motor is being removed, remove parking latch support
and parking latch bar. Pull wheel motor from the ma-
chine.
1
2
NOTE: If hydraulic fittings are to be removed from
wheel motor, note correct orientation of fittings before
loosening the fittings.
8. If required, remove hydraulic fittings and o–rings
from the wheel motor. Discard o–rings.
3
Installation (Fig. 35)
4
1. If removed, install hydraulic fittings with new o–rings
into the wheel motor. Orientate the fittings as noted dur-
ing disassembly.
5
Figure 36
2. Position and support wheel motor to the frame.
1. Parking latch link
2. Hair pin
3. Parking latch bar
4. Parking latch support
5. Wheel motor shaft
A. On front wheel motor, insert four (4) cap screws
through front fork holes and then through motor
flange. Secure motor to front fork with lock nuts.
B. On rear wheel motor, insert four (4) cap screws
through holes in parking latch support (with parking
latch bar installed) and then through motor flange
and frame. Secure motor to frame with lock nuts.
ProCore 648
Page 4 – 43
Hydraulic System
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Wheel Motor Service
1
2
3
4
6
5
6
7
8
9
10
11
12
13
16
14
15
18
19
20
22
17
21
Figure 37
1. Dust seal
9. O–ring
16. Cardan shaft
17. O–ring
18. Gearwheel set
19. End cover
20. Name plate
21. Washer (7 used)
22. Cap screws (7 used)
2. Housing
10. Spring washer
11. Balance plate
12. Disc valve
3. O–ring
4. Shaft seal
5. Axial needle bearing
6. Bearing race
7. Needle bearing
8. Shaft
13. Needle bearing
14. Bearing race
15. Distributor plate
NOTE: The three wheel motors on the ProCore 648 are
similar in construction but are different from each other.
The front wheel motor (24 c.i. per revolution) has a differ-
ent displacement than the rear motors and has a count-
er–clockwise direction for the forward direction. The
right and left rear wheel motors have the same displace-
ment (12 c.i. per revolution) but have different rotation
for the forward direction: the right rear has a clockwise
drive direction for forward and the left rear has a count-
er–clockwise direction. Displacement and primary rota-
tion (forward) direction are identified on the motor name
plate.
NOTE: For repair of the wheel motors, see the SAUER
DANFOSS OMEW HYDRAULIC MOTOR SERVICE
MANUAL at the end of this chapter.
Hydraulic System
Page 4 – 44
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ProCore 648
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Hydraulic System
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Hydraulic Lift Control Manifold
2
3
4
1
RIGHT
FRONT
5
Figure 38
1. Main frame
2. Cap screws (2 used)
3. Hydraulic lift control manifold
4. Hydraulic oil filter
5. Flange nut (2 used)
Hydraulic System
Page 4 – 46
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Removal (Fig. 38)
3. Remove caps or plugs that were put on any hydraulic
lines or fittings during disassembly.
1. Park machine on a level surface, fully raise coring
head, engage parking brake, stop engine and remove
key from the ignition switch. Secure coring head with
service latch.
4. Lightly oil new o–rings for hydraulic fitting and hose
locations.
5. Correctly connect hydraulic fittings and lines to the
manifold. Tighten all hydraulic fittings and connections.
CAUTION
6. Secure hydraulic manifold by tightening two (2) cap
screws and flange nuts.
Operate all hydraulic controls to relieve system
pressure and avoid injury from pressurized hy-
draulic oil. See Relieving Hydraulic System Pres-
sure in the General Information section of this
chapter.
7. Reconnect solenoid valve electrical connectors.
8. Follow Hydraulic System Start–up procedures.
NOTE: The ports on the manifold are marked for easy
identification of components. Example: P is the pump
connection port and R1 is the location for the relief valve
(See Hydraulic Schematic to identify the function of the
hydraulic lines and cartridge valves at each manifold
port location).
11
10
12
13
2. Disconnect solenoid valve electrical connectors.
2
3
NOTE: The hydraulic reservoir will drain when the hy-
draulic oil filter is removed from the hydraulic manifold.
4
3. Clean area around hydraulic filter mounting area.
Remove filter from hydraulic manifold and drain reser-
voir into a suitable container. Discard filter.
9
5
6
1
2
7
4. Clean manifold and hydraulic connections. Discon-
nect hydraulic lines. Label all connections for assembly.
3
8
4
5. Allow hydraulic lines to drain into a suitable contain-
er. Put caps or plugs on disconnected hoses and fittings
to prevent contamination. Discard any removed o–
rings.
Figure 39
1. Hydraulic manifold
2. O–ring
3. Hydraulic fitting
4. O–ring
5. O–ring
6. Hydraulic fitting
7. O–ring
8. Barbed fitting
9. O–ring
10. Hydraulic oil filter
11. Dust cap (2 used)
12. Quick fitting (2 used)
13. O–ring (2 used)
6. Remove two (2) cap screws and flange nuts that se-
cure hydraulic manifold to the frame mounting bracket.
7. Remove hydraulic manifold from the machine.
8. Remove hydraulic fittings from manifold as needed
(Fig. 39).
Installation (Fig. 38)
1. Position hydraulic manifold to the frame mounting
bracket. Install two (2) cap screws and flange nuts but
do not tighten.
2. Make sure all hydraulic connections, ports and fit-
tings are clean.
ProCore 648
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Hydraulic Lift Control Manifold Service
5 ft–lb
(6.8 N–m)
5 ft–lb
9
(6.8 N–m)
5
6
6
25 ft–lb
(33.9 N–m)
20 ft–lb
(27.1 N–m)
7
8
11
4
3
20 ft–lb
(27.1 N–m)
10
120 in–lb
(13.6 N–m)
2
12
1
13
20 ft–lb
(27.1 N–m)
15
14
Figure 40
1. Hydraulic lift control manifold
2. O–ring
3. Quick fitting (2 used)
4. Solenoid valve (SVL port)
5. Nut
6. Solenoid coil
11. Pres. compensating valve (PV port)
12. #4 plug (zero leak)
13. Orifice plug
7. Relief valve (R1 port)
8. Solenoid valve (SVQ port)
9. Nut
14. Check valve
10. Solenoid valve (SVR port)
15. Plug
NOTE: The ports on the manifold are marked for easy
identification of components. Example: P is the pump
connection port and R1 is the location for the relief valve
(See Hydraulic Schematics to identify the function of the
hydraulic lines and cartridge valves at each port).
NOTE: The ProCore 648 hydraulic lift control manifold
uses two zero leak plugs (item 12). These plugs have a
tapered sealing surface on the plug head that is de-
signed to resist vibration induced plug loosening. The
zero leak plugs also have an o–ring (not shown) as a
secondary seal. If zero leak plug removal is necessary,
lightly rap the plug head using a punch and hammer be-
fore using an allen wrench to remove the plug: the im-
pact will allow plug removal with less chance of damage
to the socket head of the plug. When installing plug,
torque 120 in–lb (13.6 N–m).
Hydraulic System
Page 4 – 48
ProCore 648
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Hydraulic Manifold Service
CAUTION
1. Make sure the manifold is clean before removing any
cartridge valve.
Abrupt movement of internal spools can cause
stored fluid to be released suddenly.
2. If solenoid cartridge is being serviced, remove nut
securing solenoid to the cartridge valve. Carefully slide
solenoid off the valve.
6. Clean cartridge valve by submerging valve in clean
mineral spirits to flush out contamination. Particles as
fine as talcum powder can affect the operation of high
pressure hydraulic valves. If cartridge design allows,
use a wood or plastic probe to push the internal spool in
and out 20 to 30 times to flush out contamination. Be exꢀ
tremely careful not to damage cartridge. Use comꢀ
pressed air for cleaning.
CAUTION
Operate all hydraulic controls to relieve system
pressure and avoid injury from pressurized hyꢀ
draulic oil. See Relieving Hydraulic System Presꢀ
sure in the General Information section of this
chapter.
7. Reinstall the cartridge valve:
A. Lubricate new seal kit components with clean hyꢀ
draulic oil and install on valve. The o–rings, sealing
rings and backup rings must be arranged properly on
the cartridge valve for proper operation and sealing.
IMPORTANT: Use care when handling the cartridge
valve. Slight bending or distortion of the stem tube
can cause binding and malfunction.
3. Remove cartridge valve with a deep socket wrench.
Note correct location for o–rings, sealing rings and
backup rings. Remove and discard seal kit from valve.
IMPORTANT: Use care when handling the valve
cartridge. Slight bending or distortion of the
stem tube can cause binding and malfunction.
4. Visually inspect the manifold port for damage to the
sealing surfaces, damaged threads and contamination.
B. Thread cartridge valve carefully into correct manꢀ
ifold port. The valve should go in easily without bindꢀ
ing.
5. Visually inspect cartridge valve for damaged sealing
surfaces and contamination.
C. Torque cartridge valve using a deep socket to valꢀ
ues identified in Figure 40.
A. Contamination may cause valves to stick or hang
up. Contamination can become lodged in small valve
orifices or seal areas causing malfunction.
8. If solenoid cartridge was removed, carefully install
solenoid coil onto the cartridge valve. Install nut and
torque nut to 5 ft–lb (6.8 N–m).
B. If valve sealing surfaces appear pitted or damꢀ
aged, the hydraulic system may be overheating or
there may be water in the system.
9. After assembly, if problems still exist, remove valve
and clean again or replace valve.
CAUTION
Use eye protection such as goggles when using
compressed air for cartridge valve cleaning.
ProCore 648
Page 4 – 49
Hydraulic System
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Lift Cylinder
5
6
4
RIGHT
FRONT
9
10
3
11
14
15
7
12
10
13
2
9
16
17
8
9
18
1
11
Figure 41
9
1. Main frame
7. Clevis pin (4 used)
8. Hair pin (4 used)
9. Retaining ring
10. Thrust washer
11. Cylinder pin
13. Lift cylinder
14. O–ring
15. Hydraulic fitting
16. O–ring
17. Hydraulic hose
18. Coring head frame
2. Shackle (4 used)
3. Extension spring (2 used)
4. Carriage screw (4 used)
5. Spring plate (2 used)
6. Flange nut (4 used)
12. Spacer (2 used)
Removal (Fig. 41)
4. Disconnect the lower end of one extension spring
(item 2) from frame:
1. Park machine on a level surface, fully raise coring
head, engage parking brake, stop engine and remove
key from the ignition switch. Secure coring head with
service latch.
A. Remove service latch from coring head. Turn key
switch to ON (engine not running). Move traction le-
ver to forward direction and depress lower switch on
handle to fully lower coring head.
2. Remove rear hood (see Operator’s Manual).
B. Loosen, but do not remove, both flange nuts (item
6) that secure the spring plate (item 5) for one of the
extension springs.
3. Remove tine heads from stomper arms to allow cor-
ing head to be fully lowered.
C. Using a 1/2” breaker bar, hold spring plate (item
5) to prevent it from moving and remove upper
flange nut and carriage screw (item 4) from spring
plate and coring head frame (Fig. 42).
CAUTION
The extension spring is under tension and may
cause personal injury during removal. Use cau-
tion when disconnecting spring from machine.
D. Using lower carriage screw and flange nut as a
pivot, carefully release tension on extension spring
by rotating spring plate with breaker bar.
E. Remove hair pin (item 8) and clevis pin (item 7)
that secure spring shackle (item 2) to frame.
Hydraulic System
Page 4 – 50
ProCore 648
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5. Start engine and allow coring head to fully raise. Turn
engine off. Secure coring head with service latch.
5. Remove plugs from disconnected hose and fitting.
6. Connect hydraulic hose with new o–ring to hydraulic
fitting on lift cylinder. Tighten hose connection.
CAUTION
7. Install disconnected extension spring to machine in
reverse order of disassembly.
Operate all hydraulic controls to relieve system
pressure and avoid injury from pressurized hyꢀ
draulic oil. See Relieving Hydraulic System Presꢀ
sure in the General Information section of this
chapter.
8. Install rear hood.
9. Install tine heads to stomper arms (see Operator’s
Manual).
10.Follow Hydraulic System Start–up procedures.
6. Release hydraulic pressure in lift cylinder:
A. Turn key switch to ON (engine not running).
2
B. Move traction lever to forward direction and deꢀ
press lower switch on handle to lower coring head
onto service latch.
3
7. Disconnect hydraulic hose from hydraulic fitting on
lift cylinder. Locate and discard o–ring from between
hose and fitting. Allow hose to drain into a suitable conꢀ
tainer.
4
8. Plug disconnected hose and fitting to prevent conꢀ
tamination.
1
9. Remove one retaining ring from the upper cylinder
pin. Pull upper cylinder pin from the lift cylinder and corꢀ
ing head frame. Locate and retrieve spacer and thrust
washer from each side of cylinder pivot (Fig. 43).
Figure 42
1. Extension spring
3. Lower carriage screw
4. 1/2” drive hole
2. Upper carriage screw
10.Remove one retaining ring from the lower cylinder
pin on the side of the disconnected extension spring.
Support lift cylinder and slide lower cylinder pin from the
lift cylinder and machine frame.
2
4
4
2
11.Remove lift cylinder from the machine.
3
12.If needed, remove hydraulic fitting and o–ring from
the lift cylinder. Discard o–ring.
Installation (Fig. 41)
1
1. If removed, install hydraulic fitting and new o–ring
into lift cylinder.
2. Position lift cylinder to the machine mounting points.
Make sure the port of the lift cylinder faces the front of
the machine.
Figure 43
1. Lift cylinder shaft
2. Thrust washer
3. Cylinder pin
4. Spacer
3. Align lower lift cylinder mounting hole with frame
mount. Install cylinder pin and secure with retaining ring.
4. Align upper lift cylinder pivot with slots in the coring
head frame. Install cylinder pin making sure that a
spacer is on each side of the cylinder pivot and a thrust
washer is positioned between coring head frame and reꢀ
taining ring (Fig. 43). Secure with retaining ring.
ProCore 648
Page 4 – 51
Hydraulic System
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Lift Cylinder Service
8
9
6
7
5
4
3
2
1
Figure 44
1. Retaining ring
2. Cylinder tube
3. Rod
4. O–ring
7. Seal
5. Backup ring
8. Head
6. Retaining ring
9. Wiper
Disassembly (Fig. 44)
5. Mount rod securely in a vise by clamping vise on the
flats of the pivot. Remove retaining ring (item 1) and
carefully slide head from the shaft.
1. Remove oil from the lift cylinder into a drain pan by
slowly pumping the cylinder rod. Plug port and clean
the outside of the lift cylinder.
6. Remove and discard o–ring (item 4), backup ring
(item 5), seal (item 7) and wiper (item 9) from the head.
IMPORTANT: Prevent damage when clamping the
lift cylinder into a vise; clamp on the pivot only. Do
not close vise enough to distort tube.
Spanner
wrench
2. Mount lift cylinder in a vise so that the shaft end tilts
up slightly.
3. Rotate head (item 8) with a spanner wrench and re-
move retaining ring (item 6) as shown in Figure 45.
Retaining
ring
4. Grasp end of rod; extract rod and head by carefully
twisting and pulling on the rod.
Figure 45
IMPORTANT: Do not clamp vise jaws against rod
surface. Protect rod surface before mounting in
vise.
Hydraulic System
Page 4 – 52
ProCore 648
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Inspection
CAUTION
Spanner
wrench
Use eye protection such as goggles when using
compressed air
Retaining ring
(Offset end
against left side of
barrel groove
after installing)
1. Wash all parts in solvent. Dry parts with compressed
air.
2. Inspect internal surface of tube for deep scratches,
out–of–roundness and bending. Replace if worn or
damaged.
Figure 46
3. Inspect rod and head for excessive pitting, scoring or
wear. Replace any worn or damaged parts.
Assembly (Fig. 44)
1. Coat new o–ring (item 4), backup ring (item 5), seal
(item 7) and wiper (item 9) with hydraulic oil. Install sealꢀ
ing components to the head.
IMPORTANT: Do not clamp vise jaws against rod
surface. Protect rod surface before mounting in
vise.
2. Mount rod securely in a vise by clamping vise on the
pivot end of the shaft. Carefully slide head assembly
onto the rod. Install retaining ring (item 1).
3. Remove rod assembly from vise.
IMPORTANT: Prevent damage when clamping the
tube into a vise; clamp on the pivot end only. Do not
close vise enough to distort tube.
4. Mount tube in a vise so that the rod end tilts up slightꢀ
ly.
5. Coat all internal lift cylinder parts with a light coating
of hydraulic oil. Slide rod and head assembly into tube
being careful not to damage the seals.
6. Secure head in tube by installing retaining ring (item
6). Align key slot in head with the access groove in the
tube. Rotate head clockwise as far as the retaining ring
will allow. The offset end of the retaining ring will be
against the left side of the tube groove as shown in Figꢀ
ure 46.
ProCore 648
Page 4 – 53
Hydraulic System
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Hydraulic Reservoir
5
4
6
7
3
8
2
9
1
19
18
12
10
11
12
FRONT
RIGHT
17
16
14
12
13
15
Figure 47
1. Hydraulic reservoir
2. Dipstick
3. Cap
8. Flat washer
9. Frame
10. O–ring
14. Hydraulic tube
15. Suction hose
16. Hose clamp
4. Shoulder screw
5. Tank strap
6. Cap screw
7. J clip
11. Hydraulic adapter
12. O–ring
13. Hydraulic tube
17. Hydraulic barb fitting
18. Hydraulic tee fitting
19. O–ring
Inspecting Reservoir (Fig. 47)
3. Replace any hydraulic hose, tube or fitting if dam-
aged or leaking.
1. Clean hydraulic reservoir with solvent.
4. Make sure cap screw (item 6) that secures tank strap
is tight.
2. Inspect reservoir for leaks, cracks or other damage.
Hydraulic System
Page 4 – 54
ProCore 648
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Chapter 5
Electrical System
Table of Contents
ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . 1
CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 2
OK to Lower Circuit . . . . . . . . . . . . . . . . . . . . . . . . . 2
Lockout Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Electric Clutch Circuit . . . . . . . . . . . . . . . . . . . . . . . . 6
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . 8
Starting Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
General Run Problems . . . . . . . . . . . . . . . . . . . . . . 9
Coring Head Operating Problems . . . . . . . . . . . . 10
ELECTRICAL SYSTEM QUICK CHECKS . . . . . . . . 11
Battery Test (Open Circuit Test) . . . . . . . . . . . . . . . 11
Charging System Test . . . . . . . . . . . . . . . . . . . . . . . 11
Check Operation of Interlock Switches . . . . . . . . 12
COMPONENT TESTING . . . . . . . . . . . . . . . . . . . . . . 13
Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Engine Oil Pressure Indicator Light . . . . . . . . . . . 14
Hour Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Manual Raise/Lower Switch . . . . . . . . . . . . . . . . . 16
Ground Follow Switch . . . . . . . . . . . . . . . . . . . . . . 17
Lift Reset Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Solenoid Valve Coil . . . . . . . . . . . . . . . . . . . . . . . . . 19
Head Low and Head High Limit Switches . . . . . . 20
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Proximity Switches . . . . . . . . . . . . . . . . . . . . . . . . . 22
Aerator Control Module . . . . . . . . . . . . . . . . . . . . . 24
Electric Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Diode Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . 27
SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . 28
Battery Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Battery Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Battery Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Electric Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Solenoid Valve Coil . . . . . . . . . . . . . . . . . . . . . . . . . 34
Electrical Diagrams
The electrical schematic, electrical circuit drawings and
wire harness drawings for the ProCore 648 are located
in Chapter 8 – Electrical Diagrams.
ProCore 648
Electrical System
Page 5 – 1
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Circuit Operation
NOTE: This section provides information concerning
three sequential, electrical circuits that are used on the
ProCore 648. Use these descriptions along with the
electrical diagrams and schematics found in Chapter 8
– Electrical Diagrams to better understand circuit operaꢀ
tion.
OK to Lower Circuit (Fig. 1)
The ”OK to lower” circuit is one of the inputs used by the
aerator control module to allow current output to the
raise and lower hydraulic solenoid valves (SVL, SVR
and SVQ). This circuit is composed of the manual raise/
lower switch, the neutral switch (latch) relay, the latching
relay, the reverse proximity switch and diode D1. ”OK to
lower” circuit protection is provided by fuse F3.
Aerating (Traction Lever in Forward)
Once the ”OK to lower” circuit has initially been closed
by the manual raise/lower switch, the latching relay and
diode D1 allow a latch circuit to keep the latching relay
energized. The manual raise/lower switch in the middle,
aerate position along with the energized latching relay
provide a closed path for the ”OK to lower” input to the
aerator control module. The ”OK to lower” LED on the
aerator control module will continue to be illuminated
while aerating.
Traction Lever in Neutral or Reverse
When the traction lever is in either the neutral or reverse
position, the reverse proximity switch is closed which alꢀ
lows the neutral switch (latch) relay to be energized.
This energized relay prevents an ”OK to lower” input for
the aerator control so the coring head remains in the
raised position. The ”OK to lower” LED on the aerator
control module will not be illuminated.
The ”OK to lower” input to the aerator control module will
remain closed until either the operator presses the
manual raise/lower switch to the raise position or the
traction lever is moved to the neutral or reverse position.
Begin Aerating (Traction Lever in Forward)
To begin aerating, the operator moves the traction lever
to the forward direction which opens the reverse proximꢀ
ity switch and de–energizes the neutral switch (latch)
relay. When the manual raise/lower switch is pressed to
the lower position, a complete circuit is formed to allow
the latching relay to be energized which allows an ”OK
to lower” input for the aerator control. The ”OK to lower”
LED on the aerator control module will be illuminated.
The aerator control module will provide output to the
SVQ and SVL solenoid valves to lower the coring head.
Electrical System
ProCore 648
Page 5 – 2
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CONTROL MODULE
”OK TO LOWER” LED
IS NOT ILLUMINATED
TO IGNITION
SWITCH
TRACTION LEVER IN NEUTRAL OR REVERSE
TERMINAL ”L”
GROUND
TO AERATOR
CONTROL MODULE
OK TO LOWER
(NOT ENERGIZED)
(IN RAISE POSITION)
(ENERGIZED)
GROUND
TO
TO
LOCKOUT
AERATION #3
CIRCUIT
PROX. SWITCH
CONTROL MODULE
”OK TO LOWER” LED
IS ILLUMINATED
TO IGNITION
SWITCH
BEGIN AERATING (TRACTION LEVER IN FORWARD)
TERMINAL ”L”
GROUND
TO AERATOR
CONTROL MODULE
OK TO LOWER
(ENERGIZED)
(PRESSED TO LOWER)
(2 AND 3 CLOSED, 5 AND 6 CLOSED)
(NOT ENERGIZED)
GROUND
TO
TO
LOCKOUT
AERATION #3
CIRCUIT
PROX. SWITCH
CONTROL MODULE
”OK TO LOWER” LED
IS ILLUMINATED
TO IGNITION
SWITCH
TERMINAL ”L”
AERATING (TRACTION LEVER IN FORWARD)
GROUND
TO AERATOR
CONTROL MODULE
OK TO LOWER
(ENERGIZED)
(IN MIDDLE/AERATE POSITION)
(2 AND 3 CLOSED)
(NOT ENERGIZED)
GROUND
TO
TO
LOCKOUT
AERATION #3
CIRCUIT
PROX. SWITCH
CONTROL CURRENT
OK TO LOWER
Figure 1
ProCore 648
Electrical System
Page 5 – 3
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Lockout Circuit (Fig. 2)
The lockout circuit is used on the ProCore to provide curꢀ
rent for the raise and lower hydraulic solenoid valves
(SVL, SVR and SVQ). This circuit is composed of the
transport limit #2 proximity switch, the lockout relay, the
lockout latch relay, the lift/reset switch and diode D2.
When this circuit is closed, current is provided to the aerꢀ
ator control module to allow energizing of the solenoid
valves. Lockout circuit protection is provided by fuse F3.
Coring Head Stranded
If the coring head is stranded in the lowered position
(e.g. the engine runs out of gas while aerating), the
transport limit #2 proximity switch will be open and will
prevent the relays in the lockout circuit from energizing.
In this situation, no current will be available to the soleꢀ
noid valves so the coring head cannot be raised. Pressꢀ
ing the lift/reset switch provides the necessary ground
path for completing the lockout circuit. Once the lockout
circuit is closed, solenoid valve operation is resumed to
allow the coring head to raise.
Coring Head Raised
With the coring head in the raised position, the transport
limit #2 proximity switch is closed which completes the
lockout circuit. Hydraulic solenoid valve operation is
possible at this time which allows the coring head to be
lowered and aeration to occur.
Aerating
Once the lockout circuit has initially been closed by
transport limit #2 proximity switch, the lockout latch relay
and diode D2 allow a latch circuit to keep the lockout
relay energized and hydraulic solenoid valve operation
to continue while aerating.
Electrical System
ProCore 648
Page 5 – 4
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CORING HEAD RAISED
TO AERATOR
CONTROL
MODULE
TO IGNITION
SWITCH
TERMINAL ”L”
GROUND
(ENERGIZED)
(ENERGIZED)
(NOT PRESSED)
TO ELECTRIC CLUTCH
TO IGNITION SWITCH
TERMINAL ”A”
AERATING
TO AERATOR
CONTROL
MODULE
TO IGNITION
SWITCH
TERMINAL ”L”
GROUND
(ENERGIZED)
(ENERGIZED)
(NOT PRESSED)
TO ELECTRIC CLUTCH
TO IGNITION SWITCH
TERMINAL ”A”
CORING HEAD STRANDED
TO AERATOR
CONTROL
MODULE
TO IGNITION
SWITCH
TERMINAL ”L”
GROUND
(ENERGIZED)
(ENERGIZED)
(PRESSED)
TO ELECTRIC CLUTCH
TO IGNITION SWITCH
TERMINAL ”A”
CONTROL CURRENT
POWER CURRENT
Figure 2
ProCore 648
Electrical System
Page 5 – 5
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Electric Clutch Circuit (Fig. 3)
The electric clutch circuit is used on the ProCore to proꢀ
vide current for the electric clutch which rotates the corꢀ
ing crankshaft. This circuit is composed of the aeration
#3 proximity switch, the clutch relay, the electric clutch
and diode D3. The electric clutch circuit relies on the opꢀ
eration of the ”OK to lower” circuit for completing the
clutch circuit (See OK to Lower Circuit in this section).
Electric clutch circuit protection is provided by fuse F2.
Aerating (Clutch Engaged)
The clutch relay will be energized as the coring head is
lowered to the point when the aeration #3 proximity
switch closes. This closed proximity switch provides a
complete circuit if the ”OK to lower” circuit is closed.
Once the clutch relay is energized, current is provided
to the clutch and rotation of the coring crankshaft beꢀ
gins.
Not Aerating (Clutch not Engaged)
The clutch will continue to be energized until either:
Whenever the coring head is in the raised position, the
aeration #3 proximity switch is open and the clutch relay
is not energized. The electric clutch will not be energized
so rotation of the coring crankshaft does not occur.
A. The coring head is raised which opens the aeraꢀ
tion #3 proximity switch.
B. The “OK to lower” circuit opens (e.g. the operator
releases the traction lever while aerating).
NOT AERATING (CLUTCH NOT ENGAGED)
TO IGNITION
SWITCH
TERMINAL ”L”
TO
GROUND
OK TO LOWER
CIRCUIT
(NOT ENERGIZED)
(NOT ENERGIZED)
(ENERGIZED)
AERATING (CLUTCH ENGAGED)
TO IGNITION
SWITCH
TERMINAL ”L”
TO
GROUND
OK TO LOWER
CIRCUIT
(ENERGIZED)
(ENERGIZED)
(HEAD LOWERED)
CONTROL CURRENT
CLUTCH CURRENT
Figure 3
Electrical System
ProCore 648
Page 5 – 6
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Special Tools
Multimeter
The multimeter can test electrical components and cirꢀ
cuits for current (amps), resistance (ohms) or voltage.
NOTE: Toro recommends the use of a DIGITAL Volt–
Ohm–Amp multimeter when testing electrical circuits.
The high impedance (internal resistance) of a digital meꢀ
ter in the voltage mode will make sure that excess curꢀ
rent is not allowed through the meter. This excess
current can cause damage to circuits not designed to
carry it.
Figure 4
Battery Terminal Protector
Battery Terminal Protector (Toro Part No. 107–0392) is
an aerosol spray that should be used on battery termiꢀ
nals to reduce corrosion problems. Apply terminal proꢀ
tector after battery cable has been secured to battery
terminal.
Figure 5
Battery Hydrometer
Use the Battery Hydrometer when measuring specific
gravity of battery electrolyte. Obtain this tool locally.
Figure 6
ProCore 648
Electrical System
Page 5 – 7
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Troubleshooting
For effective troubleshooting and repairs, you must
have a good understanding of the electrical circuits (see
Chapter 8 – Electrical Diagrams) and components used
on this machine.
CAUTION
Remove all jewelry, especially rings and
watches, before doing any electrical troubleꢀ
shooting or testing. Disconnect the battery
cables unless the test requires battery voltage.
If the machine has any interlock switches by–passed,
they must be reconnected for proper troubleshooting
and safety.
Starting Problems
Problem
Possible Causes
Starter solenoid clicks, but starter will not crank
(if solenoid clicks, problem is not in safety interlock
system).
Battery charge is low.
Battery cables are loose or corroded.
Battery ground to frame is loose or corroded.
Wiring at starter is faulty.
Starter solenoid is faulty.
Starter mounting bolts are loose or not supplying a
sufficient ground for solenoid.
Starter is faulty.
Nothing happens when start attempt is made (traction
lever must be in neutral position for successful start).
Traction lever is not in the neutral position.
Battery cables are loose or corroded.
Battery ground to frame is loose or corroded.
Battery is dead.
Fuse F1 (20 amp) is open.
Wiring to start circuit components is loose, corroded, or
damaged (see Chapter 8 – Electrical Diagrams).
Neutral proximity switch is out of adjustment or faulty.
Sensing plate on traction lever is loose.
Neutral switch relay is faulty.
Ignition switch is faulty.
Fuse block is faulty.
Starter solenoid is faulty.
Electrical System
ProCore 648
Page 5 – 8
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Starting Problems (continued)
Problem
Possible Causes
Engine cranks, but does not start.
Circuit wiring to engine magneto is grounded (see
Chapter 8 – Electrical Diagrams).
Circuit wiring to carburetor solenoid is loose, corroded,
or damaged (see Chapter 8 – Electrical Diagrams).
Engine or fuel system is malfunctioning (see Chapter
3 – Kohler Engine).
Engine may be too cold.
Engine cranks (but should not) with the traction lever
out of the neutral position.
Neutral proximity switch is out of adjustment or faulty.
Neutral proximity switch wiring is faulty.
Sensing plate on traction lever is loose or damaged.
General Run Problems
Problem
Possible Causes
Battery does not charge.
Wiring to the charging circuit components is loose,
corroded, or damaged (see Chapter 8 – Electrical
Diagrams).
Ignition switch is faulty.
Alternator is faulty (see Chapter 3 – Kohler Engine).
Battery is dead.
Engine kills during operation.
Ignition switch is faulty.
Circuit wiring to engine magneto is damaged (see
Chapter 8 – Electrical Diagrams).
Circuit wiring to carburetor solenoid is loose, corroded,
or damaged (see Chapter 8 – Electrical Diagrams).
Engine or fuel system is malfunctioning (see Chapter
3 – Kohler Engine).
ProCore 648
Electrical System
Page 5 – 9
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Coring Head Operating Problems
Problem
Possible Causes
Coring head runs (but should not) when raised.
Aeration #3 proximity switch is faulty or out of
adjustment.
Coring head does not lower.
Fuse F3 (10 Amp) or F4 (2 Amp) is/are faulty.
Raise/lower switch is faulty.
SVL valve solenoid is faulty.
Aerator Control Module is faulty.
”OK to lower” circuit is not functioning (see OK to
Lower Circuit in Circuit Operation section of this
chapter).
Hydraulic problem exists (see Chapter 4 – Hydraulic
System).
Coring head does not raise.
Fuse F3 (10 Amp) or F4 (2 Amp) is/are faulty.
Lift reset switch needs to be reset.
Raise/lower switch is faulty.
SVR or SVQ valve solenoid is faulty.
Aerator Control Module is faulty.
Hydraulic problem exists (see Chapter 4 – Hydraulic
System).
Electric clutch does not engage.
Fuse F2 (10 Amp) is faulty.
Coring head is not lowered.
Clutch relay is faulty.
Aeration #3 proximity switch is faulty or out of
adjustment.
Circuit wiring to electric clutch is loose, corroded, or
damaged (see Chapter 8 – Electrical Diagrams).
Diode D3 is faulty.
Electric clutch is faulty.
Electric clutch is noisy.
Clutch is loose on engine crankshaft.
Clutch strap is loose or damaged.
Broken leaf spring(s) on clutch.
Failed clutch bearing(s).
Clutch is slipping.
Lubricant has contaminated clutch lining material.
Gap between clutch rotor and armature is excessive.
Electrical System
ProCore 648
Page 5 – 10
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Electrical System Quick Checks
Battery Test (Open Circuit Test)
Use a multimeter to measure the voltage between the
battery terminals.
Voltage Measured
Battery Charge Level
Fully charged (100%)
75% charged
12.68 v (or higher)
12.45 v
Set the multimeter to the DC volts setting. The battery
o
o
o
o
should be at a temperature of 60 to 100 F (16 to 38
12.24 v
50% charged
C). The ignition key should be in the OFF position and
all accessories turned off. Connect the positive (+) meꢀ
ter lead to the positive battery post and the negative (–)
meter lead to the negative battery post.
12.06 v
25% charged
11.89 v
0% charged
NOTE: This test provides a relative condition of the batꢀ
tery. Load testing of the battery will provide additional
and more accurate information.
Charging System Test
This is a simple test used to determine if the charging
system is functioning. It will tell you if a charging system
has an output, but not its capacity.
Start the engine and run at 3400 RPM (high idle). Allow
the battery to charge for at least 3 minutes. Record the
battery voltage.
Tool required: Digital multimeter set to DC volts.
Test results should be (example):
Test instructions: Connect the positive (+) meter lead to
the positive battery post and the negative (–) meter lead
to the negative battery post. Leave the test leads conꢀ
nected and record the battery voltage.
At least 0.50 volt over initial battery voltage.
Initial Battery Voltage
Battery Voltage after 3 Minute Charge
Difference
= 12.25 v
= 12.80 v
= +0.55 v
NOTE: Upon starting the engine, the battery voltage
will drop and then should increase once the engine is
running.
NOTE: Depending upon the condition of the battery
charge and battery temperature, the charging system
voltage will increase at different rates as the battery
charges.
ProCore 648
Electrical System
Page 5 – 11
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Check Operation of Safety Interlock System
The Safety Interlock System of the ProCore 648 ensurꢀ
es the following operations:
CAUTION
1. The engine should crank only when the traction lever
is in the neutral position.
Do not disconnect interlock switches. They are
for the operator’s protection. Check operation
of the switches daily to make sure the interlock
system is operating correctly. If a switch is not
operating properly, adjust or replace it before
operating the machine.
2. When aerating, if the traction lever is released from
the forward position (moved to the neutral or reverse
position), the coring head should automatically raise
and the coring crankshaft should stop rotating.
3. If the coring head is stranded in the lowered position,
the coring head will not raise unless the lift reset switch
is depressed.
Interlock switch operation is described in the ProCore
648 Operator’s Manual. The ProCore is equipped with
an Aerator Control Module which monitors interlock
switch operation. Information on this Control Module is
described in the Operator’s Manual and in the Compoꢀ
nent Testing section of this Chapter. Testing of individual
interlock switches is included in the Component Testing
section of this Chapter.
Electrical System
ProCore 648
Page 5 – 12
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Component Testing
For accurate resistance and/or continuity checks, elecꢀ
trically disconnect the component being tested from the
circuit (e.g. unplug the ignition switch connector before
doing a continuity check).
NOTE: See the Kohler Engine Service Manual for enꢀ
gine component testing information.
CAUTION
NOTE: Electrical troubleshooting of any 12 Volt power
connection can be performed through voltage drop tests
without disconnecting the component.
When testing electrical components for continuꢀ
ity with a multimeter (ohms setting), make sure
that power to the circuit has been disconnected.
Ignition Switch
The ignition (key) switch has three positions (OFF, RUN,
and START) (Fig. 7). The terminals are marked as
shown in Figure 8.
OFF
o
45
RUN
Testing
o
45
The circuitry of the ignition switch is shown in the chart
below. With the use of a multimeter (ohms setting), the
switch functions may be tested to determine whether
continuity exists between the various terminals for each
switch position.
START
Unplug wire harness connectors from switch and verify
continuity between switch terminals. Reconnect the har-
ness connectors to the switch after testing.
Figure 7
POSITION
OFF
CIRCUIT
G + M + A
B + L + A
B + L + S
L
M
B
S
RUN
G
START
A
The Aerator Control Module monitors the operation of
the ignition switch. If the ignition switch is in the ON posi-
tion, the Module power input LED should be illuminated.
If the ignition switch is in the START position, the Module
start output LED should also be illuminated.
Figure 8
HEX NUT
KEY
SWITCH
LOCK WASHER
Figure 9
ProCore 648
Electrical System
Page 5 – 13
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Engine Oil Pressure Indicator Light
The engine oil pressure indicator light is located on the
handle control panel (Fig. 10). The indicator light should
come on when the ignition switch is in the ON position
with the engine not running. Also, it should light with the
engine running if the engine oil pressure is insufficient.
IMPORTANT: If the engine oil pressure indicator
light comes on when the engine is running, shut enꢀ
gine off immediately.
Testing
1. Turn the ignition switch to ON. The engine oil presꢀ
sure indicator light should be on.
2. If the light is not on, locate the oil pressure switch on
the engine and disconnect the wire from the switch.
Ground the disconnected wire to the engine block.
Figure 10
1. Oil pressure indicator light
3. If the light comes on, the oil pressure switch is faulty.
4. If the light does not come on, check the indicator light
and indicating circuit (see Electrical Schematic in Chapꢀ
ter 8 – Electrical Diagrams).
1B (–)
1A (+)
Testing Indicator Light
BACK OF INDICATOR LIGHT
1. Apply 12 VDC to terminal 1A (Fig. 11).
2. Ground terminal 1B (Fig. 11).
3. Indicator light should illuminate.
Figure 11
NOTE: For engine oil pressure switch information, refer
to the Kohler Engine Service Manual at the end of Chapꢀ
ter 3 – Engine.
Hour Meter
The hour meter used on the ProCore 648 uses an inducꢀ
tive pickup wire connected to the rear spark plug wire to
sense when the engine is running. The hour meter
should increase 1/10 of an hour every six (6) minutes of
engine running time.
The hour meter uses its own internal battery and thereꢀ
fore, is not connected to the ProCore 12 volt electrical
system. The hour meter battery is not replaceable.
1
Figure 12
1. Hour meter
Electrical System
ProCore 648
Page 5 – 14
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Relays
Six (6) relays are used on the ProCore 648. Four (4) of
these relays are attached under the control panel next
to the battery (Fig. 13): lockout relay, clutch relay, neutral
switch (start) relay and lockout latch relay. The remainꢀ
ing two (2) relays are attached under the handle console
(Fig. 14): neutral switch (latch) relay and latching relay.
The six relays are identical. The relays are identified by
a tag on the wire harness relay connector.
1
2
See the Circuit Operation section of this Chapter for inꢀ
formation on relay operation.
Testing
Figure 13
NOTE: Prior to taking small resistance readings with a
digital multimeter, short the meter test leads together.
The meter will display a small resistance value (usually
0.5 ohms or less). This resistance is due to the internal
resistance of the meter and test leads. Subtract this valꢀ
ue from the measured value of the component you are
testing.
1. Battery
2. Relay location
2
1. Locate relay to be tested. Disconnect the machine
wire harness connector from the relay.
2. Using a multimeter (ohms setting), measure coil reꢀ
sistance between terminals 85 and 86 (Fig. 15). Resistꢀ
ance should be between 70 and 90 ohms.
3. Connect multimeter (ohms setting) leads to relay terꢀ
minals 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.
1
Figure 14
1. Traction lever
2. Relay
4. Disconnect voltage from terminal 85 and multimeter
lead from terminal 87.
5. Connect multimeter (ohms setting) leads to relay terꢀ
minals 30 and 87A. Apply +12 VDC to terminal 85. The
relay should make and break continuity between termiꢀ
nals 30 and 87A as +12 VDC is applied and removed
from terminal 85.
86
87A
87
6. Disconnect voltage and multimeter leads from the
relay terminals. Reconnect relay to machine wire harꢀ
ness.
85
30
Figure 15
ProCore 648
Electrical System
Page 5 – 15
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Manual Raise/Lower Switch
The manual raise/lower switch is located on the handle
control panel (Fig. 16). This rocker switch is one of the
components in the ”OK to lower” circuit which is one of
the aerator control module inputs. See OK to Lower Cirꢀ
cuit in the Circuit Operation section of this chapter for
additional raise/lower switch information.
1
The switch terminals are marked as shown in Figure 17.
The circuitry of the raise/lower switch is shown in the
chart below. With the use of a multimeter (ohms setting),
the switch functions may be tested to determine whether
continuity exists between the various terminals for each
switch position. Verify continuity between switch termiꢀ
nals.
SWITCH
POSITION
NORMAL
CIRCUITS
OTHER
CIRCUITS
Figure 16
1. Manual raise/lower switch
RAISE
NONE
2 + 3
2 + 3
NONE
NONE
5 + 6
MIDDLE/
AERATE
3
2
6
5
LOWER
(MOMENTARY)
UP
Figure 17
Electrical System
ProCore 648
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Ground Follow Switch
The ground follow switch is located on the side of the
control panel (Fig. 18). This rocker switch allows the
True CoreTM ground following system to be turned on/
off. The switch is retained in position by a cap screw and
nut placed in the switch guard to prevent accidental
switch movement. In the normal, upper switch position,
the True CoreTM ground following system is ON. The
True CoreTM ground following system is OFF when the
switch is in the lower position.
1
2
The switch terminals are marked as shown in Figure 19.
The circuitry of the ground follow switch is shown in the
chart below. With the use of a multimeter (ohms setting),
the switch functions may be tested to determine whether
continuity exists between the various terminals for each
switch position. Verify continuity between switch termiꢀ
nals.
3
Figure 18
1. Ground follow switch
2. Cap screw & nut
3. Switch guard
SWITCH
POSITION
NORMAL
CIRCUITS
OTHER
CIRCUITS
UP (ON)
2 + 3
1 + 2
5 + 6
4 + 5
6
5
4
3
2
DOWN (OFF)
The Aerator Control Module monitors the operation of
the ground follow switch. If the ground follow switch is in
the ON (up) position, the Control Module ground follow
LED should be illuminated when the ignition switch is
ON (Fig. 20). If the ground follow switch is in the OFF
(lower) position, the Module ground follow output LED
should not be illuminated.
UP
1
Figure 19
2
1
Figure 20
1. Control module
2. Ground follow LED
ProCore 648
Electrical System
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Lift Reset Switch
The lift reset switch is located on the control panel (Fig.
21). This momentary rocker switch raises the coring
head in instances when the coring head has been
stranded in the aerating (lowered) position (e.g. engine
runs out of gas, coring head stuck). By depressing the
lift reset switch, the coring head lift system will reset, the
coring head will raise fully and normal coring head opꢀ
eration can resume.
1
The switch terminals are marked as shown in Figure 19.
The circuitry of the lift reset switch is shown in the chart
below. With the use of a multimeter (ohms setting), the
switch functions may be tested to determine whether
continuity exists between the various terminals for each
switch position. Verify continuity between switch termiꢀ
nals.
Figure 21
1. Lift reset switch
SWITCH
POSITION
NORMAL
CIRCUITS
OTHER
CIRCUITS
NORMAL
2 + 3
1 + 2
5 + 6
4 + 5
MOMENTARY
ON (RESET)
UP
1
2
3
4
5
6
Figure 22
Electrical System
ProCore 648
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Solenoid Valve Coil
The hydraulic system on the ProCore 648 uses three (3)
solenoid valve coils on the hydraulic lift control manifold
(Fig. 23). The aerator control module provides current to
the solenoid valve coils based on the position of several
inputs. A LED on the aerator control module will be illuꢀ
minated when the solenoid valve coils are energized
(Fig. 24).
3
4
2
NOTE: The solenoid does not have to be removed from
the cartridge valve for testing.
1. Make sure ignition switch is in the OFF position. Unꢀ
plug solenoid valve electrical connector.
1
2. Apply 12VDC source directly to the solenoid. Listen
for solenoid to switch on.
Figure 23
3. Remove 12VDC source from the solenoid. Listen for
solenoid to switch off.
1. Lift control manifold
2. SVL solenoid coil
3. SVQ solenoid coil
4. SVR solenoid coil
NOTE: Prior to taking small resistance readings with a
digital multimeter, short the test leads together. The meꢀ
ter will display a small resistance value (usually 0.5
ohms or less). This resistance is due to the internal reꢀ
sistance of the meter and test leads. Subtract this value
from from the measured value of the component you are
testing.
1
4. Measure resistance between the two coil connector
terminals. Resistance of the solenoid coil should be
approximately 8.7 ohms.
2
3
5. Reconnect electrical connector to the solenoid.
4
6. If solenoid coil needs replacement, see Solenoid
Valve Coil in the Service and Repairs section of this
chapter.
Figure 24
1. Control module
2. SVR solenoid LED
3. SVQ solenoid LED
4. SVL solenoid LED
ProCore 648
Electrical System
Page 5 – 19
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Head Low and Head High Limit Switches
The head low and head high limit switches are attached
to the coring depth control housing (Fig. 25). These
switches are normally open and close when the switch
actuator in the housing is rotated past the switch. The
head low and head high limit switches provide inputs for
the True CoreTM ground following system on the Pro-
Core 648.
3
1
The Aerator Control Module monitors the operation of
the head low and head high limit switches. With the corꢀ
ing head raised and the ignition switch in the ON position
(engine not running), the Module head high input LED
should be illuminated and the head low input LED
should not be illuminated. By slowly raising the outer turf
guard, the head high input LED should go out. If the outꢀ
er turf guard continues to be raised, the head low input
LED will illuminate slightly later.
2
Figure 25
1. Head high switch
2. Head low switch
3. Depth control housing
While aerating with the ProCore, the turf guards follow
surface undulations. With the True CoreTM ground folꢀ
lowing system on, the Aerator Control Module receives
an input if the turf guards move enough to close either
the head high or head low limit switch. The Control Modꢀ
ule uses that input to allow a current output to the apꢀ
propriate hydraulic solenoid (SVR or SVL) to raise or
lower the coring head slightly.
2
3
Head Low and Head High Switch Test
1. Park machine on a level surface, fully raise coring
head, engage parking brake, stop engine and remove
key from the ignition switch. Secure coring head with
service latch.
1
2. Locate switch on depth control housing. Disconnect
the switch electrical connector.
Figure 26
3. Check the continuity of the switch by connecting a
multimeter (ohms setting) across the connector termiꢀ
nals.
1. Control module
2. Head low LED
3. Head high LED
A. The head high switch should be closed (continuꢀ
ity) with the coring head raised and the turf guards
extended. The switch should open (no continuity) if
the turf guards are manually raised.
B. The head low switch should be open (no continuꢀ
ity) with the coring head raised and the turf guards
extended. The switch should close (continuity) if the
turf guards are manually raised.
4. Reconnect the switch electrical connector.
5. If switch replacement is necessary, apply small
amount of grease onto the switch ball before installing
switch in depth control housing.
Electrical System
ProCore 648
Page 5 – 20
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Fuses
The fuse block is located behind the console cover (Fig.
27).
1
Identification, Function, and Wiring
The fuses are held in the fuse block. Use Figure 28 to
identify each individual fuse and its correct amperage.
Each fuse holder has the following functions:
Fuse 1 (20 Amp): Supplies power to ignition switch
terminal B.
Fuse 2 (10 Amp): Supplies power to electric clutch.
Fuse 3 (10 Amp): Supplies power from ignition
switch terminal S.
Figure 27
1. Fuse block
Fuse 4 (2 Amp): Supplies power to aerator control
module.
Testing
Remove fuses from the fuse block for testing. Fuse
should have continuity between fuse terminals.
UP
20A
Fuse 1
10A
10A
2A
Fuse 2
Fuse 3
Fuse 4
Figure 28
ProCore 648
Electrical System
Page 5 – 21
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Proximity Switches
The ProCore 648 uses six (6) identical proximity
switches. These switches are normally open switches
that close when a sensing plate is positioned near the
target end of the switch (Fig. 32).
3
The reverse and neutral proximity switches are
mounted on the control handle under the handle conꢀ
sole (Fig. 29). They use sensing plates pinned to the
traction lever.
4
1
The transport limit #1 (top) and #2 switches and aeration
#3 and #4 (bottom) switches are mounted on a mounting
bracket attached to the right rear frame (Fig. 30). The
sensing plate for these switches is welded to the coring
head H–frame.
2
Figure 29
The neutral proximity switch is used in the starting circuit
to make sure that the traction lever is in the neutral posiꢀ
tion when starting the engine. This switch is closed when
the traction bail is in the neutral position and opens when
the bail is moved to either the forward or reverse direcꢀ
tion.
1. Reverse proximity switch
2. Reverse sensing plate
3. Neutral proximity switch
4. Neutral sensing plate
1
2
The reverse proximity switch is one of the components
used in the “OK to lower” circuit that acts as an input for
the aerator control module. This proximity switch is
closed when the traction lever is in either the neutral or
reverse position. When the traction lever is moved to the
forward direction, the reverse proximity switch opens.
3
The transport limit #1 proximity switch is closed when
the coring head is fully raised and opens almost immediꢀ
ately as the coring head begins to lower. This switch is
used as an input for the aerator control module to indiꢀ
cate that the coring head is in the transport (raised) posiꢀ
tion. Transport limit #1 switch operation can be
monitored using the control module transport #1 input
LED.
Figure 30
1. Switch mount bracket
3. Coring head H–frame
2. Sensing plate
5
The transport limit #2 proximity switch is closed when
the coring head is fully raised and opens as the coring
head is being lowered. This switch is one of the compoꢀ
nents in the lockout circuit used to provide current for the
raise and lower solenoids.
RIGHT
1
FRONT
2
The aeration #3 proximity switch is closed as the coring
head is lowering to allow the electric clutch to be enerꢀ
gized. The switch opens as the coring head is raising.
4
The aeration #4 proximity switch is closed when the corꢀ
ing head is fully lowered and opens as the coring head
begins to raise. This switch is used as an input for the
aerator control module to identify when the coring head
is in the aerate position. Aeration #4 switch operation
can be monitored using the control module aerate #4 inꢀ
put LED.
3
Figure 31
1. Transport limit #1
2. Transport limit #2
3. Aeration #3
4. Aeration #4
5. Switch mount bracket
Electrical System
ProCore 648
Page 5 – 22
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Proximity Switch Test
3
4
5
1. Park machine on a level surface, fully raise coring
head, engage parking brake, stop engine and remove
key from the ignition switch. Secure coring head with
service latch.
2
2. Locate proximity switch to be tested. Disconnect
proximity switch from machine wiring harness.
Tab
1
3. Check the continuity of the switch by connecting a
multimeter (ohms setting) across the switch connector
terminals.
Switch
Target
End
Figure 32
NOTE: Before checking switch continuity, clean target
end of switch to make sure that there is no metallic deꢀ
bris on the switch that could prevent correct switch opꢀ
eration.
1. Carriage screw
2. Switch mount
3. Proximity switch
4. Switch plate
5. Lock nut
4. With the sensing plate positioned near the target end
of the switch, there should be continuity across the
switch terminals.
5. When the sensing plate is positioned away from the
target end of the switch, there should be no continuity
across the switch terminals.
6. Replace proximity switch as needed. Reconnect
switch to machine wiring harness.
Proximity Switch Installation
When installing a proximity switch to the machine, place
tab on switch plate into switch mounting hole nearest
target end of switch (Fig. 32). Secure proximity switch
and switch plate to switch mount with carriage screw
and lock nut.
The switch mounting bracket that retains the transport
limit and aeration proximity switches (Fig. 30) should be
mounted to allow from .030” to .090” (.8 to 2.3 mm) clearꢀ
ance between the switch targets and sensing plate on
the coring head H–frame.
ProCore 648
Electrical System
Page 5 – 23
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Aerator Control Module
The ProCore 648 is equipped with an Aerator Control
Module to monitor and control electrical components reꢀ
quired for safe operation. This Module is located on the
inside of the console cover (Fig. 33).
2
Inputs from the start (ignition), head low limit, head high
limit, transport limit #1 proximity switch, aeration #4
proximity switch and ground follow switches are moniꢀ
tored by the Module. The condition (open or closed) of
the ”OK to lower” circuit is also monitored by the Module.
Output to the three hydraulic solenoid valves (lower
SVL, raise SVR and quick raise SVQ) are controlled
based on the inputs received by the Module.
1
The Aerator Control Module does not connect to an exꢀ
ternal computer or hand held device, can not be re–pro-
grammed and does not record intermittent fault data.
Figure 33
1. Console cover
2. Control module
The Aerator Control Module can be used to check opꢀ
eration of machine switches by monitoring the LED’s of
the module. If a module LED does not illuminate (e.g. the
ground follow LED does not illuminate when the ground
follow switch is in the ON position), testing of the switch
and circuit wiring would be required.
8
9
7
6
5
10
Control Module Inputs
The power input LED should be illuminated when the
ignition switch is in the ON position.
The head low input LED should be illuminated when the
head low limit switch is closed.
ProCore 648 Aerator
The head high input LED should be illuminated when the
head high limit switch is closed.
The transport #1 input LED should be illuminated when
the transport limit #1 proximity switch is closed (coring
head raised).
1
4
The aerate #4 input LED should be illuminated when the
aeration #4 proximity switch is closed (coring head lowꢀ
ered).
3
2
Figure 34
1. Power input LED
2. SVL output LED
3. SVR output LED
4. SVQ output LED
5. Head low input LED
6. Head high input LED
7. Transport #1 input LED
8. Aerate #4 input LED
9. Ground follow ON LED
10. “OK to lower” input LED
The ground follow ON LED should be illuminated when
the ground follow switch is in the ON position.
The ”OK to lower” input LED should be illuminated when
the ”OK to lower” circuit is closed (see OK to Lower Cirꢀ
cuit in the Circuit Operation section of this chapter).
Electrical System
ProCore 648
Page 5 – 24
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Control Module Outputs
3. The SVR output LED will be illuminated in two situaꢀ
tions:
1. The SVQ output LED will be illuminated in two situaꢀ
tions:
A. Both ”OK to lower” and transport #1 LED’s are
not illuminated.
A. Both ”OK to lower” and transport #1 LED’s are
not illuminated.
B. ”OK to lower”, ground follow, aerate #4 and head
low limit LED’s are all illuminated.
B. ”OK to lower” LED is illuminated and aerate #4
LED is not illuminated.
2. The SVL output LED will be illuminated in three situaꢀ
tions:
A. ”OK to lower” LED is illuminated and ground folꢀ
low LED is not illuminated.
B. Both ”OK to lower” and ground follow LED’s are
illuminated and aerate #4 LED is not illuminated.
C. ”OK to lower”, ground follow, aerate #4 and head
high limit LED’s are all illuminated.
ProCore 648
Electrical System
Page 5 – 25
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Electric Clutch
An electric clutch is used to engage the coring head on
the ProCore 648. The electric clutch is mounted on the
engine crankshaft and engages when current is applied
to the clutch. The clutch also incorporates a magnetic
brake to stop clutch rotation when the clutch is de–ener-
gized.
8. As an additional test, apply 12 volts to the terminals
of the clutch. The clutch should engage. If clutch does
not engage when voltage is applied, replace clutch.
9. If clutch removal is necessary, see Electric Clutch in
the Service and Repairs section of this chapter.
10.Install exhaust system shield (see Exhaust System
Installation in the Service and Repairs section of Chapꢀ
ter 3 – Kohler Engine).
When the ”OK to lower” latching circuit is closed and the
coring head is lowered enough to close the aeration #3
proximity switch, the clutch relay will be energized. This
energized relay provides a current path to energize and
engage the clutch. See Electric Clutch Circuit in the Cirꢀ
cuit Operation section of this chapter for additional elecꢀ
tric clutch information.
11.Install pump belt cover to machine (see Operator’s
Manual).
Testing
1. Park machine on a level surface, fully raise coring
head, engage parking brake, stop engine and remove
key from the ignition switch. Secure coring head with
service latch.
1
1. Remove pump belt cover from machine (see Opera-
tor’s Manual).
2. Remove exhaust system shield (see Exhaust Sysꢀ
tem Removal in the Service and Repairs section of
Chapter 3 – Kohler Engine).
3. Locate electric clutch on engine crankshaft (Fig. 35).
Unplug machine wire harness connector from clutch.
Figure 35
1. Electric clutch
4. For accurate resistance measuring, clutch should be
o
o
at approximately 68 F (20 C) when coil resistance is
measured.
NOTE: Prior to taking small resistance readings with a
digital multimeter, short the meter test leads together.
The meter will display a small resistance value (usually
0.5 ohms or less). This resistance is due to the internal
resistance of the meter and test leads. Subtract this valꢀ
ue from from the measured value of the component you
are testing.
2
1
5. Using a multimeter (ohms setting), verify clutch coil
resistance between the two terminals of the clutch wire
connector. Coil resistance should be 1.75 to 1.93 ohms.
6. If coil resistance is incorrect, replace clutch.
Figure 36
7. Measure gap between clutch rotor and armature
(Fig. 36). Gap should be less than .125” (3.18 mm). This
gap is not adjustable and increases as clutch compoꢀ
nents wear. If gap exceeds .125” (3.18 mm), replace
clutch.
1. Electric clutch
2. Feeler gauge
Electrical System
ProCore 648
Page 5 – 26
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Diode Assemblies
Diodes D1, D2 and D3 provide logic for the latch relays
used in the ProCore 648. Diode D4 is used for circuit
protection from voltage spikes when the electric clutch
is de–energized. The diodes plug into the wiring harꢀ
ness at various locations (see Wire Harness Drawings
in Chapter 8 – Electrical Diagrams).
2
Diode Test
3
1
The diodes (Fig. 37) can be individually tested using a
digital multimeter (diode test or ohms setting) and the
table to the right.
Figure 37
1. Diode
2. Male terminal
3. Female terminal
Multimeter
Red Lead (+)
on Terminal
Multimeter
Black Lead (–)
on Terminal
Continuity
Female
Male
Male
YES
NO
Female
ProCore 648
Electrical System
Page 5 – 27
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Service and Repairs
NOTE: See the Kohler Engine Service Manual for enꢀ
gine component repair information.
Battery Storage
If the machine will be stored for more than 30 days:
4. Store battery in a cool atmosphere to avoid quick deꢀ
terioration of the battery charge.
1. Remove the battery and charge it fully (see Battery
Service).
5. To help prevent the battery from freezing, make sure
it is fully charged before storing the battery/machine
(see Battery Service).
2. Either store battery on a shelf or on the machine.
3. Leave cables disconnected if the battery is stored on
the machine.
Battery Care
1. Battery electrolyte level must be properly mainꢀ
tained. The top of the battery must be kept clean. lf the
machine is stored in a location where temperatures are
extremely high, the battery will discharge more rapidly
than if the machine is stored in a location where temperꢀ
atures are cool.
3. Battery cables must be tight on terminals to provide
good electrical contact.
WARNING
Connecting cables to the wrong battery post
could result in personal injury and/or damage
to the electrical system.
WARNING
Wear safety goggles and rubber gloves when
working with electrolyte. Charge battery in a
well ventilated place so gasses produced
while charging can dissipate. Since the gases
are explosive, keep open flames and electrical
sparks away from the battery; do not smoke.
Nausea may result if the gases are inhaled. Unꢀ
plug battery charger from electrical outlet beꢀ
fore connecting or disconnecting charger
leads to or from battery posts.
4. If corrosion occurs at terminals, disconnect cables.
Always disconnect negative (–) cable first. Clean
clamps and terminals separately. Reconnect cables
with positive (+) cable first. Coat battery posts and cable
connectors with Battery Terminal Protector (Toro Part
No. 107–0392) or petroleum jelly to prevent corrosion.
5. Check electrolyte level every 25 operating hours,
and every 30 days if machine is in storage.
6. Maintain cell electrolyte level with distilled or deminꢀ
eralized water. Do not fill cells above the fill line.
IMPORTANT: Do not remove battery filler caps
while cleaning battery.
2. Check battery condition weekly or after every 50
hours of operation. Keep terminals and entire battery
case clean because a dirty battery will discharge slowly.
A. Clean battery by washing entire case with a soluꢀ
tion of baking soda and water. Rinse with clear water.
B. Spray battery terminals with Battery Terminal
Protector (Toro Part No. 107–0392) to prevent cable
and terminal corrosion. Petroleum jelly can be used
as well.
Electrical System
ProCore 648
Page 5 – 28
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Battery Service
The battery is the heart of the electrical system. With
regular and proper service, battery life can be extended.
Additionally, battery and electrical component failure
can be prevented.
2
1
CAUTION
When working with batteries, use extreme cauꢀ
tion to avoid splashing or spilling electrolyte.
Electrolyte can destroy clothing and burn skin or
eyes. Always wear safety goggles and a face
shield when working with batteries.
Figure 38
1. Negative battery cable
2. Positive battery cable
Battery Specifications
BCI Group Size UI
300 CCA at 0 F (–18 C)
o
o
Inspection and Maintenance
o
o
Reserve Capacity of 28 minutes at 80 F (27 C)
1. Check for cracks in battery case. Replace battery if
cracked or leaking.
Dimensions (including terminal posts and handle)
Length
Width
Height
7.7 inches (19.6 cm)
5.2 inches (13.2 cm)
7.2 inches (18.3 cm)
2. Check battery terminal posts for corrosion. Use wire
brush to clean corrosion from posts.
Electrolyte Specific Gravity
o
o
Fully charged: 1.265 corrected to 80 F (26.7 C)
Discharged: less than 1.240
IMPORTANT: Before cleaning the battery, tape or
block vent holes to the filler caps and make sure the
caps are on tightly.
Removal and Installation (Fig. 38)
1. Loosen and remove negative (–) cable from battery.
After negative cable is removed, loosen and remove
positive (+) cable.
3. Check for signs of wetness or leakage on the top of
the battery which might indicate a loose or missing filler
cap, overcharging, loose terminal post or overfilling.
Also, check battery case for dirt and oil. Clean the batꢀ
tery with a solution of baking soda and water, then rinse
it with clean water.
2. Remove wing nuts and washers that secure battery
hold down rod. Slide hold down rod away from battery.
3. Carefully remove battery from machine.
4. Check that the cover seal is not broken away. Reꢀ
place the battery if the seal is broken or leaking.
4. Install battery in reverse order making sure to conꢀ
nect positive (+) cable to battery before connecting negꢀ
ative (–) cable.
5. Check the electrolyte level in each cell. If the level is
below the tops of the plates in any cell, fill all cells with
distilled water between the minimum and maximum fill
lines. Charge at 15 to 25 amps for 15 minutes to allow
sufficient mixing of the electrolyte.
NOTE: Before connecting the negative (ground) cable,
connect a digital multimeter (set to amps) between the
negative battery post and the negative (ground) cable
connector. The reading should be less than 0.1 amp. If
the reading is 0.1 amp or more, the machine’s electrical
system should be tested and repaired.
5. After battery cables have been connected to battery,
make sure that speed selector lever does not come withꢀ
in 1 inch (25.4 mm) of either battery cable when moved
through its entire range of motion. Also check that batꢀ
tery cables do not contact rotating screen on engine.
ProCore 648
Electrical System
Page 5 – 29
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Testing
2. If a battery load tester is not available, the battery can
be tested by conducting a hydrometer test of the battery
electrolyte.
1. To properly test a battery, perform a high–discharge
test using an adjustable load tester. This is one of the
most reliable means of testing a battery as it simulates
the cold–cranking test. A commercial battery load tester
is required to perform this test.
IMPORTANT: Make sure the area around the cells is
clean before opening the battery caps.
A. Measure the specific gravity of each cell with a
hydrometer. Draw electrolyte in and out of the
hydrometer barrel prior to taking a reading to warm–
up the hydrometer. At the same time take the temꢀ
perature of the cell.
CAUTION
Follow the manufacturer’s instructions when usꢀ
ing a battery load tester.
B. Temperature correct each cell reading. For each
o
o
o
o
10 F (5.5 C) above 80 F (26.7 C) add 0.004 to the
o
o
specific gravity reading. For each 10 F (5.5 C) beꢀ
A. Check the voltage across the battery terminals
prior to testing the battery. If the voltage is less than
12.4 VDC, recharge the battery.
o
o
low 80 F (26.7 C) subtract 0.004 from the specific
gravity reading.
o
Example: Cell Temperature
Cell Gravity
100 F
1.245
B. If the battery has been charged, apply a 150 amp
load for 15 seconds to remove the surface charge.
Use a battery load tester following the manufactur-
er’s instructions.
o
o
o
100 F minus 80 F equals 20 F
o
o
o
(37.7 C minus 26.7 C equals 11.0 C)
o
o
20 F multiply by 0.004/10 F equals 0.008
o
o
(11 C multiply by 0.004/5.5 C equals 0.008)
C. Make sure battery terminals are free of corrosion.
D. Measure the temperature of the center cell.
ADD (conversion above)
Correction to 80 F (26.7 C)
0.008
1.253
o
o
C. If the difference between the highest and lowest
cell specific gravity is 0.050 or greater or the lowest
cell specific gravity is less than 1.225, charge the batꢀ
tery. Charge at the recommended rate and time givꢀ
en in Charging or until all cells specific gravity is
1.225 or greater with the difference in specific gravity
between the highest and lowest cell less than 0.050.
If these charging conditions can not be met, replace
the battery.
E. Connect a battery load tester to the battery termiꢀ
nals following the manufacturer’s instructions.
Connect a digital multimeter to the battery terminals.
F. Apply a test load of one half the Cranking Perforꢀ
mance (see Battery Specifications) rating of the batꢀ
tery for 15 seconds.
G. Take a voltage reading at 15 seconds, then reꢀ
move the load.
H. Using the table below, determine the minimum
voltage for the cell temperature reading:
Minimum
Voltage
Battery Electrolyte
Temperature
o
o
9.6
9.5
9.4
9.3
9.1
8.9
8.7
8.5
70 F (and up)
21.1 C (and up)
o
o
60 F
15.6 C
o
o
50 F
10.0 C
o
o
40 F
4.4 C
o
o
30 F
–1.1 C
o
o
20 F
–6.7 C
o
o
10 F
–12.2 C
o
o
0 F
–17.8 C
I. If the test voltage is below the minimum, replace
the battery. If the test voltage is at or above the miniꢀ
mum, return the battery to service.
Electrical System
ProCore 648
Page 5 – 30
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Charging
CAUTION
To minimize possible damage to the battery and allow
the battery to be fully charged, the slow charging methꢀ
od is presented here. This charging method can be acꢀ
complished with a constant current battery charger
which is available in most shops.
Do not charge a frozen battery because it can exꢀ
plode and cause injury. Let the battery warm to
60 F (15.5 C) before connecting to a charger.
o
o
Charge the battery in a well–ventilated place to
dissipate gases produced from charging. These
gases are explosive; keep open flame and elecꢀ
trical spark away from the battery. Do not smoke.
Nausea may result if the gases are inhaled. Unꢀ
plug the charger from the electrical outlet before
connecting or disconnecting the charger leads
from the battery posts.
CAUTION
Follow the manufacturer’s instructions when usꢀ
ing a battery charger.
NOTE: Using specific gravity of the battery cells is the
most accurate method of determining battery condition.
3. Following the manufacturer’s instructions, conꢀ
nect the charger cables to the battery. Make sure a good
connection is made.
1. Determine the battery charge level from either its
specific gravity or open circuit voltage.
4. Charge the battery following the manufacturer’s
instructions.
Battery Charge
Level
Specific
Gravity
Open Circuit
Voltage
5. Occasionally check the temperature of the battery
100%
75%
50%
25%
0%
1.265
1.225
1.190
1.155
1.120
12.68
12.45
12.24
12.06
11.89
o
o
electrolyte. If the temperature exceeds 125 F (51.6 C)
or the electrolyte is violently gassing or spewing, the
charging rate must be lowered or temporarily stopped.
6. Three hours prior to the end of the charging, meaꢀ
sure the specific gravity of a battery cell once per hour.
The battery is fully charged when the cells are gassing
freely at a low charging rate and there is less than a
0.003 change in specific gravity for three consecutive
readings.
2. Determine the charging time and rate using the
manufacturer’s battery charger instructions or the
following table.
Battery
Reserve
Capacity
(Minutes)
Battery Charge Level
(Percent of Fully Charged)
75%
50%
25%
0%
80 or less 3.8 hrs
@
7.5 hrs 11.3 hrs 15 hrs
@
@
@
3 amps 3 amps 3 amps 3 amps
81 to 125 5.3 hrs 10.5 hrs 15.8 hrs 21 hrs
@
@
@
@
4 amps 4 amps 4 amps 4 amps
126 to
170
5.5 hrs
@
11 hrs
@
16.5 hrs 22 hrs
@
@
5 amps 5 amps 5 amps 5 amps
171 to
250
5.8 hrs 11.5 hrs 17.3 hrs 23 hrs
@
@
@
@
6 amps 6 amps 6 amps 6 amps
above
250
6 hrs
@
12 hrs
@
18 hrs
@
24 hrs
@
10 amps 10 amps 10 amps 10 amps
ProCore 648
Electrical System
Page 5 – 31
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Electric Clutch
13
14
15
16
FRONT
RIGHT
17
18
19
21
22
18
23
24
20
12
5
25
5
11
10
7
6
6
8
8
1
9
3
2
4
7
6
50 to 55 ft–lb
(67.8 to 74.6 N–m)
Figure 39
1. Drive belt
10. Clutch strap
11. Idler mounting bracket
12. Lock nut
13. Cap screw
14. Hardened washer
15. Idler pulley
16. Torsion spring
17. Spacer
18. Flange bushing
19. Pivot sleeve
20. Idler spacer
21. Washer
2. Electric clutch
3. Hardened washer
4. Cap screw
5. Flange nut
6. Flat washer
7. Brake grommet
8. Cap screw
9. Spacer
22. Idler arm
23. Flat washer
24. Cap screw
25. Flange nut
Electrical System
ProCore 648
Page 5 – 32
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Removal (Fig. 39)
1. Park machine on a level surface, fully raise coring
head, engage parking brake, stop engine and remove
key from the ignition switch. Secure coring head with
service latch.
1
2. Remove pump belt cover from machine (see Opera-
tor’s Manual).
4
5
3. Remove muffler heat shield (see Exhaust System in
the Service and Repairs section of Chapter 3 – Kohler
Engine).
2
4. Unplug wiring harness connector from clutch.
3
5. Remove primary drive belt (coring head) (see Primaꢀ
ry Drive Belt in the Service and Repairs section of Chapꢀ
ter 7 – Coring Head).
Figure 40
1. Electric clutch
2. Cap screw
3. Harness connector
4. Clutch strap
5. Hardened washer
6. Hold hardened washer with pliers to prevent engine
crankshaft from turning. Remove cap screw and hardꢀ
ened washer that secure clutch to engine crankshaft.
7. Slide clutch from engine crankshaft.
Installation (Fig. 39)
1. Apply antisieze lubricant to engine crankshaft. Align
clutch hub with engine crankshaft keyway and slide
clutch onto crankshaft.
2. Secure clutch to crankshaft with hardened washer
and cap screw. Hold hardened washer with pliers to preꢀ
vent crankshaft from turning and torque cap screw from
50 to 55 ft–lb (67.8 to 74.6 N–m).
3. Install primary drive belt (coring head) (see Primary
Drive Belt in the Service and Repairs section of Chapter
7 – Coring Head).
4. Plug wiring harness connector into clutch. Make sure
to secure wire harness away from rotating machine
components.
5. Install muffler heat shield (see Exhaust System in the
Service and Repairs section of Chapter 3 – Kohler Enꢀ
gine).
6. Install pump belt cover to machine (see Operator’s
Manual).
ProCore 648
Electrical System
Page 5 – 33
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Solenoid Valve Coil
A solenoid valve coil on the hydraulic lift control manifold
(Fig. 41) can be replaced without opening the hydraulic
system.
5 ft–lb
5 ft–lb
(6.8 N–m)
(6.8 N–m)
4
2
5
3
Removal
1
1. Park machine on a level surface, fully raise coring
head, engage parking brake, stop engine and remove
key from the ignition switch. Secure coring head with
service latch.
2. Disconnect the wiring harness electrical connector
from the solenoid coil to be replaced.
3. Remove the nut from the spool assembly.
4. Slide the coil assembly from the spool assembly. Dis-
card the coil assembly.
5. Clean any corrosion or dirt from the spool assembly.
Installation
1. Slide new coil assembly onto the spool assembly.
2. Install the nut onto the spool assembly and torque
nut 5 ft–lb (6.8 N–m) (do not over tighten).
Figure 41
1. Solenoid valve coil (SVL)
2. Solenoid valve coil (SVQ)
3. Solenoid valve coil (SVR)
4. Nut
5. Nut
3. Connect the solenoid coil to the machine wiring har-
ness.
Electrical System
ProCore 648
Page 5 – 34
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Chapter 6
Chassis
Table of Contents
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 4
Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Parking Brake Cable . . . . . . . . . . . . . . . . . . . . . . . . 8
Steering Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 10
Traction Control Cable . . . . . . . . . . . . . . . . . . . . . . 12
ProCore 648
Page 6 – 1
Chassis
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Specifications
Item
Description
Front and Rear Tires
Size
Pressure
19 x 10.5 – 8, 2 Ply, Tubeless
12 PSI (.83 Bar)
Wheel lug nut torque
Wheel hub nut torque
45 to 55 ft–lb (61 to 75 N–m)
190 to 230 ft–lb (258 to 312 N–m)
Chassis
Page 6 – 2
ProCore 648
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Special Tools
Order special tools from your Toro Distributor.
Wheel Hub Puller
Part Number: TOR4097
The wheel hub puller allows safe removal of the wheel
hub from the shaft of wheel motors.
Figure 1
Rev. C
ProCore 648
Page 6 -- 3
Chassis
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Service and Repairs
Wheels
12
11
10
1
9
8
2
45 to 55 ft–lb
(61 to 75 N–m)
9
3
8
1
4
12
10
5
6
7
RIGHT
4
5
FRONT
45 to 55 ft–lb
(61 to 75 N–m)
6
2
Figure 2
1. Tire and wheel assembly
2. Lug nut
3. Front wheel weight
4. Wheel weight adapter
5. Weight stud
6. Thrust washer
7. Lock nut
9. Lock nut
10. Wheel hub
11. Parking latch disc
12. Wheel stud
8. Bearing plate
Chassis
Page 6 – 4
ProCore 648
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Wheel Removal (Fig. 2)
2. If front wheel was removed:
1. Park machine on a level surface, fully raise coring
head, engage parking brake, stop engine and remove
key from the ignition switch. Secure coring head with
service latch.
A. If weight studs were removed from wheel weight
adapters, thread studs fully into the correct end of the
adapter (Fig. 3).
B. Position front wheel to wheel hub.
2. Jack machine from ground and support machine
with blocking or jack stands (see Operator’s Manual and
Jacking Instructions in Chapter 1 – Safety).
C. Secure wheel to machine with two (2) lug nuts
and two (2) wheel weight adapters. Torque wheel
fasteners from 45 to 55 ft–lb (61 to 75 N–m).
3. If rear wheel is to be removed:
A. Loosen and remove four (4) lug nuts from wheel
to be removed.
CAUTION
B. Pull wheel from machine.
To prevent personal injury, make sure that
wheel weight is supported as it is installed to
the machine. Wheel weight weighs approxiꢀ
mately 73 pounds (33.1 kg).
4. If front wheel is to be removed:
A. Remove two (2) lock nuts and thrust washers that
secure wheel weight to wheel.
D. Carefully slide wheel weight to wheel.
E. Secure wheel weight with two (2) thrust washers
and lock nuts.
CAUTION
3. Lower machine to ground. Remove service latch
from coring head before machine use.
To prevent personal injury, make sure that
wheel weight is supported as it is removed
from the machine. Wheel weight weighs
approximately 73 pounds (33.1 kg).
B. Carefully slide wheel weight from weight studs.
C. Loosen and remove two (2) lug nuts and two (2)
wheel weight adapters with weight studs.
D. Pull wheel from machine.
Wheel Installation (Fig. 2)
WHEEL STUD
WEIGHT STUD
(.500–20 UNF–2B)
(.500–13 UNC–2B)
1. If rear wheel was removed:
A. Position rear wheel to wheel hub.
Figure 3
B. Secure wheel to machine with four (4) lug nuts.
Torque lug nuts from 45 to 55 ft–lb (61 to 75 N–m).
ProCore 648
Page 6 – 5
Chassis
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Parking Brake
3
6
7
1
2
4
5
5
2
10
190 to 230 ft–lb
(258 to 312 N–m)
8
9
9
3
22
45 to 55 ft–lb
(61 to 75 N–m)
20
9
11
12
14
13
21
19
18
RIGHT
15
17
16
FRONT
Figure 4
1. Extension spring
2. Bushing
3. Retaining ring
9. Hair pin
10. Parking latch link
11. Roll pin
16. Bearing plate
17. Wheel hub
18. Parking latch disc
4. Parking latch pivot
5. Flange nut
12. Parking latch bar
13. Lock nut
14. Tire and wheel assembly
15. Lug nut (4 used per wheel)
19. Drive stud (4 used per wheel)
20. Woodruff key
21. Parking brake cable
22. Clevis pin
6. Shoulder bolt
7. Compression spring
8. Parking latch clevis
Chassis
Page 6 – 6
ProCore 648
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Removal (Fig. 4)
Installation (Fig. 4)
1. Park machine on a level surface, fully raise coring
head, stop engine and remove key from the ignition
switch. Secure coring head with service latch.
CAUTION
2. Make sure parking brake is disengaged.
Be careful when installing extension spring to
parking latch pivot. The spring is under heavy
load and may cause personal injury.
3. Block front wheel. Jack or hoist rear of machine from
ground and support machine with blocking or jack
stands (see Operator’s Manual and Jacking Instructions
in Chapter 1 – Safety).
1. Install removed parking brake components using
Figure 4 as a guide.
4. Remove rear wheel assembly (see Wheel Removal
in this section).
2. If wheel hub assembly was removed:
A. Make sure that wheel studs are installed through
parking latch disc, wheel hub and bearing plate.
CAUTION
B. Make sure that wheel motor shaft and wheel hub
taper are thoroughly cleaned.
Be careful when removing extension spring from
parking latch pivot. The spring is under heavy
load and may cause personal injury.
C. Position woodruff key into wheel motor shaft.
D. Install wheel hub assembly to wheel motor shaft
and secure with nut. Torque nut from 190 to 230 ft–lb
(258 to 312 N–m).
5. Remove parking brake components as needed usꢀ
ing Figure 4 as a guide.
3. Install wheel assembly (see Wheel Installation in this
section).
6. If parking latch disc requires removal:
A. Loosen, but do not remove, nut that secures
wheel hub to wheel motor shaft.
4. Lower machine to ground. Remove service latch
from coring head before machine use.
IMPORTANT: To prevent damage to hydraulic motor,
DO NOT hit wheel hub or motor with a hammer durꢀ
ing wheel hub removal or installation.
B. Loosen wheel hub assembly from motor shaft usꢀ
ing wheel hub puller (see Special Tools). Once wheel
hub is loose on shaft, remove nut and wheel hub from
motor shaft. Locate and retrieve woodruff key from
motor shaft.
C. Remove wheel studs to allow separation of parkꢀ
ing latch disc, wheel hub and bearing plate.
7. Clean all parts. Inspect parking latch bar and parking
latch disc for excessive wear or damage. Replace any
damaged parts.
ProCore 648
Page 6 – 7
Chassis
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Parking Brake Cable
14
1
2
3
13
12
5
11
10
6
9
RIGHT
FRONT
8
4
7
Figure 5
1. Control handle
2. Grommet
3. Steering arm
4. Lower handle cover
6. Flange nut
7. Brake cable
8. Flat washer
9. Cotter pin
10. Brake lever
11. Bushing
12. Brake spacer
13. Cap screw
14. Knob
5. Washer head screw (6 used)
Chassis
Page 6 – 8
ProCore 648
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Removal (Fig. 3)
1. Park machine on a level surface, fully raise coring
head, stop engine and remove key from the ignition
switch. Secure coring head with service latch. Make
sure that parking brake is not engaged.
5
2. Remove six (6) washer head screws that secure low-
er handle cover to control handle. Remove lower handle
cover.
3. Loosen jam nut that secures parking brake cable to
underside of control handle.
4. Remove cotter pin and flat washer that retain brake
cable to brake lever. Slide brake cable from brake lever.
4
2
3
1
5. Remove brake cable from parking latch pivot on rear
cross tube of frame (Fig. 6):
A. Remove hairpin and clevis pin that secure park-
ing brake cable clevis to parking latch pivot.
Figure 6
1. Brake cable
2. Retaining ring
3. Hairpin
4. Clevis pin
5. Parking latch pivot
B. Remove retaining ring that secures brake cable
to rear cross tube of frame.
6. Note routing of parking brake cable. Remove parking
brake cable from machine.
Installation (Fig. 3)
1. Position new parking brake cable to machine noting
original routing.
2. Secure brake cable to parking latch pivot on rear
cross tube of frame (Fig. 6):
A. Position parking brake cable clevis to parking
latch pivot and secure with clevis pin and hairpin.
B. Secure brake cable to rear cross tube of frame
with retaining ring.
3. Position brake cable end to parking brake lever. Se-
cure cable to lever with flat washer and cotter pin.
4. Secure parking brake cable to underside of control
handle with jam nuts.
5. Position lower handle cover to control handle and se-
cure with six (6) washer head screws.
6. Make sure that steering components do not contact
cables or wire harness.
7. Remove service latch from coring head before ma-
chine use.
ProCore 648
Page 6 – 9
Chassis
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Steering Assembly
36
5
35
6
34
37
7
8
33
4
32
31
1
9
10
3
11
2
30
19
12
26
22
18
4
29
28
27
8
20
15
13
26
25
7
24
17
14
RIGHT
23
22
FRONT
21
16
Figure 7
1. Grommet
14. Steering spindle
15. Lock nut (3 used)
16. Lock nut (4 used)
17. Wheel motor
26. Lock nut
27. Spacer
2. Stud (3 used)
3. Steering arm
4. Cap screw (5 used)
5. Slotted hex nut
6. Washer
28. Ball joint
29. Flat washer
30. Cap screw
18. Cap screw (4 used)
19. Washer head screw (6 used)
20. Lower handle cover
21. Traction control cable
22. Jam nut
23. Spring retainer
24. Compression spring
25. Override rod
31. Control handle
7. Bearing cone
8. Bearing cup
9. Frame
10. Steering stop
11. Cap screw (2 used)
12. Cable guide
13. Cotter pin
32. Neutral proximity switch
33. Reverse proximity switch
34. Relay (neutral and latching)
35. Low oil pressure light
36. Raise/lower switch
37. Handle control cover
Chassis
Page 6 – 10
ProCore 648
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Disassembly (Fig. 7)
E. Remove lock nut and cap screw that secure tracꢀ
tion control cable to control lever. Locate and retrieve
two (2) flat washers. Loosen jam nut that secures
parking brake cable to underside of control handle.
1. Park machine on a level surface, fully raise coring
head, engage parking brake, stop engine and remove
key from the ignition switch. Secure coring head with
service latch.
11.Inspect bearing cups and cones for wear or damage.
Replace worn or damaged components.
2. Block rear wheels. Jack front of machine from
ground and support machine with blocking or jack
stands (see Operator’s Manual and Jacking Instructions
in Chapter 1 – Safety).
Assembly (Fig. 7)
1. If removed, secure steering spindle to steering arm
with four (4) cap screws.
3. Remove front wheel assembly (see Wheel Removal
in this section).
2. If bearing cups were removed from frame, install new
cups to frame.
4. Remove front wheel motor (see Wheel Motor Reꢀ
moval in Service and Repairs section of Chapter 4 – Hyꢀ
draulic System).
3. Install steering arm to frame:
A. Pack bearing cones with grease. Position lower
bearing on steering spindle shaft.
5. Remove fuel tank from machine (see Fuel Tank Reꢀ
moval in Service and Repairs section of Chapter 3 –
Kohler Engine).
B. Slide steering shaft up through frame. Position
upper bearing and washer on steering spindle shaft.
6. Remove two (2) cap screws that secure cable guide
to steering arm. Position cables and wire harness away
from steering arm.
C. Install slotted hex nut onto steering spindle, tightꢀ
en completely and then back nut off slightly. Retighꢀ
ten nut until drag is felt while rotating steering arm.
Back–off nut to align spindle shaft hole with slotted
hex nut. Make sure that steering arm rotates freely
after slotted hex nut has been tightened.
7. Support control handle. Remove three (3) lock nuts
that secure control handle to steering arm. Slide control
handle from steering arm taking care to not damage
control cables or wiring harness that will stay attached
to machine. Position handle away from steering arm.
D. Insert cotter pin through slotted hex nut and
steering spindle shaft.
8. Support steering arm. Remove cotter pin and slotted
hex nut from upper end of steering spindle. Lower steerꢀ
ing arm from frame.
4. Assemble steering components in the reverse order
of disassembly using Figure 7 as a guide.
5. Lower machine to ground. Remove service latch
from coring head before machine use.
9. If necessary, remove steering spindle from steering
arm.
6. Make sure that steering components do not contact
cables or wire harness.
10.If necessary, remove control handle from machine:
A. Remove six (6) washer head screws that secure
lower handle cover to control handle. Remove lower
handle cover.
1
2
1
3
B. Remove four (4) screws that secure handle conꢀ
trol cover to control handle. Unplug harness connecꢀ
tors from low oil pressure light and raise lower switch
on cover.
C. Unplug harness connectors from neutral relay,
latching relay, neutral proximity switch and reverse
proximity switch on control handle.
D. Disconnect parking brake cable from brake lever
(see Parking Brake Cable Removal in this section).
Figure 8
1. Relay
2. Reverse prox switch
3. Neutral prox switch
ProCore 648
Page 6 – 11
Chassis
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Traction Control Cable
Removal
7
8
1. Remove traction control cable from hydraulic pump
control (Fig. 10) and traction lever on handle and (Fig.
11).
2
2
1
2. Remove traction control cable from machine noting
routing of cable to aid in correct installation.
6
5
3. Disassemble traction control cable using Figure 9 as
a guide.
4
1
Installation
3
1. Assemble traction control cable using Figure 9 as a
guide. Tighten lock nuts (item 6) so that compression
spring (item 4) has a length from 6.750” to 6.880” (17.2
to 17.4 cm).
2
Figure 9
2. Route traction control cable from traction lever on
handle to pump control noting original routing.
1. Traction control cable
2. Jam nut
5. Override rod
6. Lock nut
3. Spring retainer
4. Compression spring
7. Ball joint (traction lever)
8. Ball joint (pump lever)
3. After assembly, make sure that steering components
do not contact traction cable.
4. Check and adjust traction drive for neutral (see Op-
erator’s Manual).
1
3
2
Figure 10
1. Pump control
3. Cable ball joint
2. Traction control cable
1
2
Figure 11
1. Traction lever
2. Cable ball joint
Rev. B
Chassis
Page 6 – 12
ProCore 648
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Chapter 7
Coring Head
Table of Contents
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 2
Coring Head Operation . . . . . . . . . . . . . . . . . . . . . . . 2
Coring Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Coring Head Service Latch . . . . . . . . . . . . . . . . . . . . 3
Coring Head Adjustments . . . . . . . . . . . . . . . . . . . . . 3
SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 4
Rotolink Dampers . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Stomper Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Coring Crankshaft Bearing Housings . . . . . . . . . . . 8
Primary Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Secondary Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . 12
Coring Head Drive Jackshaft . . . . . . . . . . . . . . . . . 14
Coring Head Pivot (H–Frame) . . . . . . . . . . . . . . . . 16
ProCore 648
Page 7 – 1
Coring Head
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General Information
Coring Head Operation
The coring head of the Procore 648 consists of a frame
that pivots for aerating depth control, a coring crankꢀ
shaft, stomper arms with rotolinks to provide vertical tine
motion, turf holders, tine holders and aerating tines.
Drive for the coring head comes from the engine
mounted electric clutch through a primary and seconꢀ
dary drive belt. The primary drive belt drives a jackshaft
which in turn drives the coring crankshaft with the seconꢀ
dary drive belt. Each of these drive belts is tensioned by
a spring loaded idler pulley.
The coring crankshaft is composed of multiple crankꢀ
arms, bearings, bearing housings and couplings. For
assembly purposes, proper component position is idenꢀ
tified by alignment marks on bearing housings and numꢀ
bers cast into crankarms. Crankshaft journals are timed
to ensure minimal vibration.
Figure 1
Aerating depth control is based on tine choice and hanꢀ
dled automatically by the TrueCoreTM ground following
system. Manual depth control aeration can be perꢀ
formed by turning the TrueCoreTM System off and adꢀ
justing the coring head manual spacers to obtain the
desired aerating depth (1/2” increments).
Turf holders are used to prevent damage to the turf as
the tines are lifted from the ground. Turf holders also
provide inputs for the TrueCoreTM ground following sysꢀ
tem.
A variety of tines, tine heads and turf holders are availꢀ
able for use on the ProCore 648. See the Operator’s
Manual for available options.
Coring Crankshaft
The coring crankshaft assembly is composed of six (6)
crankarms. One of the crankarms is incorporated into
the crankshaft pulley. The crankarms need to be timed
for proper aerating operation. For assembly purposes,
crankshaft positions are identified as #1 through #6. The
#1 position is on the right (pulley) side of the crankshaft
(Fig. 2). The crankshaft position is cast into the
crankarms to assist in correct crankshaft assembly.
The crankshaft assembly is supported with three identiꢀ
cal bearing housing assemblies. The six stomper arms
and rotolink dampers used on the ProCore 648 are the
same for all positions.
2
1
Figure 2
1. #1 position
2. #6 position
Coring Head
Page 7 – 2
ProCore 648
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Coring Head Service Latch
Whenever service is to be performed on coring head
components, fully raise coring head and install service
latch (Fig. 3).
Before using machine, remove service latch from coring
head.
1
Figure 3
1. Service latch (in raised, locked position)
Coring Head Adjustments
See Operator’s Manual for adjustment procedures for
the coring head on the ProCore 648.
CAUTION
Never work on the coring head with the engine
running. Always fully raise coring head, stop enꢀ
gine, remove key from the ignition switch and
install the coring head service latch before perꢀ
forming any service to coring head components.
ProCore 648
Page 7 – 3
Coring Head
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Service and Repairs
Rotolink Dampers
FRONT
RIGHT
4
1
2
3
17
12
13
9
13
10
11
10
12
16
15
5
9
16
150 to 170 ft–lb
(203 to 230 N–m)
8
14
7
6
10
Figure 4
1. Lock nut
7. Lock nut
13. Cap screw
2. Hardened D washer
3. Flange head screw
4. Stud
8. Hardened washer
9. Damper link
10. Bearing
14. Rubber bumper
15. Rotolink damper
16. Damper standoff
17. Damper top spacer
5. Bumper plate
6. Cap screw
11. Stomper arm
12. Flange nut
NOTE: The rotolink damper assemblies for all stomper
arms used on the ProCore 648 are identical.
Coring Head
Page 7 – 4
ProCore 648
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Disassembly (Fig. 4)
Assembly (Fig. 4)
1. Park machine on a level surface, fully raise coring
head, engage parking brake, stop engine and remove
key from the ignition switch. Secure coring head with
service latch.
1. If studs (item 4) were removed from damper (item
15), thread stud fully into damper.
2. If bearings were removed from damper links, press
new bearings into links.
2. Remove rotolink components as needed using Figꢀ
ure 4 as a guide.
3. Assemble all components before fully tightening any
fasteners so there is no preload on rotolink damper comꢀ
ponents. Tighten fasteners in the following order:
A. Secure damper links (item 9) to stomper arm
(item 11) and damper (item 15). Torque lock nuts
(item 7) from 150 to 170 ft–lb (203 to 230 N–m).
B. Tighten two (2) flange nuts (item 12) that secure
damper links.
C. Tighten two (2) lock nuts (item 1) that secure
damper to frame.
4. After assembly, rotate coring crankshaft by hand to
make sure that no binding occurs.
NOTE: If using longer, solid tines, damper top spacer
(item 17) might not be installed (see Operator’s Manuꢀ
al).
5. If damper standoff (item 16) and top spacer (item 16)
are both installed on rotolink damper, rubber bumpers
(item 16) should contact bumper plates (item 5). If only
damper standoff (item 16) is used, rubber bumpers
should contact frame (bumper plates moved forward).
6. Remove service latch from coring head before using
machine.
ProCore 648
Page 7 – 5
Coring Head
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Stomper Arms
3
1
150 to 170 ft–lb
(203 to 230 N–m)
2
FRONT
RIGHT
12
2
3
11
10
5
6
4
9
8
150 to 170 ft–lb
(203 to 230 N–m)
5
4
7
3
ANTISIEZE
LUBRICANT
2
6
STOMPER ARMS #1 AND #2 SHOWN
Figure 5
1. Coring frame
2. Cap screw
3. Flat washer
4. Retaining ring
5. Ball bearing
6. Stomper arm
7. Pulley
9. Crankarm
10. Square key
11. Coupling
8. Bearing housing
12. Spacer tube
NOTE: The six (6) stomper arms used on the ProCore
648 are identical. Coring crankshaft positions are identi-
fied as #1 through #6. The #1 position is on the right
(pulley) side of the coring crankshaft (Fig. 6).
2
1
Figure 6
1. #1 position
2. #6 position
Coring Head
Page 7 – 6
ProCore 648
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Removal (Fig. 5)
Installation (Fig. 5 and 7)
1. Park machine on a level surface, fully raise coring
head, engage parking brake, stop engine and remove
key from the ignition switch. Secure coring head with
service latch.
1. If removed, install ball bearing into upper end of
stomper arm and secure with retaining ring.
2. Install any rotolink damper components that were reꢀ
moved during disassembly (see Rotolink Dampers in
this section).
2. Remove rear hood (see Operator’s Manual).
3. Remove two (2) lock nuts and hardened D washers
that secure rotolink damper to coring head frame (see
Rotolink Dampers in this section).
3. Thoroughly apply antisieze lubricant to stomper arm
shaft surface on coring crankshaft.
4. Raise stomper arm assembly up through frame.
Slide stomper arm bearing onto coring crankshaft.
4. If outside stomper arm (#1 or #6) is to be removed:
A. If #1 stomper arm is being removed, remove secꢀ
ondary coring head drive belt (see Secondary Drive
Belt Removal in this section).
5. Secure stomper arm to coring crankshaft in the reꢀ
verse order of disassembly.
A. Torque 5/8” cap screws from 150 to 170 ft–lb (203
to 230 N–m).
B. Remove cap screw and flat washer that retain
stomper arm to coring crankshaft.
B. Torque 1/2” cap screws from 70 to 80 ft–lb (95 to
108 N–m).
C. If #6 stomper arm is being removed, remove
spacer tube (item 12) from coring crankshaft.
6. Secure rotolink damper to coring head frame with
lock nut and hardened D washer (see Rotolink Dampers
in this section).
D. Support stomper arm assembly to prevent it from
falling during removal. Slide stomper arm from corꢀ
ing crankshaft. Carefully, lower stomper arm assemꢀ
bly from frame.
7. After assembly, rotate coring crankshaft by hand to
make sure that no binding occurs.
5. If inside stomper arm (#2, #3, #4 or #5) is to be reꢀ
moved:
8. If removed, install tine holders and tines to stomper
arm (see Operator’s Manual).
A. Remove fasteners that secure coupling plate to
coupling on stomper to be removed (Fig. 7).
9. If removed, install secondary coring head drive belt
(see Secondary Drive Belt Installation in this section).
B. Remove cap screw and flat washer that secures
coupling and stomper arm to coring crankshaft.
10.Install rear hood (see Operator’s Manual). Disenꢀ
gage service latch before machine use.
C. Slide coupling from coring crankshaft. Locate
and retrieve square key.
1
150 to 170 ft–lb
(203 to 230 N–m)
D. Support stomper arm assembly to prevent it from
falling during removal. Slide stomper arm from corꢀ
ing crankshaft. Carefully, lower stomper arm assemꢀ
bly from frame.
2
4
3
8
7
6. If necessary, remove retaining ring and ball bearing
from stomper arm.
7. If necessary, remove tines and tine holders from
stomper arm (see Operator’s Manual).
6
8. Remove rotolink damper components as needed
(see Rotolink Dampers in this section).
5
70 to 80 ft–lb
(95 to 108 N–m)
Figure 7
1. Coupling (#3 shown)
2. Iso mount (2 used)
3. Coupling (#2 shown)
4. Cap screw (2 used)
5. Coupling plate
6. Cap screw (4 used)
7. Lock nut (2 used)
8. Flat washer (2 used)
ProCore 648
Page 7 – 7
Coring Head
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Coring Crankshaft Bearing Housings
70 to 80 ft–lb
(95 to 108 N–m)
23
150 to 170 ft–lb
(203 to 230 N–m)
21
FRONT
RIGHT
24
7
1
21
20
5
22
150 to 170 ft–lb
(203 to 230 N–m)
2
8
3
150 to 170 ft–lb
(203 to 230 N–m)
11
1
2
6
4
70 to 80 ft–lb
(95 to 108 N–m)
8
9
10
17
16
12
ANTISIEZE
LUBRICANT
18
ANTISIEZE
LUBRICANT
5
4
6
13
2
1
14
14
2
2
15
16
BEARING HOUSING FOR #5 AND #6
STOMPER ARMS SHOWN
150 to 170 ft–lb
(203 to 230 N–m)
19
18
Figure 8
1. Cap screw
2. Flat washer
3. Spacer tube
4. Stomper arm
5. Ball bearing
6. Retaining ring
7. Crankarm
9. Bearing housing
10. Spacer
17. Cap screw (4 used per plate)
18. Cap screw
11. Crankarm
19. Coupling
12. Square key
13. Coupling (#5 shown)
14. Lock nut
15. Coupling plate
16. Iso mount
20. Cap screw (4 used per housing)
21. Hardened washer
22. Spring pin (2 used per housing)
23. Lock nut
24. Coring head frame
8. Ball bearing
NOTE: The three (3) bearing housings used on the Pro-
Core 648 are identical. Coring crankshaft positions are
identified as #1 through #6. The #1 position is on the
right (pulley) side of the coring crankshaft.
3. If bearing housing for #1 and #2 stomper arms is to
be removed, remove secondary coring head drive belt
(see Secondary Drive Belt Removal in this section).
4. Remove stomper arms on either side of bearing
housing that is to be removed (see Stomper Arm Re-
moval in this section).
Removal (Fig. 8)
1. Park machine on a level surface, fully raise coring
head, engage parking brake, stop engine and remove
key from the ignition switch. Secure coring head with
service latch.
5. Drive Spring pins from bearing housing and coring
head frame.
6. Support bearing housing assembly to prevent it from
falling. Remove fasteners that secure bearing housing
assembly to coring head frame. Remove bearing hous-
ing assembly.
2. Remove rear hood (see Operator’s Manual).
Coring Head
Page 7 – 8
ProCore 648
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7. Disassemble bearing housing assembly:
D. Lock nuts that secure rotolink dampers to frame
(see Rotolink Damper Installation in this section).
A. Remove cap screw (item 1) and flat washer (item
2) that fasten crankarms together. Take note of align-
ment of identification number on crankarm with tim-
ing mark on bearing housing (Fig. 9).
9. After assembly, rotate coring crankshaft by hand to
make sure that no binding occurs.
10.If removed, install secondary coring head drive belt
(see Secondary Drive Belt Installation in this section).
B. Slide crankarms from bearing housing.
C. If necessary, remove bearings and spacer from
bearing housing.
11.Install rear hood (see Operator’s Manual). Disen-
gage service latch before machine use.
Installation (Fig. 8)
2
1. Install new bearings if they were removed from hous-
ing:
A. Install new bearing in one side of housing by
pressing on outer race of bearing.
1
B. Position spacer into bearing housing.
2
C. Install second new bearing by pressing on outer
race of bearing. Make sure that spacer is centered
between bearings.
2. Thoroughly apply antisieze lubricant to splines of
crankarms.
Figure 9
3. Install crankarms into bearing housing. Make sure
that correct identification number on crankarm is aligned
with timing mark on bearing housing (Fig. 9).
1. Housing timing mark
2. Crankarm position
1
150 to 170 ft–lb
(203 to 230 N–m)
4. Install cap screw (item 1) and flat washer (item 2) to
retain crankarms. Do not fully tighten cap screw.
5. Drive new spring pins into coring head frame holes.
2
4
3
6. Position bearing housing assembly to coring head
frame and secure with four (4) cap screws, eight (8)
hardened washers and four (4) lock nuts. Torque fasten-
ers from 70 to 80 ft–lb (95 to 108 N–m).
8
7
7. Install stomper arms to crankarms on either side of
bearing housing (see Stomper Arm Installation in this
section). Do not fully tighten fasteners.
6
5
NOTE: With #1 crankarm aligned with cast mark on
bearing housing, all subsequent crankarm cast timing
numbers must be in line from 1 to 6.
70 to 80 ft–lb
(95 to 108 N–m)
Figure 10
8. Once all components have been installed, fully tight-
en fasteners in the following order. Tighten fasteners to
the torque specifications identified in Figures 8 and 10:
1. Coupling (#3 shown)
2. Iso mount (2 used)
3. Coupling (#2 shown)
4. Cap screw (2 used)
5. Coupling plate
6. Cap screw (4 used)
7. Lock nut (2 used)
8. Flat washer (2 used)
A. Cap screws that fasten crankarms.
B. Cap screws that secure top and bottom of stomp-
er arms.
C. Cap screws that secure coupling plates (Fig. 10).
ProCore 648
Page 7 – 9
Coring Head
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Primary Drive Belt
13
14
15
16
FRONT
RIGHT
17
18
19
21
22
18
23
24
20
12
5
25
5
11
10
7
6
6
8
8
1
9
3
2
4
7
6
50 to 55 ft–lb
(67.8 to 74.6 N–m)
Figure 11
1. Primary drive belt
2. Electric clutch
3. Hardened washer
4. Cap screw
10. Clutch strap
11. Idler mounting bracket
12. Lock nut
13. Cap screw
14. Hardened washer
15. Idler pulley
16. Torsion spring
17. Spacer
18. Flange bushing
19. Pivot sleeve
20. Idler spacer
21. Washer
5. Flange nut
22. Idler arm
6. Flat washer
7. Brake grommet
8. Cap screw
23. Flat washer
24. Cap screw
25. Flange nut
9. Spacer
Coring Head
Page 7 – 10
ProCore 648
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Removal (Fig. 11)
Installation (Fig. 11)
1. Park machine on a level surface, fully raise coring
head, engage parking brake, stop engine and remove
key from the ignition switch. Secure coring head with
service latch.
1. Position drive belt to machine pulleys. Make sure
that belt is routed under idler pulley.
2. Position clutch strap (item 10) to clutch and secure
with cap screw (item 8), flat washers (item 6) and flange
nut (item 5).
2. Remove belt cover (see Operator’s Manual).
3. Remove exhaust system shield (see Exhaust Sysꢀ
tem Removal in the Service and Repairs section of
Chapter 3 – Kohler Engine).
3. Plug machine wire harness connector into clutch.
CAUTION
4. Insert nut driver or small piece of pipe onto the end
of the torsion spring (item 16) of the idler pulley.
Be careful when removing or applying tension
from or to the torsion spring of the idler pulley.
The spring is under heavy load and may cause
personal injury.
CAUTION
Be careful when removing or applying tension
from or to the torsion spring of the idler pulley.
The spring is under heavy load and may cause
personal injury.
4. Insert nut driver or small piece of pipe onto the end
of the torsion spring (item 16) of the idler pulley. Push
down on the spring end and hook the spring on the idler
mounting bracket to tension the idler pulley.
5. Push down on the spring end and unhook the spring
from the idler mounting bracket.
5. Install exhaust system shield (see Exhaust System
Installation in the Service and Repairs section of Chapꢀ
ter 3 – Kohler Engine).
6. Loosen and remove cap screw (item 8), flat washers
(item 6) and flange nut (item 5) that secure clutch strap
(item 10) to clutch. Position clutch strap away from
clutch.
6. Install belt cover (see Operator’s Manual).
7. Remove service latch from coring head before using
machine.
7. Unplug machine wire harness connector from clutch.
8. Remove primary drive belt from pulleys and maꢀ
chine.
ProCore 648
Page 7 – 11
Coring Head
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Secondary Drive Belt
5
8
7
6
5
9
10
4
3
11
12
2
13
1
14
FRONT
RIGHT
15
Figure 12
1. Secondary drive belt
2. Cap screw
3. Secondary pulley
4. Cap screw
5. Flange bushing
6. Idler pulley
7. Idler pivot tube
8. Idler arm
9. Lock nut
10. Carriage screw (2 used)
11. Flange nut (2 used)
12. Idler spring arm
13. Extension spring (2 used)
14. Coring crankshaft pulley
15. #1 stomper arm
Removal (Fig. 12)
3
1. Park machine on a level surface, fully raise coring
head, engage parking brake, stop engine and remove
key from the ignition switch. Secure coring head with
service latch.
1
2
2. Remove belt cover and rear hood from machine (see
Operator’s Manual).
4
CAUTION
Figure 13
Be careful when lifting the idler pulley. The idler
pulley is spring loaded and may cause personal
injury.
1. Extension springs
2. Spring arm
3. Upper flange nut
4. 1/2” drive hole
Coring Head
Page 7 – 12
ProCore 648
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NOTE: If desired, extension spring tension can be reꢀ
moved from idler pulley by loosening two (2) flange nuts
that secure spring arm to frame. Use 1/2” drive breaker
bar inserted into spring arm to hold arm, remove upper
carriage screw and flange nut and rotate spring arm to
relax spring (Fig. 13).
2
1
3. Lift idler pulley to release tension on secondary drive
belt (Fig. 14). While holding idler away from belt, remove
belt from secondary drive pulley. Carefully lower idler
pulley.
3
4. Loosen and remove two (2) lock nuts and hardened
D washers that secure rotolink damper for #1 stomper
arm (see Rotolink Damper Removal in this section).
Lower rotolink damper from coring head frame.
Figure 14
1. Secondary drive pulley
2. Idler pulley
3. Secondary drive belt
5. Remove secondary drive belt from coring crankshaft
pulley.
2
6. Route drive belt down through coring head frame
and around lower end of #1 stomper arm to remove secꢀ
ondary drive belt from machine (Fig. 15 and 16).
1
Installation (Fig. 12)
1. Route secondary drive belt around lower end of #1
stomper arm and up through coring head frame (Fig. 15
and 16).
2. Position drive belt to coring crankshaft pulley.
3. Lift idler pulley to allow installation of belt to seconꢀ
dary drive pulley (Fig. 14). Carefully lower idler pulley to
tension drive belt.
Figure 15
1. Secondary drive belt
2. #1 stomper arm
4. Raise rotolink damper for #1 stomper arm to coring
head frame. Make sure that damper standoff and top
spacer are on damper studs. Secure damper to coring
head frame with two (2) hardened D washers and lock
nuts (see Rotolink Damper Installation in this section).
2
5. Install belt cover and rear hood to machine (see Op-
erator’s Manual).
6. Remove service latch from coring head before using
machine.
1
Figure 16
1. Secondary drive belt
2. #1 rotolink damper
ProCore 648
Page 7 – 13
Coring Head
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Coring Head Drive Jackshaft
6
5
7
6
8
10
9
9
8
4
3
2
11
11
1
12
5
10
13
2
3
12
4
14
15
FRONT
RIGHT
Figure 17
1. Primary pulley
2. Taper lock bushing
3. Lock washer
4. Cap screw
6. Woodruff key
7. Jackshaft
8. Cap screw (2 used per bearing)
9. Flange mount bearing
10. Plug
11. Set screw
12. Lock nut (2 used per bearing)
13. Secondary pulley
14. Secondary drive belt
15. Coring crankshaft
5. Set screw
Removal (Fig. 17)
5. Loosen taper lock bushings (Fig. 18):
1. Park machine on a level surface, fully raise coring
head, engage parking brake, stop engine and remove
key from the ignition switch. Secure coring head with
service latch.
A. Remove three (3) cap screws and lockwashers
that secure taper lock bushing to pulley.
IMPORTANT: Excessive or unequal pressure on the
cap screws can break the taper lock bushing flange.
When removing taper lock bushing, tighten screws
progressively and evenly.
2. Remove belt cover and rear hood from machine (see
Operator’s Manual).
3. Remove primary and secondary drive belts from
jackshaft pulleys (see Primary Drive Belt Removal and
Secondary Drive Belt Removal in this section).
B. Insert cap screws into threaded removal holes of
the bushing. Tighten screws progressively and even-
ly until the pulley is loose on the bushing.
4. Loosen cap screws and lock nuts that secure flange
mount bearings to machine frame. Support jackshaft as-
sembly, remove loosened cap screws and lock nuts and
remove jackshaft assembly from machine.
6. Loosen set screws (item 5) that secure taper lock
bushings to jackshaft. Remove bushings and pulleys
from the jackshaft. Locate and retrieve woodruff keys
(item 6) that locate bushings on jackshaft.
Coring Head
Page 7 – 14
ProCore 648
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NOTE: Jackshaft rotates counterclockwise as viewed
from right side of machine (Fig. 18).
10.Install primary and secondary drive belts to jackshaft
pulleys (see Primary Drive Belt Installation and Seconꢀ
dary Drive Belt Installation in this section).
7. Loosen set screw that secures each flange mount
bearing locking collar to jackshaft. Using the blind hole
in bearing collar as a striking point, unlock collar from
jackshaft by rotating the collar in the opposite direction
of jackshaft rotation with a punch (Fig. 19).
11.Check that belt alignment is still correct. If needed,
readjust pulley location on jackshaft.
12.Install belt cover and rear hood to machine (see Op-
erator’s Manual). Remove service latch from coring
head before using machine.
8. Slide flange mount bearings from jackshaft.
Installation (Fig. 17)
1. Make sure that tapered surfaces of pulleys and taper
lock bushings are thoroughly clean (no oil, grease, dirt,
rust, etc.).
2. Slide flange mount bearings onto jackshaft.
3
1
3. Place woodruff keys (item 6) in jackshaft. Slide pulꢀ
leys and taper lock bushings onto jackshaft making sure
that tapered surfaces of pulley and bushing align. Align
threaded holes of pulley with non–threaded holes of
bushing. Loosely install three (3) cap screws with lock
washers to both bushing and pulley assemblies.
ROTATION
2
DIRECTION
Figure 18
1. Cap screw/lock washer
2. Threaded hole
3. Set screw
4. Position jackshaft assembly to machine frame. Seꢀ
cure flange mount bearings to frame with cap screws
and lock nuts.
1
IMPORTANT: When tightening bushing cap screws,
tighten in three equal steps and in a circular pattern
to prevent bushing flange damage.
2
5. Align taper lock bushing in primary pulley flush with
end of jackshaft and secure with set screw. Tighten
three (3) cap screws to a torque from 180 to 200 in–lb
(20.3 to 22.6 N–m) in three equal steps and in a circular
pattern to secure primary pulley and taper lock bushing.
LOOSEN
Figure 19
6. Position jackshaft to align primary pulley and electric
clutch pulley on engine.
1. Flange mount bearing
2. Jackshaft
7. Using the blind hole in flange mount bearing locking
collars as a striking point, lock collars to jackshaft by roꢀ
tating the collars with a punch in the direction of jackꢀ
shaft rotation (Fig. 20). Tighten set screw (item 11) to
secure each bearing locking collar to jackshaft.
TIGHTEN
2
8. Position secondary pulley on jackshaft to align secꢀ
ondary pulley and coring head pulley. Secure in position
with taper lock bushing set screw.
1
IMPORTANT: When tightening bushing cap screws,
tighten in three equal steps and in a circular pattern.
9. Secure taper lock bushing by tightening three (3) cap
screws to a torque from 180 to 200 in–lb (20.3 to 22.6
N–m) in three equal steps and in a circular pattern to seꢀ
cure secondary pulley and taper lock bushing.
3
Figure 20
1. Flange mount bearing
2. Jackshaft
3. Set screw
ProCore 648
Page 7 – 15
Coring Head
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Coring Head Pivot (H–Frame)
15
14
1
2
4
3
14
5
13
6
13
10
12
3
4
7
12
RIGHT
8
9
FRONT
11
Figure 21
1. Coring frame
6. Jam nut (LH thread)
7. Upper link
11. Main frame
2. H–frame
12. Thrust washer
3. Hex nut
4. Lock washer
5. Rod end (LH thread)
8. Jam nut
13. Carriage screw
14. Pivot shaft
15. Flange nut
9. Rod end
10. Flange bushing (4 used)
Coring Head
Page 7 – 16
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Disassembly (Fig. 21)
5
6
1. Park machine on a level surface, fully raise coring
head, engage parking brake, stop engine and remove
key from the ignition switch. Secure coring head with
service latch.
7
4
3
2
2. Remove belt cover and rear hood from machine (see
Operator’s Manual).
8
1
3. Chock wheels to prevent the machine from moving.
9
10
11
4. Remove tine heads from stomper arms to allow cor-
ing head to be fully lowered.
12
RIGHT
FRONT
CAUTION
Figure 22
The extension springs are under tension and
may cause personal injury during removal. Use
caution when disconnecting springs from ma-
chine.
1. Shackle
2. Clevis pin
3. Hair pin
4. Extension spring
5. Carriage screw
6. Spring plate
7. Flange nut
8. Cylinder pin
9. Spacer
10. Thrust washer
11. Retaining ring
12. Lift cylinder
5. Disconnect the upper end of both extension springs
from spring plates on coring head frame (Fig. 22):
2
4
4
2
A. Remove service latch from coring head. Turn key
switch to ON (engine not running). Move traction le-
ver to forward direction and depress lower switch on
handle to fully lower coring head.
3
B. Loosen, but do not remove, both flange nuts (Fig.
22 item 6) that secure the spring plates (Fig. 22 item
5) for both extension springs.
1
C. Using a 1/2” breaker bar, hold spring plate to pre-
vent it from moving. Remove upper flange nut and
carriage screw (Fig. 22 item 4) from spring plate and
coring head frame.
Figure 23
1. Lift cylinder shaft
2. Thrust washer
3. Cylinder pin
4. Spacer
D. Using lower carriage screw and flange nut as a
pivot, carefully release tension on extension spring
(Fig. 22 item 3) by rotating spring plate with breaker
bar.
1
E. Remove hair pin (Fig. 22 item 3) and clevis pin
(Fig. 22 item 2) that secure spring shackle (Fig. 22
item 1) to spring plate. Position extension spring
away from coring head frame.
2
6. Start engine and allow coring head to fully raise. Turn
engine off. Secure coring head with service latch.
7. Lower coring head onto service latch to allow lift cyl-
inder to be disconnected from coring head. Turn key
switch to ON (engine not running). Move traction lever
to forward direction and depress lower switch on handle
to lower coring head onto service latch. Return key
switch to OFF and remove key from the ignition switch.
Figure 24
1. Proximity switch bracket
2. Machine frame
ProCore 648
Page 7 – 17
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8. Disconnect upper end of lift cylinder from coring
head frame (Figs. 22 and 23):
2. Position H–frame to machine frame making sure that
thrust washers are placed between H–frame and maꢀ
chine frame. Align both sides of H–frame to pivot shaft
holes in machine frame. Slide pivot shaft into H–frame
and machine frame.
A. Remove retaining ring from one end of cylinder
pin that secures lift cylinder to coring head frame.
B. Pull cylinder pin from coring head frame and lift
cylinder. Locate and retrieve two (2) thrust washers
and two (2) spacers as pin is removed.
3. Position coring head to allow alignment of both sides
of H–frame to pivot shaft holes in coring head frame.
Slide pivot shaft into H–frame and coring head frame.
C. Rotate lift cylinder toward front of machine.
4. Complete assembly of coring head to machine in the
reverse order of disassembly.
9. Disconnect wire harness connectors from limit
switches on depth actuator assembly.
10.Remove proximity switch bracket from machine
frame (Fig. 24). Position switch bracket with proximity
switches still attached away from H–frame.
2
11.Remove right rear wheel from machine (see Wheel
Removal in Service and Repairs section of Chapter 6 –
Chassis). Make sure that machine is supported well with
jackstands or blocking.
1
CAUTION
The coring head assembly weighs approximateꢀ
ly 650 pounds (294.8 kg). Make sure that proper
lift or hoist is used to support coring head during
repairs.
Figure 25
1. Bearing housing
2. Lifting eyelet
2
12.Using suitable lift or hoist, support coring head using
lifting eyelets on coring crankshaft as lift points (Fig. 25).
Once coring head is well supported, remove service
latch from coring head.
1
13.Remove upper link assemblies from machine frame
and coring head frame.
2
17.720” to 17.780”
(45.0 to 45.2 cm)
14.Remove flange nuts (item 15) and carriage screws
(item 13) that secure end of pivot shafts to machine.
15.Carefully slide pivot shafts from H–frame. Locate
and retrieve thrust washers (item 12) from between H–
frame and machine frame.
16.Remove H–frame from machine.
Figure 26
1. Upper link
2. Rod end
Assembly (Fig. 21)
1. If upper links were disassembled, install rod ends
equally to make link assembly 17.720” to 17.780” (45.0
to 45.2 cm) long (rod center to rod center) (Fig. 26).
IMPORTANT: When installing pivot shaft to H–
frame, make sure that both sides of H–frame are
aligned with holes in machine frame before instalꢀ
ling pivot shaft.
Coring Head
Page 7 – 18
ProCore 648
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Chapter 8
Electrical Diagrams
Table of Contents
ELECTRICAL SCHEMATIC
Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . 3
ELECTRICAL CIRCUIT DRAWINGS
Start Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Lower Coring Head . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Aerating (Level Ground Surface) . . . . . . . . . . . . . . 6
Aerating (Low Spot in Turf Encountered) . . . . . . . 7
Aerating (High Spot in Turf Encountered) . . . . . . . 8
Raise Coring Head . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
WIRE HARNESS DRAWINGS
Wire Harness Drawing . . . . . . . . . . . . . . . . . . . . . . . 11
Wire Harness Diagram . . . . . . . . . . . . . . . . . . . . . . 12
ProCore 648
Page 8 – 1
Electrical Diagrams
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This page is intentionally blank.
Electrical Diagrams
Page 8 – 2
ProCore 648
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ProCore 648
Electrical Schematic
All relays and solenoids
are shown as de–energized.
All ground wires are black.
Page 8 – 3
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(ENERGIZED)
(NOT ENERGIZED)
(NEUTRAL POSITION)
(NOT ENERGIZED)
(NOT ENERGIZED)
(NOT ENERGIZED)
ProCore 648
Start Engine
Power Current
Control Current
Indication Current
(NOT ENERGIZED)
Page 8 – 4
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ON
ON
ON
ProCore 648 Aerator
ON
ON
ON
Aerator Control Module
(RUN)
(NOT ENERGIZED)
(NOT IN NEUTRAL)
(NOT ENERGIZED)
(ENERGIZED)
(ON)
(HEAD BEING LOWERED)
(ENERGIZED)
(ENERGIZED)
(PRESSED TO LOWER)
(HEAD BEING LOWERED)
(NOT ENERGIZED)
(IN FORWARD)
(HEAD BEING LOWERED)
(HEAD BEING LOWERED)
(HEAD BEING LOWERED)
(ENERGIZED)
ProCore 648
(ENERGIZED)
Lower Coring Head
Manual Raise/Lower Switch Pressed to Lower
Power Current
Control Current
(NOT ENERGIZED)
(HEAD BEING LOWERED)
Page 8 – 5
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ON
ON
ON
ProCore 648 Aerator
ON
Aerator Control Module
(RUN)
(NOT ENERGIZED)
(NOT IN NEUTRAL)
(NOT ENERGIZED)
(NOT ENERGIZED)
(NOT ENERGIZED)
(ON)
(HEAD LOWERED)
(ENERGIZED)
(NEUTRAL POSITION)
(HEAD LOWERED)
(NOT ENERGIZED)
(IN FORWARD)
(HEAD LOWERED)
(HEAD LOWERED)
(HEAD LOWERED)
(ENERGIZED)
ProCore 648
(ENERGIZED)
Aerating
Coring Head Fully Lowered
Level Ground Surface
Power Current
Control Current
(ENERGIZED)
(ENERGIZED)
(HEAD LOWERED)
Page 8 – 6
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ON
ON
ON
ON
ProCore 648 Aerator
ON
ON
Aerator Control Module
(RUN)
(NOT ENERGIZED)
(NOT ENERGIZED)
(NOT IN NEUTRAL)
(NOT ENERGIZED)
(ENERGIZED)
(ON)
(CLOSED BY TURF GUARD)
(ENERGIZED)
(NEUTRAL POSITION)
(HEAD LOWERED)
(NOT ENERGIZED)
(IN FORWARD)
(HEAD LOWERED)
(HEAD LOWERED)
(HEAD LOWERED)
ProCore 648
(ENERGIZED)
Aerating
(ENERGIZED)
Coring Head Fully Lowered
Low Spot in Turf Encountered
(Head High Limit Switch Closed by Turf Guard Movement)
Power Current
Control Current
(ENERGIZED)
(ENERGIZED)
(HEAD LOWERED)
Page 8 – 7
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ON
ON
ON
ON
ProCore 648 Aerator
ON
ON
Aerator Control Module
(RUN)
(NOT ENERGIZED)
(NOT IN NEUTRAL)
(ENERGIZED)
(NOT ENERGIZED)
(NOT ENERGIZED)
(ON)
(HEAD LOWERED)
(ENERGIZED)
(NEUTRAL POSITION)
(HEAD LOWERED)
(NOT ENERGIZED)
(IN FORWARD)
(CLOSED BY TURF GUARD)
(HEAD LOWERED)
(HEAD LOWERED)
ProCore 648
(ENERGIZED)
Aerating
(ENERGIZED)
Coring Head Fully Lowered
High Spot in Turf Encountered
(Head Low Limit Switch Closed by Turf Guard Movement)
Power Current
Control Current
(ENERGIZED)
(ENERGIZED)
(HEAD LOWERED)
Page 8 – 8
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ON
ON
ProCore 648 Aerator
ON
ON ON
Aerator Control Module
(RUN)
(NOT ENERGIZED)
(NOT IN NEUTRAL)
(ENERGIZED)
(ENERGIZED)
(ON)
(HEAD LOWERED)
(NOT ENERGIZED)
(NOT ENERGIZED)
(NEUTRAL POSITION)
(HEAD LOWERED)
(ENERGIZED)
(HEAD LOWERED)
(HEAD LOWERED)
(HEAD LOWERED)
(ENERGIZED)
(ENERGIZED)
ProCore 648
Raise Coring Head
Traction Lever Moved from Forward
Power Current
Control Current
(ENERGIZED)
(NOT ENERGIZED)
(HEAD LOWERED)
Page 8 – 9
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ON
ON
ON
ProCore 648 Aerator
ON
Aerator Control Module
(RUN)
(NOT ENERGIZED)
(NOT ENERGIZED)
(NOT IN NEUTRAL)
(NOT ENERGIZED)
(NOT ENERGIZED)
(ON)
(HEAD RAISED)
(NOT ENERGIZED)
(NEUTRAL POSITION)
(HEAD RAISED)
(NOT ENERGIZED)
(IN FORWARD)
(HEAD RAISED)
(HEAD RAISED)
(HEAD RAISED)
(ENERGIZED)
ProCore 648
(ENERGIZED)
Transport
Traction Lever Moved to Forward
Coring Head Fully Raised
Power Current
Control Current
(ENERGIZED)
(NOT ENERGIZED)
(HEAD RAISED)
Page 8 – 10
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1
2
3
5
4
3
4
5
2
1
ProCore 648
Wire Harness Drawing
Page 8 – 11
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NEUTRAL SW. RELAY
(START)
LOW OIL
REVERSE
SWITCH
FUSE BLOCK
P27
IGNITION SWITCH
PRESSURE
MAGNETO
ACM 1
P9
P1
J5
P4
P5
P16
L
G
4
S
1
M
2
B
5
1A 1B 2A 2B
1
2
3
4
5
3
A
B
C
D
E
F
A
B
1
1
2
3
4
5
6
7
8
SP9
HOUR
METER
1
J1
BLACK
PINK/BLACK
ORANGE
A
B
C
D
E
F
BLUE/WHITE
1
30
85
WHITE/BLACK
TAN
2
3
4
5
SP7
LATCHING
RELAY
P8
ACM 2
P3 87A
YELLOW
87
86
G
H
PINK
SP1
PINK/BLACK
YELLOW
1
2
3
4
5
6
7
8
SP4
1
2
3
4
5
BLACK
BLACK
BLACK
SP3
NEUTRAL SWITCH
RELAY
P2
VIOLET
GROUND FOLLOW
SWITCH
P28
A
B
1
2
3
4
5
6
7
8
HEAD LOW
P18
P14
LIMIT SWITCH
RAISE / LOWER
SWITCH
P15
TAN
A
B
HEAD HIGH
LIMIT SWITCH
1
2
3
4
5
PINK
PINK
PINK
SP2
ORANGE
LOCKOUT
RELAY
P24
RED
PINK/BLACK
1
2
3
4
5
YELLOW
GREEN
LOCKOUT LATCH
RELAY
P25
A
B
WHITE
ORANGE
NEUTRAL
SWITCH
P22
PINK
BLACK
YELLOW
A
B
YELLOW
DIODE D1
DIODE D2
P31
P32
YELLOW
SP6
BLUE
A
B
SP5
SP8
BLACK
BLACK
A
B
DIODE D3 P33
YELLOW
A
B
A
B
A
B
A
B
A
B
1
2
3
4
5
1
1
A
B
1
2
3
4
5
6
7
8
1
2
3
4
5
A
B
A
B
A
B
ProCore 648
Wire Harness Diagram
P34
P26
P7
P13
P12
RAISE
SOLENOID
(SVR)
P10
P11
P19
P17
P29
CLUTCH RELAY
P20
ENGINE CONNECTOR
J3
J4
P23
TRANSPORT
LIMIT #2
SWITCH
AERATION #3
SWITCH
CLUTCH
DIODE
D4
LIFT RESET
SWITCH
GROUND
B+
LOWER
SOLENOID
(SVL)
FAST RAISE
SOLENOID
(SVQ)
TRANSPORT LIMIT #1
SWITCH
AERATION #4
SWITCH
Page 8 – 12
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