Toro 648 User Manual
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.
REFER TO THE OPERATOR’S MANUALS FOR OPERATING, MAINTENANCE AND ADJUSTMENT
INSTRUCTIONS. Space is provided in Chapter 2 of this
book to insert the Operator’s Manuals and Parts Catalogs for your machine. Replacement Operator’s Manuals and Parts Catalogs are available on the internet at
www.toro.com.
The Toro Company reserves the right to change product
specifications or this publication without notice.
Part No. 04129SL (Rev. C)
Service Manual
ProCoreR648
This safety symbol means DANGER, WARNING,
or CAUTION, PERSONAL SAFETY INSTRUCTION. When you see this symbol, carefully read
the instructions that follow. Failure to obey the
instructions may result in personal injury.
NOTE: A NOTE will give general information about the
correct operation, maintenance, service, testing or repair of the machine.
IMPORTANT: The IMPORTANT notice will give im portant instructions which must be followed to prevent damage to systems or components on the
machine.
E The Toro Company -- 2004, 2006, 2009
This page is intentionally blank.
ProCore 648
Table Of Contents
Chapter 1 – Safety
Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . 1 – 2
Jacking Instructions
Safety and Instruction Decals
Chapter 2 – Product Records and Maintenance
Product Records . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 – 1
Maintenance
Equivalents and Conversions
Torque Specifications
Chapter 3 – Kohler Engine
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 2
Specifications
General Information
Adjustments
Service and Repairs
KOHLER ENGINE SERVICE MANUAL
Chapter 4 – Hydraulic System
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 – 2
General Information
Hydraulic Schematic
Hydraulic Flow Diagrams
Special Tools
Troubleshooting
Testing
Service and Repairs
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
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 – 1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 5
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 – 17
. . . . . . . . . . . . . . . . . . . . . . . . . 1 – 4
. . . . . . . . . . . . . . . . 1 – 5
. . . . . . . . . . . . . . . . 2 – 2
. . . . . . . . . . . . . . . . . . . . . . . 2 – 3
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 3
. . . . . . . . . . . . . . . . . . . . . . . . 3 – 4
. . . . . . . . . . . . . . . . . . . . . . . . 3 – 7
. . . . . . . . . . . . . . . . . . . . . . . . 4 – 4
. . . . . . . . . . . . . . . . . . . . . . . . 4 – 7
. . . . . . . . . . . . . . . . . . . . 4 – 8
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 – 12
. . . . . . . . . . . . . . . . . . . . . . . . . . . 4 – 14
. . . . . . . . . . . . . . . . . . . . . . . 4 – 30
Chapter 5 – Electrical System
Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 1
Circuit Operation
Special Tools
Troubleshooting
Electrical System Quick Checks
Component Testing
Service and Repairs
Chapter 6 – Chassis
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 2
Special Tools
Service and Repairs
Chapter 7 – Coring Head
General Information . . . . . . . . . . . . . . . . . . . . . . . . 7 – 2
Service and Repairs
Chapter 8 – Electrical Diagrams
Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . 8 – 3
Electrical Circuit Drawings
Wire Harness Drawings
. . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 2
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 7
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 8
. . . . . . . . . . . . . 5 – 11
. . . . . . . . . . . . . . . . . . . . . . . . 5 – 13
. . . . . . . . . . . . . . . . . . . . . . . 5 – 28
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 3
. . . . . . . . . . . . . . . . . . . . . . . . 6 – 4
. . . . . . . . . . . . . . . . . . . . . . . . 7 – 4
. . . . . . . . . . . . . . . . . . . 8 – 4
. . . . . . . . . . . . . . . . . . . . 8 – 11
SafetyProduct Records
and Maintenance
Kohler
Engine
System
Hydraulic
System
Electrical
ChassisCoring HeadElectrical
ProCore 648
Diagrams
This page is intentionally blank.
ProCore 648
Table of Contents
SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . 2
Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
While Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Maintenance and Service . . . . . . . . . . . . . . . . . . . . 3
JACKING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . 4
SAFETY AND INSTRUCTION DECALS . . . . . . . . . . 5
Chapter 1
Safety
Safety
ProCore 648
Page 1 – 1
Safety
Safety Instructions
The ProCore 648 is designed and tested to offer safe
service when operated and maintained properly. Although 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 personnel involved in the operation, transport, maintenance
and storage of the machine. Improper use or maintenance of the machine can result in injury or death. To reduce the potential for injury or death, comply with the
following safety instructions.
Before Operating
WARNING
To reduce the potential for injury or death,
comply with the following safety instructions.
1. Read and understand the contents of the Operator’s
Manual before starting and operating the machine. Become 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.
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.
3. Assure interlock switches are adjusted correctly so
engine cannot be started unless traction lever is in NEUTRAL and coring head is DISENGAGED.
While Operating
1. Operator should be standing at the side console
when starting the engine and at the handle when operating the machine. Stay away from the coring head when
it is engaged.
2. Before starting the engine:
A. Engage the parking brake.
B. Make sure traction lever is in neutral.
4. Since gasoline is highly flammable, handle it carefully:
A. Store fuel in containers specifically designed for
this purpose.
B. Do not remove machine fuel tank cap while engine is hot or running.
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.
E. Wipe up any spilled fuel.
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.
B. Raise coring head and wait for coring head to
stop.
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 adjusted incorrectly . Shut engine off and adjust traction
linkage until machine does not move when traction lever
is released (see Operator’s Manual).
4. Do not run engine in a confined area without adequate ventilation. Exhaust fumes are hazardous and
could possibly be deadly.
Safety
Page 1 -- 2
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.
8. Do not park on slopes unless wheels are chocked or
blocked.
Rev. C
ProCore 648
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.
Maintenance and Service
8. Do not park on slopes unless wheels are chocked or
blocked.
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.
2. Make sure machine is in safe operating condition by
keeping all nuts, bolts and screws tight.
3. Never store the machine or fuel container inside
where there is an open flame, such as near a water heater or furnace.
4. Make sure all hydraulic line connectors are tight and
all hydraulic hoses and lines are in good condition before applying pressure to the hydraulic system.
5. Keep body and hands away from pin hole leaks in hydraulic 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.
6. Before disconnecting any hydraulic component or
performing any work on the hydraulic system, all pressure in system must be relieved. See Relieving Hydraulic System Pressure in the General Information section
of Chapter 4 – Hydraulic System.
7. If major repairs are ever needed or assistance is desired, 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.
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.
13.Disconnect battery before servicing the machine.
Disconnect negative battery cable first and positive battery cable last. If battery voltage is required for troubleshooting or test procedures, temporarily connect the
battery. Reconnect positive battery cable first and negative battery cable last.
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.
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 accessories. Replacement parts and accessories made
by other manufacturers may result in non-conformance
with the safety standards, and the warranty may be
voided.
17.When changing tires or performing other service,
use correct blocks, hoists and jacks. Make sure machine is parked on a solid level floor such as a concrete
floor. Prior to raising the machine, remove any attachments 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 machine. 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).
Safety
10.If engine must be running to perform maintenance or
make an adjustment, keep hands, feet, clothing and other parts of the body away from all moving machine parts.
Keep bystanders away.
ProCore 648
Page 1 – 3
Safety
Jacking Instructions
CAUTION
When changing attachments, tires or performing 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 attachments 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 machine. If the machine is not properly supported by blocks or
jack stands, the machine may move or fall,
which may result in personal injury.
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. Position jack securely under the front of the frame
(Fig. 1).
1
Figure 1
1. Front wheel 2.
2
2
Frame jacking point
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.
Jacking the Rear End
1. Chock front tire to prevent the machine from moving.
Install service latch to secure coring head.
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).
3. Jack (or lift) rear of machine off the ground.
4. Position jack stands or hardwood blocks under the
frame to support the machine.
1
Figure 2
1. Rear wheel 2. Frame jacking point
2
1
Figure 3
1. Bearing housing 2. Lifting eyelet
Safety
Page 1 – 4
ProCore 648
Safety and Instruction Decals
Numerous safety and instruction decals are affixed to
the ProCore 648. If any decal becomes illegible or damaged, install a new decal. Part numbers for replacement
decals are listed in your Parts Catalog. Order replacement decals from your Authorized Toro Distributor.
Safety
ProCore 648
Page 1 – 5
Safety
This page is intentionally blank.
Safety
Page 1 – 6
ProCore 648
Product Records and Maintenance
Table of Contents
Chapter 2
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
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 Instructions, Operator’s Manuals and Parts Catalogs for those
options at the end of this chapter.
Maintenance
Maintenance procedures and recommended service intervals for the ProCore 648 are covered in the Operator’s Manual. Refer to that publication when performing
regular equipment maintenance. Refer to the Engine
Operator’s Manual for additional engine specific maintenance procedures.
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
Conversion Factors
. . . . . . . . . . . . . . . . . . . . . . . . . 6
. . . . . . . . . . . . . . . . . . 6
Product Records
and Maintenance
ProCore 648
Page 2 – 1
Product Records and Maintenance
Equivalents and Conversions
0.09375
Product Records and Maintenance
Page 2 -- 2
Rev. C
ProCore 648
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 specified in this Service Manual.
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 Service 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.
Fastener Identification
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 engagement, etc.
The standard method of verifying torque shall be performed 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.
Product Records
and Maintenance
Grade 1
Grade 5 Grade 8
Inch Series Bolts and Screws
Figure 1 Figure 2
Class 8.8 Class 10.9
Metric Bolts and Screws
ProCore 648
Page 2 – 3
Product Records and Maintenance
Standard Torque for Dry, Zinc Plated and Steel Fasteners (Inch Series)
Grade 1, 5 & SAE Grade 1 Bolts, Screws, Studs & SAE Grade 5 Bolts, Screws, Studs & SAE Grade 8 Bolts, Screws, Studs &
Thread Size
8 with Thin Sems with Regular Height Nuts Sems with Regular Height Nuts Sems with Regular Height Nuts
Height Nuts (SAE J995 Grade 2 or Stronger Nuts) (SAE J995 Grade 2 or Stronger Nuts) (SAE J995 Grade 5 or Stronger Nuts)
in–lb in–lb N–cm in–lb N–cm in–lb N–cm
# 6 – 32 UNC 15 + 2 170 + 20 23 + 2 260 + 20
# 6 – 40 UNF
# 8 – 32 UNC 29 + 3 330 + 30 41 + 4 460 + 45
# 8 – 36 UNF
# 10 – 24 UNC 42 + 4 475 + 45 60 + 6 675 + 70
# 10 – 32 UNF
1/4 – 20 UNC 48 + 7 53 + 7 599 + 79 100 + 10 1125 + 100 140 + 15 1580 + 170
1/4 – 28 UNF 53 + 7 65 + 10 734 + 113 115 + 10 1300 + 100 160 + 15 1800 + 170
5/16 – 18 UNC 115 + 15 105 + 17 1186 + 169 200 + 25 2250 + 280 300 + 30 3390 + 340
5/16 – 24 UNF 138 + 17 128 + 17 1446 + 192 225 + 25 2540 + 280 325 + 30 3670 + 340
3/8 – 16 UNC 16 + 2 16 + 2 22 + 3 30 + 3 41 + 4 43 + 4 58 + 5
3/8 – 24 UNF 17 + 2 18 + 2 24 + 3 35 + 3 47 + 4 50 + 4 68 + 5
7/16 – 14 UNC 27 + 3 27 + 3 37 + 4 50 + 5 68 + 7 70 + 7 95 + 9
7/16 – 20 UNF 29 + 3 29 + 3 39 + 4 55 + 5 75 + 7 77 + 7 104 + 9
10 + 2
+ 2 13 + 2
13 + 2
+ 2
18 + 2
+ 2 30 + 5
ft–lb ft–lb N–m ft–lb N–m ft–lb N–m
+ 2 147 + 23
25 + 5
+ 5
+ 5 339 + 56
282 + 30
+ 23
17 + 2 190 + 20 25 + 2 280 + 20
+ 30
31 + 3 350 + 30 43 + 4 485 + 45
+ 56
48 + 4 540 + 45 68 + 6 765 + 70
1/2 – 13 UNC 30 + 3 48 + 7 65 + 9 75 + 8 102 + 11 105 + 10 142 + 14
1/2 – 20 UNF 32 + 3 53 + 7 72 + 9 85 + 8 115 + 11 120 + 10 163 + 14
5/8 – 11 UNC 65 + 10 88 + 12 119 + 16 150 + 15 203 + 20 210 + 20 285 + 27
5/8 – 18 UNF 75 + 10 95 + 15 129 + 20 170 + 15 230 + 20 240 + 20 325 + 27
3/4 – 10 UNC 93 + 12 140 + 20 190 + 27 265 + 25 359 + 34 375 + 35 508 + 47
3/4 – 16 UNF 115 + 15 165 + 25 224 + 34 300 + 25 407 + 34 420 + 35 569 + 47
7/8 – 9 UNC 140 + 20 225 + 25 305 + 34 430 + 45 583 + 61 600 + 60 813 + 81
7/8 – 14 UNF 155 + 25 260 + 30 353 + 41 475 + 45 644 + 61 660 + 60 895 + 81
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 minimum 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
Page 2 – 4
ProCore 648
Standard Torque for Dry, Zinc Plated and Steel Fasteners (Metric Fasteners)
Class 8.8 Bolts, Screws and Studs with
Thread Size
M8 X 1.25 19 + 2 ft–lb 26 + 3 N–m 27 + 2 ft–lb 36 + 3 N–m
M10 X 1.5 38 + 4 ft–lb 52 + 5 N–m 53 + 5 ft–lb 72 + 7 N–m
M12 X 1.75 66 + 7 ft–lb 90 + 10 N–m 92 + 9 ft–lb 125 + 12 N–m
M16 X 2.0 166 + 15 ft–lb 225 + 20 N–m 229 + 22 ft–lb 310 + 30 N–m
M20 X 2.5 325 + 33 ft–lb 440 + 45 N–m 450 + 37 ft–lb 610 + 50 N–m
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: 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.
Size
M5 X 0.8 57 + 5 in–lb 640 + 60 N–cm 78 + 7 in–lb 885 + 80 N–cm
M6 X 1.0 96 + 9 in–lb 1018 + 100 N–cm 133 + 13 in–lb 1500 + 150 N–cm
Regular Height Nuts
(Class 8 or Stronger Nuts)
Height Nuts
NOTE: The nominal torque values listed above are
based on 75% of the minimum proof load specified in
SAE J1199. The tolerance is approximately +
nominal torque value.
Class 10.9 Bolts, Screws and Studs with
Regular Height Nuts
(Class 10 or Stronger Nuts)
Height Nuts
10% of the
Product Records
and Maintenance
ProCore 648
Page 2 – 5
Product Records and Maintenance
Other Torque Specifications
SAE Grade 8 Steel Set Screws Wheel Bolts and Lug Nuts
Recommended Torque
Size Thread Size
Square Head Hex Socket
1/4 – 20 UNC 140 + 20 in–lb 73 + 12 in–lb
5/16 – 18 UNC 215 + 35 in–lb 145 + 20 in–lb
3/8 – 16 UNC 35 + 10 ft–lb 18 + 3 ft–lb
1/2 – 13 UNC 75 + 15 ft–lb 50 + 10 ft–lb
Thread Cutting Screws
(Zinc Plated Steel)
Type 1, Type 23 or Type F
Thread Size Baseline Torque*
No. 6 – 32 UNC 20 + 5 in–lb
No. 8 – 32 UNC 30 + 5 in–lb
Thread Size
7/16 – 20 UNF
Grade 5
1/2 – 20 UNF
Grade 5
M12 X 1.25
Class 8.8
M12 X 1.5
Class 8.8
** For steel wheels and non–lubricated fasteners.
Thread Cutting Screws
(Zinc Plated Steel)
Thread
Size
No. 6 18 20 20 + 5 in–lb
No. 8 15 18 30 + 5 in–lb
Threads per Inch
Type A Type B
Recommended Torque**
65 + 10 ft–lb 88 + 14 N–m
80 + 10 ft–lb 108 + 14 N–m
80 + 10 ft–lb 108 + 14 N–m
80 + 10 ft–lb 108 + 14 N–m
Torque* Baseline Torque*
No. 10 – 24 UNC 38 + 7 in–lb
1/4 – 20 UNC 85 + 15 in–lb
5/16 – 18 UNC 110 + 20 in–lb
3/8 – 16 UNC 200 + 100 in–lb
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
No. 10 12 16 38 + 7 in–lb
No. 12 11 14 85 + 15 in–lb
* Hole size, material strength, material thickness & finish
must be considered when determining specific torque
values. All torque values are based on non–lubricated
fasteners.
Product Records and Maintenance
Page 2 – 6
ProCore 648
Table of Contents
Chapter 3
Kohler Engine
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
Kohler
Engine
ProCore 648 Page 3 – 1 Kohler Engine
Introduction
This Chapter gives information about specifications and
repair of the Kohler engine used in the ProCore 648.
General engine maintenance procedures are described
in your Operator’s Manual. Information on engine troubleshooting, testing, disassembly, and reassembly is
identified in the Kohler Engine Service Manual that is included at the end of this section.
Most repairs and adjustments require tools which are
commonly available in many service shops. Special
tools are described in the Kohler Engine Service Manual. The use of some specialized test equipment is explained. 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.
Service and repair parts for Kohler engines are supplied
through your local Kohler dealer or distributor.
Kohler Engine
Page 3 – 2
ProCore 648
Specifications
Item Description
Make / Designation Kohler, CH23S, 4–stroke, V–Twin
Air Cooled, OHV
Number of Cylinders 2
Bore x Stroke 3.15” x 2.64” (80 mm x 67 mm)
Total Displacement 41.1 Cubic Inches (674 cc)
Compression Ratio 8.5:1
Dry Weight (approximate) 90 Pounds (41 Kilograms)
Fuel Unleaded, Regular Gasoline (Minimum 87 Octane)
Fuel Tank Capacity 7.5 U.S. Gallons (28.4 Liters)
Governor Mechanical
Idle Speed (no load) 1400 + 50 RPM
High Idle (no load) 3400 + 50 RPM
Engine Oil See Operator’s Manual
Oil Pump Gear driven trochoid type
Kohler
Engine
Crankcase Oil Capacity 2 U.S. Quart (1.9 Liters) with filter
Starter 12 VDC
ProCore 648 Page 3 – 3 Kohler Engine
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 engine from the machine. Additionally, close the shutoff
valve if the machine is being transported on a trailer or
when placing the machine in long term storage.
1
Figure 1
1. Fuel shutoff valve (under the fuel tank)
Kohler Engine
Page 3 – 4
ProCore 648
Adjustments
Adjust Choke Control
Proper choke operation is dependent upon proper adjustment of choke control cable.
1. Park machine on a level surface, fully raise coring
head, engage parking brake, stop engine and remove
key from the ignition switch.
1
2. Remove air cleaner cover from engine to view choke
plate in carburetor.
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.
5. If needed, choke cable can be adjusted by loosening
cable clamp screw and repositioning control cable until
choke plate operates correctly.
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.
3. Using a tachometer, check that engine is operating
at 3400 + 50 RPM.
2
Figure 2
1. Choke cable 2. Cable clamp
1
Kohler
Engine
4. If high idle speed is incorrect, adjust high speed
screw on governor assembly until high idle is 3400 + 50
RPM (Fig. 3).
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 Chapter.
ProCore 648 Page 3 – 5 Kohler Engine
Figure 3
1. High speed screw
This page is intentionally blank.
Kohler Engine
Page 3 – 6
ProCore 648
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.
NOTE: Perform this maintenance procedure at the interval 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 engine overheating and engine damage.
1
1
1. Park machine on a level surface, fully raise coring
head, engage parking brake, stop engine and remove
key from the ignition switch.
IMPORTANT: Never clean engine with pressurized
water. Water could enter and contaminate the fuel
system.
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 machine (see Engine Removal and Installation in this section).
IMPORTANT: Never operate engine without the
blower housing installed. Overheating and engine
damage will result.
5. Make sure grass screen and blower housing are reinstalled to the engine if removed.
1. Cylinder head
2. Grass screen
2
Figure 4
3. Blower housing
3
Kohler
Engine
ProCore 648 Page 3 – 7 Kohler Engine
Fuel System
RIGHT
FRONT
Anti–seize
Lubricant
2
1
12
11
8
10
30 to 60 in–lb
(3.4 to 6.8 N–m)
1. Fuel tank
2. Fuel cap
3. Hose clamp
4. Fuel hose
5. Fuel shut–off valve
6. Hose clamp
7. Fuel hose
8. Flat washer (4 used)
DANGER
Because gasoline is highly flammable, use caution 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.
8
4
3
7
5
6
Figure 5
9. Clamp
10. Cap screw (4 used)
11. Flange bushing (4 used)
12. Machine frame
Check Fuel Lines and Connections
Check fuel lines and connections periodically as recommended in the Operator’s Manual. Check fuel lines for
deterioration, damage or leaking connections. Replace
hoses, clamps and connections as necessary.
Drain and Clean Fuel Tank
Drain and clean the fuel tank periodically as recommended 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.
9
10
6
Kohler Engine
To clean fuel tank, flush tank out with clean solvent.
Make sure tank is free of contaminates and debris.
Page 3 – 8
ProCore 648
Fuel Tank Removal (Fig. 5)
1. Park machine on a level surface, fully raise coring
head, engage parking brake, stop engine and remove
key from the ignition switch. Secure coring head with
service latch.
2. Close tank fuel shut–off valve. Disconnect fuel hose
from the fuel filter (Fig. 6).
2
3
3. Use shut–off valve to empty fuel tank into a suitable
container.
4. Remove fuel tank using Figure 5 as a guide.
Fuel Tank Installation (Fig. 5)
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).
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.
1. Fuel shut–off valve
2. Fuel filter
Figure 6
3. Fuel hose
1
Kohler
Engine
ProCore 648 Page 3 – 9 Kohler Engine
Exhaust System
1
17 to 21 ft–lb
(23.1 to 28.5 N–m)
FRONT
RIGHT
3
4
2
6
5
7
8
8
9
10
11
7
12
1. Engine
2. Exhaust manifold
3. Hex nut (4 used)
4. Frame
5. Flange nut (2 used)
Figure 7
6. Muffler bracket
7. Flange head screw (3 used)
8. Muffler clamp (2 used)
9. Exhaust elbow
10. Carriage screw (2 used)
13
14
15
11. Heat shield
12. Lock washer (2 used)
13. Cap screw (2 used)
14. Flange nut (2 used)
15. Muffler
Kohler Engine
Page 3 – 10
ProCore 648
Removal (Fig. 7)
CAUTION
Installation (Fig. 7)
NOTE: Make sure exhaust manifold and engine seal-
ing surfaces are free of debris or damage that may prevent a tight, leak–free seal.
The muffler and exhaust pipe may be hot. To
avoid possible burns, allow the engine and exhaust system to cool before working on the exhaust system.
1. Park machine on a level surface, fully raise coring
head, engage parking brake, stop engine and remove
key from the ignition switch. Secure coring head with
service latch.
2. Remove 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. Loosen muffler clamps that secure muffler and exhaust elbow.
4. Remove two (2) flange nuts that secure muffler to
frame. Retrieve two (2) carriage screws. Remove muffler and exhaust elbow from machine.
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.
6. Remove exhaust gaskets.
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).
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.
3. Slide exhaust elbow onto exhaust manifold and then
slide muffler onto elbow.
4. Secure muffler to frame with two (2) carriage screws
and flange nuts.
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.
7. Return coring head service latch to stored position
before using machine.
Kohler
Engine
ProCore 648 Page 3 – 11 Kohler Engine
Engine
1
2
3
FRONT
19
21
4
5
6
7
13
9
16
19
11
8
12
13
14
19
8
10
15
20
RIGHT
12
17
18
1. Engine
2. Negative battery cable
3. Wire harness ground
4. Flange screw
5. Lock washer
6. Exhaust manifold
7. Hex nut (4 used)
8. Cap screw (4 used)
9. Frame
10. Flange nut (2 used)
11. Muffler bracket
12. Flange head screw (3 used)
13. Muffler clamp (2 used)
14. Exhaust elbow
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. Chock wheels to keep the machine from
moving.
2. Disconnect negative (--) and then positive (+) battery
cables at the battery .
3. Remove pump belt cover from machine (see Operator’s Manual).
Kohler Engine
Page 3 -- 12
Figure 8
15. Carriage screw (2 used)
16. Heat shield
17. Lock washer (2 used)
18. Cap screw (2 used)
19. Flange nut (6 used)
20. Muffler
21. Starter cable
4. Remove exhaust system (see Exhaust System Removal in this section).
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.
Rev. C
ProCore 648
7. Disconnect electrical connections from engine.
NOTE: Label all electrical connections for reassembly
purposes.
A. Remove harness red wire and positive battery
cable from the starter motor solenoid stud (Fig. 9).
B. Disconnect negative battery cable and wire harness ground wire from the front corner of engine
base (Fig. 10). Locate and retrieve starwasher from
between engine and wire connectors.
C. Unplug machine harness connector from electric
clutch.
D. Remove cable tie that secures hourmeter wire to
spark plug wire. Position hourmeter wire clear of engine.
E. Unplug machine wire harness connector from engine connector. Position wiring harness away from
the engine.
8. Remove primary drive belt (coring head) (see Primary Drive Belt in the Service and Repairs section of Chapter 7 – Coring Head).
2
1. Solenoid stud
2. Positive battery cable
3
Figure 9
3. Harness red wire
1
Kohler
Engine
2
9. Remove hydraulic pump drive belt (see Pump Drive
Belt in the Service and Repairs section of Chapter 4 –
Hydraulic System).
10.Remove engine from machine:
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.
CAUTION
One person should operate lift or hoist while
another person guides the engine out of the machine.
IMPORTANT: Make sure not to damage the engine,
fuel hoses, hydraulic lines, electrical harness or
other parts while removing the engine.
C. Remove engine from the machine.
1
1. Flange head screw
2. Wire harness ground
2
(67.8 to 74.6 N–m)
3
Figure 10
3. Negative battery cable
1
Anti–seize
Lubricant
3
4
50 to 55 ft–lb
5
11.If needed, remove electric clutch (see Electric Clutch
in the Service and Repairs section of Chapter 5 – Electrical System) and hydraulic pump drive pulley from engine (Fig. 11).
1. Engine
2. Pump pulley
3. Electric clutch
Figure 11
4. Hardened washer
5. Cap screw
12.If needed, remove belt tensioning components from
engine (see Belt Tensioners in this section).
ProCore 648 Page 3 – 13 Kohler Engine
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 machine from moving.
2. Make sure that all parts removed from the engine
during maintenance or rebuilding are reinstalled to the
engine.
3. If electric clutch and hydraulic pump drive pulley
were removed from engine crankshaft (Fig. 11):
A. Apply anti–seize lubricant to crankshaft.
B. Install hydraulic pump drive pulley with the hub
away from engine.
C. Slide clutch onto crankshaft and secure to crankshaft with screw and hardened washer. Hold hardened washer with pliers to prevent crankshaft from
turning and torque screw from 50 to 55 ft–lb (67.9 to
74.6 N–m).
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 connectors and secure with flange head screw.
D. Plug machine harness connector to electric
clutch.
E. Connect red wire and positive battery cable to the
starter motor solenoid stud (Fig. 9).
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. Retighten pulley set screws after adjustment.
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 engine assembly (see Belt Tensioners in this section).
5. Reinstall engine to machine.
A. Connect a hoist or chain fall to lift tabs located on
each of the cylinder heads.
CAUTION
One person should operate lift or hoist while
another person guides the engine to the machine.
IMPORTANT: Make sure not to damage the engine,
fuel hoses, hydraulic lines, electrical harness or
other parts while installing the engine.
B. Reinstall engine to the machine. Make sure fastener holes of the engine are aligned with the holes in
the machine frame.
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.
6. Reconnect electrical connections to engine:
9. Adjust hydraulic pump drive belt tension (see Operator’s Manual).
10.Install primary drive belt (coring head) (see Primary
Drive Belt in the Service and Repairs section of Chapter
7 – Coring Head).
11. Remove plug installed in fuel hose during disassembly. Connect fuel hose to the fuel filter and secure with
hose clamp.
12.Install exhaust system (see Exhaust System Installation in this section).
13.Check engine oil level (see Operator’s Manual).
14.Check all wires, control cables and hoses to make
sure that they are not contacted by rotating or moving
parts.
15.Connect positive (+) and then negative (–) battery
cables at the battery.
16.Install pump belt cover to machine (see Operator’s
Manual).
17.Open fuel shut–off valve under the fuel tank.
18.Return coring head service latch to stored position
before using machine.
A. Plug engine wire harness connector into machine
harness connector.
Kohler Engine
Page 3 – 14
ProCore 648
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