ProCore® 648s Aerator

1. Insert the studs at the end of the handlebar into the holes in the steering arm (Figure 5).

   Note: Have another person help hold the handlebar.

   

   Figure 5

   1. Handlebar
   2. Stud
   3. Steering arm
   4. Flange locknuts (1/2 inch)

2. Thread a flange locknut (1/2 inch) onto each of the 3 studs.

3. Torque the flange locknuts to 91 to 113 N∙m (67 to 83 ft-lb).

4. Rotate the handlebar up and secure it with the handlebar-latch pin (Figure 6).

   

   Figure 6

   1. Handlebar-latch pin
   2. Detent plate
   3. Handlebar-latch knob

1. Route the fitting of the brake cable under the bottom of the handle-bar channel (Figure 7).

   

   Figure 7

   1. Handle-bar channel
   2. Brake-cable fitting
   3. Washer (5/16 inch)
   4. Clevis pin
   5. Hairpin

2. Assemble the brake-cable fitting on to the clevis pin, and secure the fitting to the pin with the washer and hairpin.

1. Route the 6-pin connector and the 12-pin connector of the machine wire harness through the grommet in the handle-bar channel (Figure 8).

   

   Figure 8

   1. 6-pin connector (machine wire harness)
   2. 12-pin connector (machine wire harness)

2. Plug the 12-pin connector of the machine harness into the 12-socket connector of the handlebar wire harness (Figure 9).

   

   Figure 9

   1. 12-socket connector (handle wire harness)
   2. 6-socket connector (handle wire harness)
   3. 6-pin connector (machine wire harness)
   4. 12-pin connector (machine wire harness)

3. Plug the 6-pin connector of the machine harness into the 6-socket connector of the handlebar harness.

4. Insert the push-in anchor of the machine harness into the hole in the handle-bar channel (Figure 10).

   

   Figure 10

   1. Push-in anchor
   2. Handle-bar channel
   3. Guide bracket

5. Insert the push-in anchor of the machine harness into the hole in the guide bracket.

6. Secure the machine harness to the handle-bar channel with a cable tie through the slots in the channel (Figure 11).

   

   Figure 11

   1. Slot (handle-bar channel)
   2. Cable tie
   3. Slot (guide bracket)

7. Secure the machine harness to the guide bracket with a cable tie through the slots in the bracket.

1. Align the small notch in the handlebar cover with the notch up (Figure 12).

   

   Figure 12

   1. Thread-forming screw (1/4 inch)
   2. Handle-bar channel
   3. Small notch (handle-bar cover)

2. Align the holes in the cover with the holes in the handle-bar channel.

3. Secure the cover to the handlebar with the 6 thread-forming screws (1/4 inch).

1. Unlatch and open the battery-compartment door (Figure 13).

   

   Figure 13

   1. Latch
   2. Battery-compartment door

2. Remove the battery from the battery compartment.

3. Use a battery charger with a 3 to 4 A charging capacity to charge the battery.

4. When the battery is charged, disconnect the charger from the electrical outlet and battery posts.

1. Assemble the battery into the tray in the battery compartment (Figure 14). Position the battery so that the terminals are aligned the outward.

   

   Figure 14

   1. Battery tray
   2. Hold-down rod
   3. J-rod
   4. Positive terminal (+)
   5. Negative terminal (–)

2. Secure the battery to the compartment base with a hold-down rod, 2 J-rods, 2 flat washers, and 2 wing nuts.

3. Secure the positive cable (red) to the positive (+) battery terminal with a carriage bolt and nut.

4. Slide the rubber boot over the positive terminal.

5. Secure the negative cable (black) to the negative (–) terminal of the battery with a carriage bolt and nut.

6. Close and latch the battery compartment door.

Use the handle-bar latch (Figure 21) to secure the handlebar in the upward position and to engage the parking brake.

Important: Secure the handlebar in the up position anytime you leave the operator’s position.

The operator-presence bail (Figure 21) helps ensure that you are in the operator’s position while driving the machine or running the coring head.

Note: Releasing the operator-presence bail does not shut off the engine.

Use the InfoCenter (Figure 21) to adjust how the coring head controls work.

If you contact the bump-stop switch (Figure 21), the machine performs the following actions:

• The machine stops driving forward.

• The coring head raises and stops running.

Note: Contacting the bump-stop switch does not shut off the engine. You can drive the machine in the reverse direction, but you must reset the bump switch to drive forward.

Use the transport/aeration switch (Figure 22) to control the maximum speed you can drive the machine while aerating or transporting the machine.

• The AERATION position allows aeration and limits ground speed to 4.0 kph (2.5 mph) or slower.

• The TRANSPORT position allows you to drive the machine at full ground speed or slower between job sites.

  Note: You cannot aerate with the transport/aeration switch in the TRANSPORT position.

Use the left or right traction control (Figure 22) to drive the machine forward or backward.

Use the speed-lock switch (Figure 22) to maintain the ground speed at which you drive the machine; similar to cruise control in an automobile.

• The ENGAGE position locks the current ground speed at which the machine is driving.

• The ON position activates the ground-speed lock.

• The OFF position shuts off the ground-speed lock.

Use the speed-lock switch (Figure 22) to maintain the ground speed at the aeration hole spacing rate.

• The ON position—activates and engages the ground-speed lock to maintain the ground speed at the aeration hole spacing rate when you release the aerate bail at the end of an aeration pass.

• The OFF position shuts off the ground-speed lock—the machine stops moving forward when you release the aerate bail.

Use the aerate bail (Figure 23) to lower and raise the coring head.

Use the drop control switch (Figure 23) to change how the coring head lowers when aerating, you can select the following modes:

• Immediate-drop

• Delayed-drop

Use the throttle lever (Figure 24) to control the engine speed:

• Moving throttle lever forward increases engine speed—toward the FAST position.

• Moving throttle lever backward decreases engine speed—toward the SLOW position.

Note: The engine speed regulates the speed of the coring head.

Use the choke when starting a cold engine (Figure 24).

Use the ignition switch (Figure 24) to start and shut off the engine. The switch has 3 positions:

• START—rotate key clockwise to the START position to engage the starter motor.

• RUN—when the engine starts, release the key and it moves automatically to the ON position.

• OFF—rotate the key counterclockwise to the OFF position to shut off the engine.

Use the tachometer to determine the engine speed (Figure 24).

Use the fuel-shutoff valve to control fuel from the fuel tank (Figure 25).

Figure 25

1. Fuel-shutoff valve

Before starting the machine each day, perform the each Use/Daily procedure listed in .

• The safety interlock system prevents the engine from starting unless the traction control is in the NEUTRAL position.

• The safety interlock system prevents the engine from starting unless the operator presence bail is fully released.

• The safety interlock system prevents the engine from starting unless the coring head bail is fully released.

• The safety interlock system raises the coring head and shuts it off if you drive the machine backward while aerating or contact the bump-stop switch.

Important: If the safety interlock system does not operate as described, have an authorized Toro distributor repair the safety interlock system immediately.

Important: You must calibrate tine ground height each time you change from longer tines to shorter tines or from shorter tines to longer tines.

A wide selection of tine holders, turf guards, and tines are available for the machine. Choose the required components per the accessory chart in Attachments and Accessories.

Assembling the Turf Guards

Note: The factory ships turf guard clamps, washers, and flange locknuts secured to the turf guard brackets (Figure 39).

Loosely assemble the turf guards to the turf guard brackets with 4 turf-guard clamps and 12 flange locknuts (3/8 inch) and 12 washers (7/16 x 13/16 inch).

Note: Do not tighten the flange locknuts.

Figure 39

1. Washer (7/16 x 13/16 inch)
2. Flange locknut (3/8 inch)
3. Turf guard clamp
4. Turf guard
5. Stud (turf-guard bracket)

1. Ensure that the coring head is raised; refer to Raising the Coring Head.

2. Rotate the ignition key to the RUN position.

   

   Figure 51

3. Press the right InfoCenter button until the Setting the Hole Depth screen displays (Figure 51 and Figure 52).

4. Press the center button to select the Set Depth option.

   Note: The Set Depth screen displays.

   

   Figure 52

5. Adjust the tine depth (Figure 53) as follows:

   • Press the InfoCenter center button to decrease hole depth.

   • Press the right button to increase hole depth.

   

   Figure 53

6. Press the left InfoCenter button to save your setting and exit the set depth screen.

7. Rotate the ignition key to the OFF position.

   Note: If aerating at the maximum allowable depth (with any length tine) after running the ground-height calibration, the turf-guard bolts drag or contact the turf, reduce the depth by a step (1/4 inch).

Note: When you select a target hole spacing rate, the machine controls the ground speed to maintain the hole spacing distance.

1. Ensure that the coring head is raised; refer to Raising the Coring Head.

2. Rotate the ignition key to the RUN position.

   

   Figure 54

3. Press the right InfoCenter button until the Setting the Hole Spacing screen displays (Figure 54 and Figure 55).

   

   Figure 55

4. Press the center button to select the Set Spacing option.

   Note: The Set Spacing screen displays.

5. Adjust the hole spacing (Figure 56) as follows:

   • Press the InfoCenter center button to decrease hole spacing.

   • Press the right button to increase hole spacing.

   

   Figure 56

6. Press the left InfoCenter button to save your setting and exit the Set Hole Spacing screen.

7. Rotate the ignition key to the OFF position.

1. Ensure that the coring head is raised; refer to Raising the Coring Head.

2. Rotate the ignition key to the RUN position.

   

   Figure 57

3. Press the right InfoCenter button until the Setting the Tine Diameter screen displays (Figure 58).

   

   Figure 58

4. Press the center button to select the Set Diameter option.

   Note: The Set Diameter screen displays.

5. Adjust the tine diameter (Figure 59) as follows:

   • Press the InfoCenter center button to decrease tine diameter.

   • Press the right button to increase tine diameter.

   

   Figure 59

6. Press the left InfoCenter button to save your setting and exit the Set Hole Spacing screen.

7. Rotate the ignition key to the OFF position.

1. Ensure that the coring head is raised; refer to Raising the Coring Head.

2. Rotate the ignition key to the RUN position.

   

   Figure 60

3. Press the right InfoCenter button until the Setting the Tine Quantity screen displays (Figure 61).

   

   Figure 61

4. Press the center button to select the Set Quantity option.

   Note: The Set Quantity screen displays.

5. Adjust the tine quantity (Figure 62) as follows:

   Important: The tine quantity is the number of tines of 1 holder.

   • Press the InfoCenter center button to decrease tine quantity.

   • Press the right button to increase tine quantity.

   

   Figure 62

6. Press the left InfoCenter button to save your setting and exit the Set Hole Spacing screen.

7. Rotate the ignition key to the OFF position.

Important: Calibrate the tine ground height each time you change tines or replace worn tines.

1. Fully raise the handlebar to engage the parking brake (Figure 72).

   

   Figure 72

2. Ensure that the handlebar-latch pin extends through the hole in the detent plate (Figure 73).

   Warning

   If the parking brake does not engage, the machine may move injuring you or bystanders.

   Ensure that the handlebar is fully raised and securely latches to the detent plate.

   

   Figure 73

   1. Handlebar-latch pin
   2. Detent plate
   3. Handlebar-latch knob

1. Pull the knob for the handlebar latch (Figure 74).

   

   Figure 74

   1. Handlebar-latch knob

   Important: Do not rotate the knob so that the latch pin cannot retract (Figure 75).

   

   Figure 75

2. Lower the handlebar to release the parking brake (Figure 76).

   

   Figure 76

3. Release the handlebar-latch knob.

1. Fully raise and latch the handlebar engage the parking brake; refer to Engaging Parking Brake.

2. Use the choke (Figure 77) as follows:

   • Before starting a cold engine, move the choke control to the ON position.

   • When starting a warm or hot engine, you may not need to use the choke.

   

   Figure 77

   1. Key (ignition switch)
   2. Throttle lever
   3. Choke
   4. Tachometer

3. Move the throttle lever to the FAST position before starting a cold engine.

4. Turn the ignition key to the START position. When the engine starts, release the key.

   Important: Do not engage the starter for more than 10 seconds at a time. If the engine fails to start, allow a 30-second cool-down period between attempts. Failure to follow these instructions can burn out the starter motor.

5. After the engine starts, move the choke toward the OFF position. If the engine runs rough or stalls, move the choke back toward the ON position for a few seconds. Then move the throttle lever to desired engine speed.

   Note: Repeat this step as required.

1. Fully raise and latch the handlebar to engage the parking brake; refer to Engaging Parking Brake.

2. Move the throttle lever (Figure 78) to the SLOW position.

   

   Figure 78

   1. Key (ignition switch)
   2. Throttle lever
   3. Choke
   4. Tachometer

3. Let the engine idle for 60 seconds.

4. Turn the ignition key to the OFF position and remove the key.

5. If you are hauling or storing the machine, close the fuel-shutoff valve (Figure 79).

   Important: Close the fuel-shutoff valve before hauling the machine on a trailer or storing the machine. Fully raise and latch the handlebar to engage the parking brake before hauling the machine. Remove the key from the ignition switch to prevent the fuel pump from running and causing the battery to discharge.

   

   Figure 79

   1. Fuel-shutoff valve

Important: Walk in front of the machine in a forward direction while operating it, do not walk and face rearward when operating the machine.

Figure 80

1. Right side
2. Left side
3. Forward (operating direction)

Stopping the Machine

Important: To immediately stop the machine press the bump-stop switch (Figure 85).

Figure 85

1. Bump-stop switch

1. If you are aerating, release the aerate bail (Figure 86) to raise the coring head; refer to Raising the Coring Head.

   

   Figure 86

   1. Operator-presence bail
   2. Aerate bail
   3. Traction control

2. Release the traction control, and allow it to move to the NEUTRAL position.

3. Release the operator-presence bail.

4. Fully raise and latch the handlebar to engage the parking brake; refer to Engaging Parking Brake.

Raising the Coring Head

Delay-Drop Mode

Use the front tire (Figure 91) to sight the raise point when in delay-drop mode.

Figure 91

To raise the core head, perform 1 of the following:

• As the front tire rolls over the perimeter of aeration area, release the aerate bail (Figure 92).

  Note: The machine delays lifting the coring head until the coring head reaches the targeted spot you identified using the front tire and released the aerate bail.

  

  Figure 92

  1. Aerate bail

• Drive the machine in the reverse direction; refer to Driving the Machine in the Reverse Direction.

Use the line marker to align aeration rows (Figure 101).

Figure 101

1. Line marker (storage position)
2. Line marker (alignment position)

The machine uses 2 counters to log the area aerated and the displaced soil-core volume. Use the information from these counters to estimate the amount of top dressing to apply to the aerated turf area(s).

• The Area 1 counter is not PIN code protected, and is intended to be reset by the machine operator.

  Note: If the operator records the Area 1 counter for each aeration site, you can estimate the amount of topsoil and delivery requirements for each site.

• The Area 2 counter is PIN code protected, and is intended to be reset by the supervisor or their delegate.

  

  Figure 102

  1. Lock icon (PIN code protected)

• The area aerated displays in m² (SI) or ft² (English) units of measure.

• The displaced-coring volume displays as m³ (SI) or yd³ (English) units of measure.

• When viewing the displaced-coring volume counters, the machine calculates the volume using the tine diameter and the tine quantity that you entered in the InfoCenter.

  Important: If the tine diameter and/or the tine quantity value(s) are incorrect before aerating the site, the InfoCenter will calculate and display incorrect core volume values for Area 1 and Area 2. If the diameter and/or quantity values are changed after aerating, the InfoCenter will change the displayed volume values.

Install the service latch before performing coring head maintenance or when storing the machine for more than a couple of days.

1. Raise the coring head.

2. Park the machine on a level surface, fully raise and latch and latch the handlebar to engage the parking brake, shut off the engine, remove the key, and wait for all moving parts to stop.

3. Remove the coring head cover; refer to Removing the Coring-Head Cover.

4. Remove the lynch pin securing the service latch to the side plate (Figure 111).

   

   Figure 111

   1. Support pin (side plate)
   2. Lynch pin
   3. Service latch
   4. Support pin (coring head)

5. Rotate the service latch rearward and align it over the support pin of the coring head.

6. Secure the latch to the support pin with the lynch pin.

7. If needed, install the coring-head cover; refer to Installing the Coring-Head Cover.

1. Park the machine on a level surface, fully raise and latch and latch the handlebar to engage the parking brake, shut off the engine, remove the key, and wait for all moving parts to stop.

2. If the coring-head cover is installed, remove it; refer toRemoving the Coring-Head Cover.

3. Remove the lynch pin securing the service latch to the support pin of the coring head (Figure 112).

   

   Figure 112

   1. Service latch
   2. Lynch pin
   3. Support pin (coring head)
   4. Support pin (side plate)

4. Rotate the service latch down and align it over the support pin of the side plate.

5. Secure the latch to the support pin with the lynch pin.

6. Install the coring-head cover; refer to Installing the Coring-Head Cover.

Important: Replacing a damaged tine with one that is the same length. Different tine lengths negatively affect hole appearance.

Different tine lengths affect hole appearance.

Refer to Installing Turf Guards, Tine Holders, and Tines for illustrations.

1. Raise the coring head and lock it in position with the service latch.

2. Park the machine on a level surface, fully raise and latch the handlebar to engage the parking brake, shut off the engine, remove the key, and wait for all moving parts to stop.

3. Loosen the tine holder bolts and remove the old tine(s).

4. Insert the new tine(s) into the tine holder.

5. Torque the tine holder bolts to 40.6 N∙m (30 ft-lb).

6. If needed, repeat this procedure on the remaining arms.

Use the ground height calibration recall application to quickly check the current tine ground height.

The machine transfers weight from the traction unit to the coring head to help maintain hole depth in various soil structures. However, if the soil structure is firm enough to not allow full aeration depth, the coring head may need additional weight transfer. The machine is set for normal weight transfer at the factory. To increase the down pressure of the weight transfer springs, proceed as follows:

1. Park the machine on a level surface, fully raise and latch the handlebar to engage the parking brake, shut off the engine, remove the key, and wait for all moving parts to stop.

2. Loosen the forward flange locknut and carriage bolt that secure the spring-tension plate to the support bracket of the coring head (Figure 118).

   Note: Do not remove locknut and carriage bolt.

   

   Figure 118

   Normal Weight Transfer Position—Upper Hole

   1. Spring-tension plate
   2. Flange locknut (rear)
   3. Support bracket (coring head)
   4. Weight transfer springs

3. Remove the rear flange locknut that secures the spring brackets to the support bracket.

   Note: Do not remove carriage bolt.

4. Insert a 1/2 inch-drive ratchet or breaker bar into the square hole in the spring-tension plate (Figure 119).

   

   Figure 119

   Higher Weight Transfer Position—Lower Hole

   1. Carriage bolt (rear)
   2. Flange locknut

5. Rotate the ratchet or breaker bar to relieve the tension on the rear carriage bolt and remove it from the upper hole.

   Note: The upper hole is the normal weight transfer position.

6. Rotate the spring-tension plate until it aligns with the lower hole in the support bracket, insert the carriage bolt through the holes in the plate and bracket.

   Note: The lower hole is the higher weight transfer position. Rotating the spring plates upward increases the weight transfer.

7. Secure the carriage bolt to the support bracket and spring-tension plate with the flange locknut.

8. Torque the locknuts to 37 to 45 N∙m (27 to 33 ft-lb).

For optimum hole quality and machine performance, aerate using the automatic ground following system.

Use manual ground following only if the tine-position sensor is damaged.

1. Park the machine on a level surface, fully raise and latch the handlebar to engage the parking brake, shut off the engine, remove the key, and wait for all moving parts to stop.

2. Remove the coring-head cover; refer to Removing the Coring-Head Cover.

3. Remove the lynch pin that secures the depth-stop pin and spacers to the stop bracket (Figure 125).

   

   Figure 125

   1. Lynch pin
   2. Spacers
   3. Stop bracket
   4. Depth-stop pin

4. Position the all the spacers above the stop bracket.

5. Assemble the depth-stop pin and the spacers to the stop bracket with the lynch pin.

   Note: You must stow all spacers.

6. Repeat steps 3 through 5 at the other side of the machine.

7. Install the coring-head cover; refer to Installing the Coring-Head Cover.

With the weight transfer adjusted, it is possible to aerate turf that is hard enough ground cause the machine to lift the rear tires off the ground. This may lead to irregular hole spacing.

If this lifting occurs, you can add optional counterweight plates to the rear frame axle tube. Each counterweight plate adds 28.5 kg (63 lb) to the machine. You can add up to 2 plates. Refer to the Parts Catalog of your machine for the counterweight and hardware part numbers.

If the engine stops running while the coring head lowered and the tines engaged in the soil and you cannot start the engine, perform either Lifting the Coring Head using the Starter or Removing the Tine holders from the Stomper Arms.

Important: Do not use brackish or reclaimed water to clean the machine.

Important: Do not pressure wash the machine.

1. Park the machine on a level surface, fully raise and latch the handlebar to engage the parking brake, shut off the engine, remove the key, and wait for all moving parts to stop.

2. Thoroughly wash the machine.

   • Use a garden hose without a nozzle to avoid forcing water past the seals and contaminating bearing grease.

   • Use a brush to remove caked-on material.

   • Use mild detergent to clean the covers.

3. After cleaning, apply a coat of auto wax periodically to maintain the glossy finish of the cover.

4. Inspect the machine for damage, oil leaks, and component and tine wear.

5. Remove, clean, and oil the tines. Spray a light oil mist on coring head bearings (crank and damper links).

Important: Secure the coring head with the service latch if you store the machine for more than a couple of days.

There are tie-down hoops located at the front and rear sides of the machine (Figure 135, Figure 136, and Figure 137).

Note: Use properly-rated DOT-approved straps to tie down the machine; refer to Specifications for the weight of the machine.

Figure 135

Front Hoop

Figure 136

Right, Rear Hoop

Figure 137

Left, Rear Hoop

Important: Use full-width ramps for loading the machine onto a trailer or truck.

1. Load the machine onto the trailer or truck (coring head forward—preferred).

2. Fully raise and latch the handlebar to engage the parking brake, shut off the engine, remove the key, and wait for all moving parts to stop.

3. Secure the coring head with the service latch; refer to Supporting the Coring Head with the Service Latch.

4. Close the fuel-shutoff valve; refer to Fuel-Shutoff Valve.

5. At the tie-down points, bind the machine to the trailer or truck with cables, chains, or straps; refer to Tie-Down Points

Trailer Recommendations

1. Park the machine on a level surface.

2. Fully raise and latch the handlebar to engage the parking brake; refer to Engaging Parking Brake.

3. Shut off the engine, remove the key, and wait for all movement to stop before leaving the machine; refer to Shutting Off the Engine.

4. Allow the machine to cool.

1. If your machine has the CE belt-cover latch lanyard, loosen the lanyard bolt until it separates from the cover latch (Figure 141).

   

   Figure 141

   1. Belt cover
   2. Latch
   3. Lanyard bolt

2. Lift the latch handle (Figure 142).

   

   Figure 142

   1. Belt cover
   2. Latch

3. Lift the belt cover from the machine (Figure 143).

   

   Figure 143

1. Align the mount bracket of the belt cover with the cover-support bracket of the machine frame (Figure 144).

   

   Figure 144

   1. Mount bracket (belt cover)
   2. Cover-support bracket (machine frame)

2. Lower the belt cover (Figure 145).

   

   Figure 145

3. Fully lower the latch handle to secure the cover (Figure 146).

   

   Figure 146

   1. Belt cover
   2. Latch handle

4. If your machine has the CE belt-cover latch lanyard, thread the lanyard bolt into the hole in the cover latch, and tighten the bolt (Figure 147).

   

   Figure 147

   1. Belt cover
   2. Latch
   3. Lanyard bolt

Figure 148

1. If you machine has CE latch locks, loosen the lock-plate bolt until the lock plate clears the slot in the side of the coring-head cover (Figure 149).

   

   Figure 149

   1. Lock-plate bolt
   2. Lock plate

2. Rotate the lock plate to clear the latch (Figure 149).

3. Repeat 1 and 2 at the other side of the cover.

4. Unlatch the coring head cover at the 4 latch location (Figure 148 and Figure 150).

   

   Figure 150

   1. Latch hook
   2. Latch

5. Lift the coring-head cover from the machine (Figure 151).

   

   Figure 151

1. Align the coring-head cover to the machine as shown in Figure 152.

   

   Figure 152

2. Latch the coring head cover at the 4 latch location (Figure 153).

   

   Figure 153

   1. Latch hook
   2. Latch

3. If you machine has CE latch locks, rotate the lock plate until it aligns with the slot in the side of the coring-head cover (Figure 154).

   

   Figure 154

   1. Lock plate
   2. Lock-plate bolt
   3. Slot (coring-head cover)

4. Tighten the lock-plate bolt (Figure 154).

5. Repeat steps 3 and 4 at the other side of the cover.

The machine has no grease fittings that must be lubricated.

Important: Bearings rarely fail from defects in materials or workmanship. The most common reason for failure is moisture and contamination working its way past the protective seals. Bearings that are greased rely upon regular maintenance to purge harmful debris from the bearing area. Sealed bearings rely on an initial fill of special grease and a robust integral seal to keep contaminants and moisture out of the rolling elements.

The sealed bearings require no lubrication or short term maintenance. This minimizes routine service required and reduces the potential of turf damage due to grease contamination. These sealed bearing packages provide good performance and life under normal use, but periodic inspections of bearing condition and seal integrity should be conducted to avoid downtime. Inspect the bearings seasonally and replace them if they are damaged or worn. Bearings should operate smoothly with no detrimental characteristics such as high heat, noise, looseness, or rust weeping.

Due to the operating conditions these bearing/seal packages are subject to (e.g., sand, turf chemicals, water, impacts, etc.) they are considered normal wear items. Bearings that fail due to causes other than defects in materials or workmanship are typically not covered under warranty.

Note: You can negatively affect bearing by using improper wash down procedures. Do not wash down the machine when it is still hot and avoid directing high-pressure or high volume spray at the bearings.

It is common for new bearings to purge some grease out the seals on a new machine. This purged grease turns black in color due to collection of debris and not due to excessive heat. It is good practice to wipe this excess grease from the seals after the initial 8 hours. There may always appear to be a wet area around the seal lip. This is not detrimental to bearing life, and keeps the seal lip lubricated.

Oil Type: High-quality, detergent engine oil API service SJ or higher

Oil viscosity: Refer to the table below that follows:

Figure 159

The engine is shipped with oil in the crankcase; however, check the oil level before and after the engine is first started.

Use high-quality engine oil as described in Engine Oil Specification.

Important: Do not overfill the crankcase with oil .Do not run the engine with the engine-oil level below the low mark.

Note: The best time to check the engine oil is when the engine is cool before it has been started for the day. If it has already been run, allow the oil to drain back down to the sump for at least 10 minutes before checking.

1. Prepare the machine for maintenance refer to Preparing the Machine for Maintenance.

2. Allow the engine to cool.

3. Clean around the oil-fill cap and dipstick (Figure 160).

   

   Figure 160

   1. Dipstick
   2. Oil-fill cap (valve cover)
   3. Dipstick oil-level marking

4. Remove the dipstick, wipe it clean, and install until it is fully seated.

5. Remove the dipstick and check the oil level.

   The engine-oil level should be between the ‘‘F’’ full and ‘‘L’’ low marks on the dipstick.

6. If the oil level is below the ‘‘L’’ low mark, remove the oil-fill cap and add the specified oil until the level reaches the ‘‘F’’ full mark on the dipstick.

7. Install the oil-fill cap and dipstick.

Before each use, check and clean the engine screen. Remove any buildup of grass, dirt, or other debris from the engine air intake screen.

Important: Never install a dirty filter if it is removed from the fuel line.

1. Prepare the machine for maintenance refer to Preparing the Machine for Maintenance.

2. Close the fuel-shutoff valve (Figure 167).

   

   Figure 167

   1. Hose
   2. Clamp
   3. Filter
   4. Fuel shutoff valve

3. Squeeze the ends of the hose clamps together and slide them away from the filter.

4. Remove the filter from the fuel hoses.

5. Align the fuel filter with the arrow pointing toward the engine, and assemble the fuel hose over the filter fittings.

6. Position the hose clamps close to the fuel filter, and tighten the clamp.

7. Wipe up any spilled fuel.

8. Open the fuel-shutoff valve.

1. Prepare the machine for maintenance refer to Preparing the Machine for Maintenance.

2. Close the fuel-shutoff valve (Figure 168).

   

   Figure 168

   1. Hose
   2. Clamp
   3. Filter
   4. Fuel shutoff valve

3. Loosen the hose clamp at the fuel filter and slide it up the fuel line away from the fuel filter.

4. Pull the fuel line off the fuel filter.

5. Open the fuel-shutoff valve and allow fuel to drain into a fuel can or drain pan.

   Note: Now is the best time to install a new fuel filter because the fuel tank is empty.

6. Assemble the fuel hose over the filter fitting.

7. Position the hose clamp close to the fuel filter, and tighten the clamp.

The electrical system is protected by fuses. If a fuse opens, check the component and wiring for a short circuit to ground.

1. Unlatch and open the battery-compartment door (Figure 171).

   

   Figure 171

   1. Latch
   2. Battery-compartment door

2. Remove the cover from the fuse block (Figure 172).

   Note: The fan fuse is located in-line behind the battery (Figure 173).

   

   Figure 172

   1. Cover
   2. Fuse block
   

   Figure 173

   1. In-line fan fuse

3. Remove the open fuse.

4. Install a new fuse of a rated amperage indicated on the fuse block decal.

5. Assemble the cover onto the fuse block (or onto the in-line fan fuse).

6. Close and latch the battery compartment door.

1. Prepare the machine for maintenance refer to Preparing the Machine for Maintenance.

2. Check to ensure that the air pressure in all tires is 83 kPa (12 psi). Check the tires when they are cold to get the most accurate pressure reading.

   Important: Uneven tire pressure can cause uneven coring depth.

Figure 174

1. Valve stem
2. Wheel weight

The drive belts of the machine are durable. However, the normal exposure to UV radiation, ozone, or incidental exposure to chemicals can deteriorate the rubber over time and lead to premature wear or material loss (i.e., separated or missing belt plies).

1. Remove the belt cover; refer to Removing the Belt Cover.

2. Inspect the hydraulic-pump, jackshaft, and crankshaft belts (Figure 175) for damage, wear, excessive cushion cracks, or large embedded debris.

   Note: Replace the belt(s) when needed.

   

   Figure 175

   1. Crankshaft belt
   2. Hydraulic-pump belt
   3. Jackshaft belt

3. Install the belt cover; refer to Installing the Belt Cover.

1. Prepare the machine for maintenance refer to Preparing the Machine for Maintenance.

2. Remove the belt cover; refer to Removing the Belt Cover.

3. Loosen the flange-head capscrew and flange locknut that secure the idler pulley for the hydraulic-pump belt, until the bolt moves in the slot of the idler support (Figure 176).

   

   Figure 176

   1. Tensioning spring
   2. Flange-head capscrew
   3. Idler pulley
   4. Flange locknut
   5. Hydraulic-pump belt

4. Tap the top of the idler pulley and allow the tensioning spring to adjust the belt tension.

   Important: Do not apply more belt tension than the tensioning spring applies, or component damage may result.

5. Torque the flange-head capscrew and flange locknut to 37 to 45 N∙m (27 to 33 ft-lb).

6. Install the belt cover; refer to Installing the Belt Cover.

• Seek immediate medical attention if fluid is injected into skin. Injected fluid must be surgically removed within a few hours by a doctor.

• Ensure that all hydraulic-fluid hoses and lines are in good condition and all hydraulic connections and fittings are tight before applying pressure to the hydraulic system.

• Keep your body and hands away from pinhole leaks or nozzles that eject high-pressure hydraulic fluid.

• Use cardboard or paper to find hydraulic leaks.

• Safely relieve all pressure in the hydraulic system before performing any work on the hydraulic system.

1. Support the coring head with the service latch; refer to Supporting the Coring Head with the Service Latch.

2. Shut off the engine.

3. Move the ignition switch to the RUN position.

4. In the InfoCenter, navigate to the MAIN MENU (Figure 177).

   

   Figure 177

5. Press the center InfoCenter button until the SERVICE option is selected, and press the right button.

   Note: The coring head lowers until it is fully supported by the service latch.

6. Press the center InfoCenter button until the SERVICE LOWER option is selected (Figure 178), press the right button.

   

   Figure 178

7. Move the key to the STOP position.

Note: Start the engine and run it to raise the coring head hydraulically so that you can stow the service latch; refer to Stowing the Service Latch.

Before each use, check the hydraulic tubes and hoses for leaks, loose fittings, kinked hoses, loose mounting supports, wear, and weather or chemical deterioration. Make replace worn or damaged hydraulic lines before operating the machine.

Note: Keep the areas around the hydraulic system clean from debris buildup.

The reservoir is filled at the factory with high-quality hydraulic fluid. Check the level of the hydraulic fluid before you first start the engine and daily thereafter; refer to Checking the Engine-Oil Level.

Recommended hydraulic fluid: Toro PX Extended Life Hydraulic Fluid; available in 19 L (5 US gallon) pails or 208 L (55 US gallon) drums.

Note: A machine using the recommended replacement fluid requires less frequent fluid and filter changes.

Alternative hydraulic fluids: If Toro PX Extended Life Hydraulic Fluid is not available, you may use another conventional, petroleum-based hydraulic fluid having specifications that fall within the listed range for all the following material properties and that it meets industry standards. Do not use synthetic fluid. Consult with your lubricant distributor to identify a satisfactory product.

Note: Toro does not assume responsibility for damage caused by improper substitutions, so use products only from reputable manufacturers who will stand behind their recommendation.

High Viscosity Index/Low Pour Point Anti-Wear Hydraulic Fluid, ISO VG 46

Note: Many hydraulic fluids are almost colorless, making it difficult to spot leaks. A red dye additive for the hydraulic fluid is available in 20 ml (0.67 fl oz) bottles. A bottle is sufficient for 15 to 22 L (4 to 6 US gallons) of hydraulic fluid. Order Part No. 44-2500 from your authorized Toro distributor.

Important: Toro Premium Synthetic Biodegradable Hydraulic Fluid is the only synthetic biodegradable fluid approved by Toro. This fluid is compatible with the elastomers used in Toro hydraulic systems and is suitable for a wide-range of temperature conditions. This fluid is compatible with conventional mineral oils, but for maximum biodegradability and performance, the hydraulic system should be thoroughly flushed of conventional fluid. The oil is available in 19 L (5 US gallon) pails or 208 L (55 US gallon) drums from your authorized Toro distributor.

Important: Check the level of the hydraulic fluid before the engine is first started and daily thereafter

The hydraulic reservoir is filled at the factory with high-quality hydraulic fluid.

1. Prepare the machine for maintenance refer to Preparing the Machine for Maintenance.

2. Remove the belt cover; refer to Removing the Belt Cover.

3. Clean the area around the filler neck and the cap of the hydraulic tank (Figure 179). Remove the cap from the filler neck.

   

   Figure 179

   1. Dipstick
   2. Cap
   3. Hydraulic tank

4. Remove the dipstick from the filler neck and wipe it with a clean rag. Insert the dipstick into the filler neck; then remove it and check the level of the fluid. The fluid level should be up to the mark on the dipstick (Figure 180).

   

   Figure 180

   1. Dipstick
   2. Full mark

5. If the level is low, add the specified hydraulic fluid to raise the level to the full mark.

6. Install the dipstick and cap onto the filler neck.

7. Install the belt cover; refer to Installing the Belt Cover.

Hydraulic reservoir capacity: approximately 6.6 L (1.75 US gallons)

Important: Do not substitute automotive oil filters or severe hydraulic system damage may result.

Note: Removing the return filter drains the entire fluid reservoir.

1. Prepare the machine for maintenance refer to Preparing the Machine for Maintenance.

2. Place a drain pan under the filters, remove the old filters, and wipe the filter adapter gasket surface clean (Figure 181).

   

   Figure 181

   1. Hydraulic charge filter
   2. Hydraulic return filter

3. Apply a thin coat of clean hydraulic fluid to the gasket on the new filters.

4. Install the hydraulic filters onto the filter adapters. Turn each filter clockwise until the gasket contacts the filter adapter, then tighten each an additional 1/2 turn.

5. Add the specified hydraulic fluid until the fluid level is at the Full mark on the dipstick, refer to Hydraulic Fluid Specifications and Checking the Hydraulic-Fluid Level.

6. Start the engine and run it for 2 minutes to purge air from the system. Shut off the engine, remove the key, and check for hydraulic-fluid leaks.

7. Check the hydraulic fluid level. Add the specified hydraulic fluid to raise the level to the FULL mark on the dipstick, if required.

   Note: Do not overfill the hydraulic reservoir with fluid.

8. Install the belt cover; refer to Installing the Belt Cover.

1. Prepare the machine for maintenance refer to Preparing the Machine for Maintenance.

2. Remove the coring-head cover; refer to Removing the Coring-Head Cover.

3. Check the coring head fasteners, tiller handle fasteners, and wheel lug nuts to ensure that the proper torque is maintained. Fastener torque requirements are listed on the bolt torque decal located on the coring head support channel (Figure 182).

   

   Figure 182

   1. Bolt torque decal location

4. Install the coring-head cover; refer to Installing the Coring-Head Cover.

1. Prepare the machine for maintenance refer to Preparing the Machine for Maintenance.

2. Loosen the capscrews and flange locknuts that secure the side shield to coring-head frame (Figure 183).

   

   Figure 183

   1. Side shield

3. Adjust the shield up or down until you measure a 25 to 38 mm (1 to 1.5 inches) between the shield and the ground.

4. Tighten the capscrews and flange locknuts.

5. Repeat steps 2 through 4 at the other side of the machine.

Replace turf guards if they are broken, or worn to less than 6 mm (1/4 inch) thickness. Broken turf guards can catch and tear the turf, damaging it.

Figure 184

1. Turf guard

The coring head timing marks are easily identified by the cast-in marks on the 3 bearing housings.

Figure 185

1. Timing marks