Toro 648 User Manual

Page 1

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

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ProCore 648

Page 3

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

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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

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ProCore 648

Page 5

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

ProCore 648

Page 1 – 1

Safety

Page 6

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

Page 7

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

Page 8

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).

Figure 1

1. Front wheel 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.

Figure 2

1. Rear wheel 2. Frame jacking point

Figure 3

1. Bearing housing 2. Lifting eyelet

Safety

Page 1 – 4

ProCore 648

Page 9

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

Page 10

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Safety

Page 1 – 6

ProCore 648

Page 11

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

Page 12

Equivalents and Conversions

0.09375

Product Records and Maintenance

Page 2 -- 2

Rev. C

ProCore 648

Page 13

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

Page 14

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

Page 15

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

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

Page 16

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

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

Page 17

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

Page 18

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

Page 19

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

Page 20

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.

Figure 1

1. Fuel shutoff valve (under the fuel tank)

Kohler Engine

Page 3 – 4

ProCore 648

Page 21

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.

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.

Figure 2

1. Choke cable 2. Cable clamp

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

Page 22

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Kohler Engine

Page 3 – 6

ProCore 648

Page 23

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. 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

Figure 4

3. Blower housing

Kohler

Engine

ProCore 648 Page 3 – 7 Kohler Engine

Page 24

Fuel System

RIGHT

FRONT

Anti–seize

Lubricant

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.

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.

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

Page 25

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).

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

Kohler

Engine

ProCore 648 Page 3 – 9 Kohler Engine

Page 26

Exhaust System

17 to 21 ft–lb

(23.1 to 28.5 N–m)

FRONT

RIGHT

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)

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

Page 27

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

Page 28

Engine

FRONT

RIGHT

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

Page 29

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).

1. Solenoid stud

2. Positive battery cable

Figure 9

3. Harness red wire

Kohler

Engine

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. Flange head screw

2. Wire harness ground

(67.8 to 74.6 N–m)

Figure 10

3. Negative battery cable

Anti–seize

Lubricant

50 to 55 ft–lb

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

Page 30

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

Page 31

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Kohler

Engine

ProCore 648 Page 3 – 15 Kohler Engine

Page 32

Belt Tensioners

41 to 49 ft–lb

(55.6 to 66.4 N–m)

Anti–seize

Lubricant

41 to 49 ft–lb

(55.6 to 66.4 N–m)

1. Engine

2. Hydraulic pump drive pulley

3. Electric clutch

4. Flange nut

5. Hardened washer

6. Cap screw

7. Flat washer

8. Grommet

9. Spacer

10. Cap screw

11. Clutch strap

12. Cap screw

50 to 55 ft–lb

(67.8 to 74.6 N–m)

Figure 12

13. Flange nut

14. Flat washer

15. Idler arm assembly

16. Washer

17. Idler spacer

18. Idler arm spacer

19. Torsion spring

20. Idler pulley

21. Hardened washer

22. Cap screw

23. Cap screw

24. Spacer (.750” long)

25. Idler mounting bracket

26. Spacer (.560” long)

27. Lock nut

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)

Kohler Engine

Page 3 – 16

ProCore 648

Page 33

Removal (Fig. 12)

Installation (Fig. 12)

1. Release tension on idler torsion spring (item 19):

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.

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.

2. Remove belt tensioner components from engine as needed using Figure 12 as a guide.

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).

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.

4. Adjust the hydraulic pump drive belt (see Operator’s Manual) and primary drive belt (coring head) (see Primary Drive Belt in the Service and Repairs section of Chapter 7 – Coring Head).

Kohler

Engine

ProCore 648 Page 3 – 17 Kohler Engine

Page 34

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Kohler Engine

Page 3 – 18

ProCore 648

Page 35

Table of Contents

Chapter 4

Hydraulic System

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)

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.................

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

SAUER DANFOSS GROUP 2GEAR PUMPS AND MO-

TORS SERVICE MANUAL

SAUER DANFOSS OMEW HYDRAULIC MOTOR

SERVICE MANUAL

System

Hydraulic

ProCore 648 Hydraulic SystemPage 4 -- 1

Rev. C

Page 36

Specifications

Item Description

Traction Pump (P1) Variable displacement piston pump

Displacement at full stroke (per revolution) .976 Cubic Inches (16 cc) Forward relief pressure 2900 PSI (200 Bar) Reverse relief pressure 2900 PSI (200 Bar)

Charge/Lift Pump (P2) Gear pump

Displacement (per revolution) .37 Cubic Inches (6.1 cc) Charge Pressure 40 PSI (2.8 Bar)

Lift System Relief (R1) Pressure 1000 PSI (69 Bar)

Front Wheel Motor Orbital rotor motor

Displacement 24 Cubic Inches (393 cc)

Rear Wheel Motors Orbital rotor motor

Displacement 12 Cubic Inches (197 cc)

Hydraulic Filter Spin–on cartridge type

Hydraulic Oil See Operator’s Manual

Hydraulic Reservoir Capacity 1.75 U.S. Gal. (6.6 L)

Total Hydraulic System Capacity 3 U.S. Gal. (11.4 L) (Approximate)

Hydraulic System Page 4 – 2 ProCore 648

Page 37

This page is intentionally blank.

System

Hydraulic

ProCore 648 Page 4 – 3 Hydraulic System

Page 38

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 conditions, or mishandling during operation and maintenance. These conditions can cause damage or premature deterioration. Some hoses are more susceptible 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 Pressure in this section.

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

1. Make sure both threads and sealing surfaces are free of burrs, nicks, scratches, or any foreign material.

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.

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.

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 surgically removed within a few hours by a doctor familiar with this type of injury. Gangrene may result from such an injury.

Nut

Sleeve

Seal

Body

Figure 1

5. Mark the nut and fitting body. Hold the body with a wrench. Use another wrench to tighten the nut to the correct Flats From Finger Tight (F.F.F.T.). The markings on the nut and fitting body will verify that the connection has been tightened.

Size F.F.F.T.

4 (1/4 in. nominal hose or tubing) 0.75 + 0.25 6 (3/8 in.) 0.75 + 0.25 8 (1/2 in.) 0.75 + 0.25 10 (5/8 in.) 1.00 + 12 (3/4 in.) 0.75 + 0.25 16 (1 in.) 0.75 +

0.25

Finger Tight After Proper Tightening

Final Position

Mark Nut and Body

Extend Line

Figure 2

Initial Position

Hydraulic System Page 4 – 4 ProCore 648

Page 39

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 fitting shows signs of leakage.

3. Lubricate the O–ring with a light coating of oil.

O–Ring

4. Install the fitting into the port and tighten it down full length until finger tight.

5. Tighten the fitting to the correct Flats From Finger Tight (F.F.F.T.).

Size F.F.F.T.

4 (1/4 in. nominal hose or tubing) 1.00 + 6 (3/8 in.) 1.50 + 0.25 8 (1/2 in.) 1.50 + 0.25 10 (5/8 in.) 1.50 + 0.25 12 (3/4 in.) 1.50 + 16 (1 in.) 1.50 +

0.25

NOTE: Installation torque values for non–adjustable fittings 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.

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 fitting shows signs of leakage.

Figure 3

Fitting Size Installation Torque

4 9–10 ft–lb (12–13 N–m)

6 20–21 ft–lb (27–28 N–m)

8 35–37 ft–lb (47–50 N–m)

10 60–66 ft–lb (81–89 N–m)

12 81–87 ft–lb (110–117 N–m)

16 121–131 ft–lb (164–177 N–m)

Figure 4

System

Hydraulic

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).

5. Install the fitting into the port and tighten finger tight

Figure 5

Lock Nut

Back–up Washer

O–Ring

until the washer contacts the face of the port (Step 2).

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 3

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) 1.00 + 0.25 6 (3/8 in.) 1.50 + 0.25 8 (1/2 in.) 1.50 + 0.25 10 (5/8 in.) 1.50 + 12 (3/4 in.) 1.50 + 16 (1 in.) 1.50 +

0.25

Step 2

Step 4

Figure 6

ProCore 648 Page 4 – 5 Hydraulic System

Page 40

Pushing/Pulling Machine

IMPORTANT: If push/pull limits are exceeded, severe damage to the piston (traction) pump may occur.

If it becomes necessary to push/pull the machine, push/ pull at a speed below 1 mph (1.6 kph), and for a dis- 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.

See Operator’s Manual for pushing/pulling procedures.

Check Hydraulic Fluid

The ProCore 648 hydraulic system is designed to operate 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.

Figure 7

1. By–pass valve location

See Operator’s Manual for fluid level checking procedure and hydraulic oil recommendations.

Relieving Hydraulic System Pressure

Before disconnecting or performing any work on the hydraulic 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 coring head with service latch.

To relieve hydraulic pressure in traction circuit, move traction lever to both forward and reverse directions.

Figure 8

1. Hydraulic reservoir 2. Hydraulic reservoir cap

To relieve lift system pressure, 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 when pressure has been relieved. Remove key from the ignition switch.

Hydraulic System Page 4 – 6 ProCore 648

Page 41

Hydraulic Schematic

ORF1

LIFT CYLINDER

CYL

SVR

SVL

SVQ

CONTROL

CHG

FORWARD

’B’ PORT (BOTTOM)

’P’ PORT

MANIFOLD

FRONT

WHEEL

System

Hydraulic

’A’ PORT

(TOP)

COMPONENT

P1 P2 PV R1 R2 M1 M2 M3 ORF1

CIR

.98 .37

23.8

12.1

.050

GPM

10.5

4.1

PSI

2900

1000

ProCore 648 Hydraulic SystemPage 4 -- 7

Rev. C

’P’ PORT

M2 M3

ProCore 648

Hydraulic Schematic

All solenoids are shown as de--energized

Page 42

Hydraulic Flow Diagrams

ORF1

CYL

SVR

(NOT ENERGIZED)

SVQ

CHG

FORWARD

(NOT ENERGIZED)

’B’ PORT (BOTTOM)

’P’ PORT

SVL

(NOT ENERGIZED)

CONTROL MANIFOLD

FRONT WHEEL

LIFT CYLINDER

’A’ PORT

(TOP)

’P’ PORT

M2 M3

’P’ PORT

Traction Circuit (Forward Shown)

Working Pressure Low Pressure (Charge) Return or Suction Flow

Rev. C

ProCore 648Hydraulic System Page 4 -- 8

Page 43

Traction Circuit

The traction (piston) pump (P1) is driven by the engine through the pulleys and pump drive belt. The traction circuit 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.

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 manifold (manifold port P, proportional valve PV and manifold 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 always available for the charge oil needs of the traction circuit. 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 hydraulic oil filter.

Forward Direction

Reverse Direction

The traction circuit operates essentially the same in reverse as it does in the forward direction. However, the flow through the circuit is reversed. When the traction lever 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.

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.

With the engine running and the traction lever in the neutral 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 lower port of the pump. Oil flow from the pump is directed to the wheel motors (front motor first and then rear motors) 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 assembly.

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.

System

Hydraulic

ProCore 648 Hydraulic SystemPage 4 – 9

Page 44

ORF1

CYL

LIFT CYLINDER (EXTENDING)

FROM

GEAR

PUMP

TRACTION

PUMP

SVR

(ENERGIZED)

TCHGP

SVQ

(ENERGIZED)

ORF1

SVL

(NOT

ENERGIZED)

SVL

(ENERGIZED)

CORING HEAD

RAISE

CONTROL MANIFOLD

LIFT CYLINDER

CYL

(RETRACTING)

FROM

GEAR PUMP

TRACTION

PUMP

SVR

(NOT ENERGIZED)

TCHGP

SVQ

(ENERGIZED)

CONTROL

MANIFOLD

LOWER

Coring Head Raise/Lower Circuits

Working Pressure Low Pressure (Charge) Return or Suction Flow

CORING HEAD

ProCore 648Hydraulic System Page 4 – 10

Page 45

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.

Maximum lift/lower circuit pressure is limited to 1000 PSI (69 Bar) by relief valve R1 in the lift control manifold.

Flow from gear pump (P2) goes to the lift control manifold (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 hydraulic 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 manifold port CYL to the lift cylinder. Hydraulic pressure against the lift cylinder rod extends the cylinder and raises the coring head.

When the coring head reaches the aerating position, solenoid valves SVQ and SVL in the hydraulic manifold are de–energized. The valve shift of SVQ removes the bypass to orifice (ORF1). The valve shift of SVL prevents oil flow from the lift cylinder. Without flow from the lift cylinder, the cylinder and coring head are held in place.

True Core

Ground Following System

When aerating with the ground follow switch in the ON

position, the True Core

Ground Following System hydraulically 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 depending on movement of the turf guards over ground irregularities. These switches are used as inputs for the aerator control module to energize or de–energize solenoid 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.

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. Solenoid valve SVL is always energized while aerating when the ground follow switch is in the OFF position.

System

Hydraulic

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 bypass 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 manifold orifice (ORF1) for more immediate cylinder movement. 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 cylinder to retract and the coring head to lower. Oil flowing from the retracting lift cylinder returns to the reservoir.

ProCore 648 Hydraulic SystemPage 4 – 11

Page 46

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.

Hydraulic Tester (Pressure and Flow)

Figure 9

Toro Part Number: TOR214678

This tester requires O--ring Face Seal (ORFS) adapter fittings for use on this machine (see Hydraulic Test Fitting Kit -- TOR4079 in this section).

1. INLET HOSE: Hose connected from the system circuit 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 PRESSURE GAUGE: Lowrange gauge toprovide accurate reading at low pressure: 0 to 1000 PSI.

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.

Figure 10

6. OUTLET HOSE: A hose from the outlet side of the hydraulic tester connects to the hydraulic system circuit.

Rev. C

ProCore 648Hydraulic System Page 4 -- 12

Page 47

Hydraulic Test Fitting Kit

Part Number: TOR4079

This kit includes a variety of O–ring Face Seal fittings to enable connection of test gauges to the ProCore 648 hydraulic system.

The kit includes: tee’s, unions, reducers, plugs, caps, and male test fittings.

Wheel Hub Puller

Part Number: TOR4097

The wheel hub puller allows safe removal of the wheel hub from the shaft of wheel motors.

TORO TEST FITTING KIT (NO. TOR4079)

Figure 11

Figure 12

System

Hydraulic

ProCore 648 Hydraulic SystemPage 4 – 13

Page 48

Troubleshooting

The cause of an improperly functioning hydraulic system is best diagnosed with the use of proper testing equipment and a thorough understanding of the complete hydraulic system.

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.

Problem

Hydraulic oil leaks

БББББББББББ

Foaming hydraulic fluid

БББББББББББ

Hydraulic system operates hot

БББББББББББ

Possible Cause

Fitting(s), hose(s), or tube(s) are loose or damaged.

ББББББББББББББББББББ

O–ring(s) or seal(s) are missing or damaged.

ББББББББББББББББББББ

Oil level in reservoir is low.

ББББББББББББББББББББ

Hydraulic system has wrong kind of oil.

ББББББББББББББББББББ

Pump suction line(s) has an air leak.

ББББББББББББББББББББ

Traction system pressure is high due to excessive load.

ББББББББББББББББББББ

Oil level in reservoir is low.

ББББББББББББББББББББ

Traction pump by–pass valve is open or defective.

ББББББББББББББББББББ

Excessive dirt and debris on hydraulic components.

ББББББББББББББББББББ

Oil is contaminated or too light.

ББББББББББББББББББББ

Charge pressure is low.

ББББББББББББББББББББ

Air trapped in traction circuit.

ББББББББББББББББББББ

Wheel motor(s) are worn or damaged.

ББББББББББББББББББББ

Traction pump is worn or damaged.

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.

Refer to the Testing section of this Chapter for precautions and specific test procedures.

Neutral is difficult to find or unit oper-

БББББББББББ

ates in one direction only

БББББББББББ

Traction response is sluggish

БББББББББББ

External control linkage is misadjusted, disconnected, binding or

ББББББББББББББББББББ

damaged.

ББББББББББББББББББББ

Excess air in the traction lines.

ББББББББББББББББББББ

Traction pump is worn or damaged.

Hydraulic oil is very cold.

ББББББББББББББББББББ

Traction pump by–pass valve is open or worn.

ББББББББББББББББББББ

Engine speed is too low.

ББББББББББББББББББББ

Pump drive belt is loose or worn.

ББББББББББББББББББББ

Charge pressure is low.

ББББББББББББББББББББ

Traction pump or wheel motor(s) are worn or damaged.

ББББББББББББББББББББ

ProCore 648Hydraulic System Page 4 – 14

Page 49

Problem

Possible Cause

No traction in either direction

БББББББББББ

Wheel motor will not turn

БББББББББББ

Wheel motor will not hold load in neutral

БББББББББББ

Coring head will not lift or lifts slowly

БББББББББББ

Parking brake is engaged.

ББББББББББББББББББББ

Oil level in reservoir is low.

ББББББББББББББББББББ

Traction pump by–pass valve is open.

ББББББББББББББББББББ

Pump drive belt is loose, worn or broken.

ББББББББББББББББББББ

Traction cable broken or damaged.

ББББББББББББББББББББ

Charge pressure is low.

ББББББББББББББББББББ

Hydraulic pump pulley not secure to pump shaft.

ББББББББББББББББББББ

Traction pump or wheel motor(s) are worn or damaged.

Parking brake is engaged (rear wheel motors).

ББББББББББББББББББББ

Key on wheel motor shaft is sheared or missing.

ББББББББББББББББББББ

Internal parts in wheel motor are damaged.

ББББББББББББББББББББ

Make up fluid from charge pump is not available.

ББББББББББББББББББББ

Wheel motor(s) is/are worn or damaged.

System reset switch needs to be pressed.

ББББББББББББББББББББ

Engine speed is too low.

ББББББББББББББББББББ

Reservoir oil level is low.

ББББББББББББББББББББ

Pump pulley drive belt is loose or worn.

ББББББББББББББББББББ

Lift cylinder is binding.

ББББББББББББББББББББ

Coring head is binding.

ББББББББББББББББББББ

Lift control manifold relief valve (R1) is stuck open.

ББББББББББББББББББББ

Lift control manifold orifice (ORF1) is damaged or plugged.

ББББББББББББББББББББ

Lift control manifold SVQ cartridge valve solenoid is not being energized.

ББББББББББББББББББББ

Gear pump (P2) is worn or damaged.

System

Hydraulic

Coring head raises, but will not stay

БББББББББББ

ProCore 648 Hydraulic SystemPage 4 – 15

Lift control manifold SVL cartridge stuck open.

ББББББББББББББББББББ

Lift control manifold SVL cartridge valve leaks.

Page 50

This page is intentionally blank.

ProCore 648Hydraulic System Page 4 – 16

Page 51

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).

CAUTION

Failure to use gauges with recommended pressure (PSI/Bar) rating as listed in test procedures could result in damage to gauge and possible personal injury from leaking hot oil.

Before Performing Hydraulic Tests

All obvious areas such as oil supply, filter, binding linkage, loose fasteners, improper adjustments or improper operation must be checked before assuming that a hydraulic component is the source of the problem being experienced.

Precautions For Hydraulic Testing

WARNING

Before disconnecting or performing any work on the hydraulic system, all pressure in the system must be relieved. See Relieving Hydraulic System Pressure in the General Information section of 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.

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.

4. Because the hydraulic pump is belt driven, check for proper pump belt adjustment before performing any hydraulic test. Check pump speed with a phototac when performing hydraulic pump flow tests.

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 possibility of component damage.

7. Install fittings finger tight, far enough to insure that they are not cross–threaded, before tightening with a wrench.

8. To prevent hose or tester damage, position the tester hoses so that moving machine parts will not make contact with them.

System

Hydraulic

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.

ProCore 648 Hydraulic SystemPage 4 – 17

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.

Page 52

Charge Pressure Test (Using Pressure Gauge)

PRESSURE GAUGE

FORWARD

ORF1

CYL

SVR

SVQ

TCHGP

’B’ PORT (BOTTOM)

’P’ PORT

SVL

CONTROL

MANIFOLD

FRONT

WHEEL

LIFT CYLINDER

’A’ PORT

(TOP)

Figure 13

’P’ PORT

M2 M3

’P’ PORT

Working Pressure Low Pressure (Charge) Return or Suction

Flow Direction

Rev. C

ProCore 648Hydraulic System Page 4 -- 18

Page 53

Procedure for Charge Pressure

1. Make sure hydraulic oil is at normal operating temperature 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. Secure coring head with service latch.

3. Read Precautions For Hydraulic Testing in this section.

Test:

CAUTION

C. While machine is moving, monitor the charge pressure reading on the pressure gauge (do not activate the lift control while monitoring pressure).

D. The charge pressure should drop no more than 15% from initial test reading (Step 8 above). A pressure drop of more than 15% indicates a traction circuit problem (e.g. damaged or leaking proportional valve (PV), worn or damaged piston pump (P1)).

11. Shut off engine.

12.Disconnect pressure gauge from hydraulic control manifold port G2.

Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil.

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.

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.

Figure 14

1. Hydraulic manifold 2. G2 port quick fitting

System

Hydraulic

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 operate at full speed (3400 + lever fully forward.

ProCore 648 Hydraulic SystemPage 4 – 19

50 RPM). Move the traction

Page 54

Coring Head Raise/Lower Relief (R1) Pressure Test (Using Pressure Gauge)

PRESSURE

GAUGE

FORWARD

SVR

(ENERGIZED)

TCHGP

ORF1

SVQ

(ENERGIZED)

’B’ PORT (BOTTOM)

’P’ PORT

SVL

(NOT

ENERGIZED)

CONTROL

MANIFOLD

FRONT WHEEL

’P’ PORT

CYL

’P’ PORT

M2 M3

LIFT CYLINDER

Figure 15

’A’ PORT

(TOP)

Rev. C

Working Pressure Low Pressure (Charge) Return or Suction

Flow Direction

ProCore 648Hydraulic System Page 4 -- 20

Page 55

Procedure for Coring Head Raise/Lower Relief (R1) Pressure Test:

1. Make sure hydraulic oil is at normal operating temperature 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.

3. Read Precautions For Hydraulic Testing in this section.

CAUTION

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 pressure setting. Use an allen wrench and turn adjustment socket clockwise. A 1/8 turn on the socket will make a measurable change in relief pressure.

D. Reinstall cap on relief valve after adjustment.

E. Repeat steps 9 through 11 above until the relief valve pressure setting is correct.

F. If the relief valve pressure setting cannot be adjusted to specification, the relief valve (R1), gear pump or lift cylinder should be suspected of wear or damage.

Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil.

4. Connect pressure gauge to the hydraulic control manifold G1 port quick fitting (Fig. 14).

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.

7. Make sure that traction lever is in the neutral position and the parking brake is engaged.

8. With proximity switch #1 disconnected, system pressure will increase to relief (R1) pressure shortly after the engine is started.

9. Start and run engine at full speed (3400 + Watch the pressure gauge and note pressure when the relief valve (R1) opens.

10.Shut off engine. Record measured relief valve (R1) pressure.

50 RPM).

13.When testing is complete, disconnect pressure gauge from the hydraulic manifold G1 fitting. Reconnect proximity switch #1. Install rear hood.

Figure 16

1. Hydraulic manifold

2. G1 port quick fitting

3. Relief valve (R1)

System

Hydraulic

11. Pressure gauge should read approximately 1000 PSI (69 Bar).

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.

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 Hydraulic SystemPage 4 – 21

Figure 17

1. Relief valve cap 2. Adjustment socket

Page 56

Traction (Piston) Pump (P1) Flow Test (Using Tester With Flow Meter and Pressure Gauge)

FORWARD

ORF1

CYL

SVR

SVQ

TCHGP

’B’ PORT

(BOTTOM)

TESTER

SVL

CONTROL

MANIFOLD

’P’ PORT

FRONT

WHEEL

’P’ PORT

LIFT CYLINDER

’P’ PORT

M2 M3

Figure 18

Procedure for Traction (Piston) Pump (P1) Flow Test:

1. Make sure hydraulic oil is at normal operating temperature 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 parking brake is disengaged. Secure coring head with service latch.

’A’ PORT

(TOP)

Working Pressure Low Pressure (Charge) Return or Suction

Flow Direction

3. Read Precautions For Hydraulic Testing in this section.

4. Remove pump control assembly from traction pump (see Hydraulic (Traction/Charge) Pump Removal in the Service and Repairs section of this c hapter). Position pump control assembly away from pump.

5. Make sure that hydraulic pump drive belt is adjusted properly (see Operator’s Manual).

Rev. C

ProCore 648Hydraulic System Page 4 -- 22

Page 57

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.

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.

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.

TESTER READING: A pump in good condition should have a flow of approximately 9.5 GPM

CAUTION

Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil.

8. Clean hose fitting and disconnect hydraulic hose from the lower 45 pump (Fig. 19).

NOTE: An alternate testing location would be at the hydraulic hose connection to the P1 port of the front wheel motor.

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.

9. Install hydraulic tester with flow meter and pressure gauges in series with the traction pump and the disconnected hose. Make sure flow control valve on the

tester is fully open.

fitting on the rear side of the traction

15.Open flow control valve on tester, return trunnion shaft to the neutral position and turn off engine. Record results of hydraulic flow test.

16. If flow is less than 7.6 GPM or a pressure of 1000 PSI cannot be obtained, consider that a pump problem exists.

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.

17.When testing is complete, disconnect tester from lower 45 fitting. Secure pump control assembly to traction pump (see Hydraulic (Traction/Charge) Pump Installation in the Service and Repairs section of this chapter).

fitting and hydraulic hose. Reconnect hose to

System

Hydraulic

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.

12.Start and run engine at full speed (3400 +

50 RPM).

CAUTION

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 trunnion shaft clockwise (reverse) during testing.

13.Using a wrench, slowly rotate traction pump trunnion shaft counter–clockwise to the fully forward position.

Figure 19

1. Lower 45o fitting 2. Hydraulic hose

ProCore 648 Hydraulic SystemPage 4 – 23

Rev. B

Page 58

Traction Circuit Relief Pressure Test (Using Tester With Flow Meter and Pressure Gauge)

FORWARD

ORF1

CYL

SVR

SVQ

TCHGP

’B’ PORT (BOTTOM)

SVL

CONTROL MANIFOLD

PRESSURE

GAUGE

’P’ PORT

FRONT

WHEEL

’P’ PORT

LIFT CYLINDER

’P’ PORT

M2 M3

NOTE: FORWARD TRACTION CIRCUIT

RELIEF PRESSURE TEST IS SHOWN

’A’ PORT

(TOP)

Figure 20

Rev. C

Working Pressure Low Pressure (Charge) Return or Suction

Flow Direction

ProCore 648Hydraulic System Page 4 -- 24

Page 59

Procedure for Traction Circuit Relief Pressure

1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes. Make sure that traction lever is adjusted to the neutral position (see Operator’s Manual).

Test:

10.One person should operate the machine while another person reads the gauge.

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.

3. Read Precautions For Hydraulic Testing in this section.

4. Set the aerator spacing lever to the transport position.

5. Make sure that hydraulic pump drive belt is adjusted properly (see Operator’s Manual).

6. Lift or jack front of machine so front wheel is off the floor. Support front of machine with jackstands or blocking.

CAUTION

Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil.

7. Clean hose fitting and disconnect appropriate hydraulic hose from fitting on the rear side of the traction pump (Fig. 21):

A. For forward direction relief pressure test, disconnect hose from lower 45 pressure can also be measured with hydraulic tester installed as described in TEST NO. 3: Traction (Piston) Pump Flow. Make sure flow control valve on the tester is fully open.

NOTE: An alternate testing location for forward direction relief would be at the hydraulic hose connection to the front wheel motor P1 port.

B. For reverse direction relief pressure test, disconnect hose from upper 90

fitting. NOTE: forward relief

fitting.

CAUTION

Use extreme caution when conducting test. The front wheel of the machine will be trying to move the machine.

12.Slowly move traction lever fully in direction of relief valve to be tested (forward or reverse).

IMPORTANT: DO NOT hold system at relief for more than 4 seconds.

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.

14.Release traction lever and turn off engine. Record results of hydraulic pressure test.

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, piston (traction) pump should be suspected of wear and inefficiency.

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.

16.Disconnect Tee–fitting with pressure gauge from pump fitting and hydraulic hose. Reconnect hose to pump fitting.

System

Hydraulic

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.

9. Check and adjust the oil level in the reservoir after connecting pressure gauge.

ProCore 648 Hydraulic SystemPage 4 – 25

Figure 21

1. Lower 45o fitting 2. Upper 90o fitting

Page 60

Gear Pump (P2) Flow Test (Using Tester With Flow Meter and Pressure Gauge)

TESTER

FORWARD

ORF1

CYL

SVR

SVQ

TCHGP

’B’ PORT (BOTTOM)

’P’ PORT

SVL

MANIFOLD

FRONT WHEEL

CONTROL

LIFT CYLINDER

’A’ PORT

(TOP)

Figure 22

’P’ PORT

M2 M3

’P’ PORT

Working Pressure Low Pressure (Charge) Return or Suction

Flow Direction

Rev. C

ProCore 648Hydraulic System Page 4 -- 26

Page 61

Procedure for Gear Pump (P2) Flow

1. Make sure hydraulic oil is at normal operating temperature 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. Secure coring head with service latch.

3. Read Precautions For Hydraulic Testing in this section.

Test:

7. Start and operate engine at full speed (3400 + RPM).

8. Watch flow and pressure gauges carefully while slowly closing the flow control valve until pressure gauge reads 500 PSI.

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.

11. If specification is not met, repair or replace gear pump.

CAUTION

Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil.

4. Remove hydraulic tube that connects the gear pump (P2) outlet to port P of hydraulic manifold (Fig. 23).

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.

5. Install elbows to fittings on pump and manifold to allow 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.

6. Make sure that traction lever is in neutral and the parking brake is engaged.

12.Disconnect tester from the pump and control manifold. Reconnect hydraulic tube to the pump and manifold.

Figure 23

1. Gear pump outlet 2. Manifold port P

System

Hydraulic

ProCore 648 Hydraulic SystemPage 4 – 27

Page 62

Wheel Motor Efficiency Test (Using Tester With Flow Meter and Pressure Gauge)

FORWARD

ORF1

CYL

SVR

SVQ

TCHGP

’B’ PORT (BOTTOM)

SVL

CONTROL

MANIFOLD

’P’ PORT

CAP

FRONT WHEEL

’P’ PORT

LIFT

CYLINDER

TEST CONNECTION FOR REAR WHEEL MOTOR SHOWN

’P’ PORT

M2 M3

’A’ PORT

(TOP)

Figure 24

NOTE: Over a period of time, a wheel motor can wear internally. A worn motor will be less efficient and eventually, 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 andother components in the hydraulicsystem and affect overall machine performance.

TESTER

CAP

Working Pressure Low Pressure (Charge) Return or Suction

Flow Direction

Rev. C

ProCore 648Hydraulic System Page 4 -- 28

Page 63

Procedure for Wheel Motor Efficiency

1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes. Make sure the hydraulic reservoir is full.

2. Make sure that traction lever is adjusted to the neutral 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.

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.

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.

10.Start engine and move throttle to full speed (3400 + 50 RPM).

4. Read Precautions For Hydraulic Testing in this section.

CAUTION

Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil.

5. Attach a heavy chain between the rear of the machine frame and an immovable object to prevent the machine from moving during testing.

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.

B. Position front wheel on the ground. Immobilize front wheel to prevent it from turning.

7. If a rear wheel motor requires testing:

A. Disconnect both hydraulic lines from rear wheel motor that is not being tested. Cap disconnected hydraulic lines and plug wheel motor ports to prevent contamination.

CAUTION

Use extreme caution when performing test. The tire(s) on the ground will be trying to move the machine forward.

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.

13.Release traction lever and turn off engine. Record results of hydraulic flow test.

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.

16.If additional wheel motor(s) require testing, complete steps 6 to 14 for the remaining wheel motor(s).

17.Disconnect tester from machine. Reconnect hose to pump connection.

System

Hydraulic

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

fitting on traction pump (Fig. 25).

Figure 25

1. Upper 90o fitting 2. Lower 45o fitting

ProCore 648 Page 4 – 29 Hydraulic System

Page 64

Service and Repairs

General Precautions for Removing and Installing Hydraulic System Components

Before Repair or Replacement of Components

1. Before removing any parts from the hydraulic system, 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. 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.

CAUTION

Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil. See Relieving Hydraulic System Pressure in the General Information section of this chapter.

3. Put caps or plugs on any hydraulic lines, hydraulic fittings or hydraulic components left open or exposed to prevent hydraulic system contamination.

4. Put labels on disconnected hydraulic lines and hoses for proper installation after repairs are completed.

After Repair or Replacement of Components

1. Check oil level in the hydraulic reservoir and add correct 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. Lubricate O–rings and seals with clean hydraulic oil before installing hydraulic components.

3. Make sure caps or plugs are removed from the hydraulic tubes, hydraulic fittings and components before reconnecting.

4. Use proper tightening methods when installing hydraulic hoses and fittings (see Hydraulic Fitting Installation 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 components, operate machine functions slowly until air is out of system (see Hydraulic System Start Up in this section).

7. Check for hydraulic oil leaks. Shut off engine and correct leaks if necessary. Check oil level in hydraulic reservoir and add correct oil if necessary.

5. Note the position of hydraulic fittings (especially elbow 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

WARNING

Hydraulic System Page 4 – 30 ProCore 648

lines, loose mounting supports, wear, loose fittings, weather deterioration and/or chemical deterioration. Make all necessary repairs before operating machine.

Page 65

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 contains metal particles).

IMPORTANT: Flush hydraulic system when changIng 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 before draining.

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 pump belt cover from machine (see Operator’s Manual).

NOTE: The hydraulic reservoir will drain when the hydraulic oil filter is removed from the hydraulic manifold.

3. Clean area around filter mounting area (Fig. 26). Remove 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.

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.

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.

14.Install pump belt cover to machine (see Operator’s Manual).

15.Operate the machine for two (2) hours under normal operating conditions.

16.Check condition of hydraulic oil. If the fluid shows any signs of contamination, or if you are changing to biodegradable fluid, repeat steps 1 through 13 again.

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 hydraulic oil to gasket on the new filter. Screw filter on until gasket contacts mounting surface of manifold, then tighten filter half a turn.

NOTE: Use biodegradable fluid, such as Mobil EAL Envirosyn 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.

6. Fill hydraulic reservoir.

7. Disconnect and ground both spark plug wires to prevent 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.

Figure 26

1. Hydraulic filter 2. Hydraulic manifold

System

Hydraulic

ProCore 648 Page 4 – 31 Hydraulic System

Page 66

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.

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).

2. Make sure all hydraulic connections and lines are secured 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.

4. After repairs, check control linkage for proper adjustment, binding or broken parts. Correct any problems before proceeding.

5. Disconnect and ground both engine spark plug wires to prevent engine from starting.

C. Attach a heavy chain between the rear of the machine 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.

D. Connect inlet end of hydraulic tester with flow meter 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.

E. Check hydraulic reservoir level and fill if necessary.

F. Start engine and move traction lever to the forward direction to allow the wheels to rotate slowly.

NOTE: Bleeding the traction circuit might require approximately five (5) minutes of running.

IMPORTANT: When bleeding the traction circuit, tester valve should be barely open which will al low a slow stream of oil from tester outlet.

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.

9. If traction circuit was repaired (e.g. hydrostat or wheel motor was replaced), bleed the traction circuit to evacuate air from the circuit:

NOTE: Before bleeding the traction circuit, review the following procedure (steps A through L) completely.

A. Stop engine and relieve pressure in traction circuit by moving traction lever to both forward and reverse direction.

B. Jack up machine from floor and support machine with jack stands or blocking to allow wheels to turn freely.

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.

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.

I. When all evidence of foamy oil has been evacuated from the traction circuit, close tester valve, release traction lever and stop engine.

J. Remove tester from traction circuit test port. Check hydraulic reservoir level and fill if necessary.

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.

L. Lower machine to ground. Remove chain from rear of machine.

Hydraulic System Page 4 -- 32

Rev. A

ProCore 648

Page 67

10.Start engine and operate the traction system at varying speeds for a 10 minute period.

11. Stop the machine. Check hydraulic reservoir level and fill if necessary. Check hydraulic components for leaks and tighten any loose connections.

Figure 27

1. Test port 2. Hydraulic manifold

System

Hydraulic

ProCore 648 Page 4 -- 33

Rev. A

Hydraulic System

Page 68

Hydraulic Pump Drive Belt

Anti–seize

lubricant

FRONT

RIGHT

1. Flange nut (2 used)

2. Hydraulic (traction/charge) pump

3. Key

4. Engine

5. Engine pulley

6. Flange head screw

Figure 27

7. Spring bracket

8. Idler support bracket

9. Idler pulley

10. Flange nut

11. Tensioning spring

12. Set screw

13. Hydraulic pump pulley

14. Pump drive belt

15. L bracket

16. Flange head screw

17. Flange head screw (2 used)

ProCore 648Hydraulic System Page 4 – 34

Page 69

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.

2. Remove pump belt cover from machine (see Operator’s Manual).

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).

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 pulleys and the machine.

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.

4. Install coring head primary drive belt to electric clutch (see Primary Drive Belt Installation in Service and Repairs section of Chapter 7 – Coring Head).

5. Install pump belt cover to machine (see Operator’s Manual).

System

Hydraulic

ProCore 648 Page 4 – 35 Hydraulic System

Page 70

Hydraulic Pump Control Assembly

RIGHT

Loctite #242

FRONT

1. Hydraulic pump

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

Figure 28

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

ProCore 648Hydraulic System Page 4 – 36

Page 71

Disassembly (Fig. 28)

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 pump belt cover from machine (see Operator’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.

CAUTION

The extension spring is under tension and may cause personal injury during removal. Use caution when removing spring from neutral lever.

4. Remove components from pump control assembly as needed using Figures 28, 29 and 30 as guides.

Assembly (Fig. 28)

1. Install removed components to pump control assembly 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 installing rod ends.

1. Hydraulic pump

2. Cap screw (2 used)

3. Control bracket

4. Flange nut (2 used)

5. Flat washer

6. Pump lever

Figure 29

7. Trunnion clamp

8. Socket hd screw (2 used)

9. Washer head screw

10. Lock nut

11. Pump shield

System

Hydraulic

B. Damper should be secured to third hole from outer 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 secure with two (2) lock nuts.

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).

Figure 30

1. Damper 2. Rod end location

ProCore 648 Hydraulic SystemPage 4 – 37

Page 72

Hydraulic (Traction/Charge) Pump

Anti–seize

lubricant

FRONT

RIGHT

Figure 31

1. Hydraulic (traction/charge) pump

2. O–ring

3. O–ring

4. 90

hydraulic fitting

5. Engine

6. Engine pulley

7. Flange head screw

8. Spring bracket

9. Idler support bracket

10. Idler pulley

11. Flange nut

12. Tensioning spring

13. Set screw

14. Pump pulley

15. Pump drive belt

16. L bracket

17. Flange head screw

18. Flange head screw (2 used)

19. O–ring

20. 90

hydraulic fitting

Removal (Fig. 31)

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.

21. O–ring

22. Flange nut (2 used)

23. 45

hydraulic fitting

24. O–ring

25. O–ring

26. Hydraulic adapter

27. O–ring

28. 90

hydraulic fitting

29. Hydraulic fitting

30. Key

CAUTION

Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil. See Relieving Hydraulic System Pressure in the General Information section of this chapter.

ProCore 648Hydraulic System Page 4 – 38

Page 73

2. Remove pump belt cover from machine (see Operator’s Manual).

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 hydraulic pump pulley.

8. Remove both flange head screws and flange nuts securing the hydraulic pump to the pump support. Lift pump assembly from the machine.

NOTE: If hydraulic fittings are to be removed from hydraulic 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.

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.

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.

6. Disconnect hydraulic pump controls (Fig. 32 and 33) from the pump as follows:

CAUTION

The extension spring is under tension and may cause personal injury during removal. Use caution when removing spring from neutral lever.

A. Remove extension spring from the neutral lever.

B. Loosen two (2) socket head screws (item 8, Fig.

32) that secure pump lever to pump trunnion shaft.

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.

D. Carefully lift pump control assembly and position away from pump.

9. Remove hydraulic fittings and o–rings from the pump as required.

10.Discard all removed o–rings.

Figure 32

1. Hydraulic pump

2. Cap screw (2 used)

3. Control bracket

4. Flange nut (2 used)

5. Flat washer

6. Pump lever

7. Trunnion clamp

8. Socket hd screw (2 used)

9. Washer head screw

10. Lock nut

11. Pump shield

System

Hydraulic

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 contamination.

CAUTION

Support hydraulic pump when removing it from the pump support to prevent the pump from falling and causing personal injury.

ProCore 648 Hydraulic SystemPage 4 – 39

1. Extension spring

2. Socket head screw

Figure 33

3. Flange nut/cap screw

4. Washer head screw

Page 74

Installation (Fig. 31)

1. Install hydraulic fittings with new o–rings to the hydraulic pump. Orientate the fittings as noted during disassembly.

7. Place two (2) flat washers to tops of studs on pump control assembly. Position pump shield to pump and secure with two (2) lock nuts.

8. Lift idler pulley and install drive belt to the pump pulley. Adjust drive belt tension (see Operator’s Manual).

CAUTION

Support hydraulic pump when installing it to the pump support to prevent the pump from falling and causing personal injury.

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.

3. Make sure the bore of the pump pulley is clean. Apply anti–seize lubricant to the hydraulic pump shaft. Position 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:

9. Install pump belt cover to machine (see Operator’s Manual).

10.Follow Hydraulic System Start–up procedures.

11. Check traction drive for neutral and adjust if needed (see Operator’s Manual).

12.Operate machine and check hole spacing. Adjust if needed (see Operator’s Manual).

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 ProCore 648

Page 75

Hydraulic (Traction/Charge) Pump Service

Figure 34

1. Retaining ring

2. Seal

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

12. Valve plate

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

NOTE: For repair of the hydraulic (traction/charge)

pump, see the HYDRO–GEAR BDP–10A/16A/21L HYDROSTATIC PUMPS SERVICE AND REPAIR MANUAL (hydrostat) and the SAUER DANFOSS GROUP 2 GEAR PUMPS AND MOTORS SERVICE MANUAL (gear pump) at the end of this chapter.

23. Guide slot

24. Trunnion arm

25. 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)

System

Hydraulic

ProCore 648 Hydraulic SystemPage 4 – 41

Page 76

Wheel Motors

RIGHT

FRONT

190 to 230 ft–lb (258 to 312 N–m)

45 to 55 ft–lb

(61 to 75 N–m)

190 to 230 ft–lb

(258 to 312 N–m)

45 to 55 ft–lb

(61 to 75 N–m)

Figure 35

1. Rear wheel motor (LH shown)

2. Woodruff key

3. Parking latch support (2 used)

4. Stud (4 used per wheel)

5. Parking latch disc (2 used)

6. Wheel hub

7. Lock nut

8. Bearing plate

9. Lug nut

10. Tire and wheel assembly

11. Cap screw (4 used per rear motor)

12. Lock nut (4 used per motor)

13. Frame

14. Front wheel weight

Removal (Fig. 35)

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.

15. Wheel weight adapter

16. Stud

17. Thrust washer

18. Front wheel motor

19. Front fork

20. Cap screw (4 used)

CAUTION

Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil. See Relieving Hydraulic System Pressure in the General Information section of this chapter.

ProCore 648Hydraulic System Page 4 – 42

Page 77

2. Remove wheel from machine (see Wheel Removal in Service and Repairs section of Chapter 6 – Chassis).

IMPORTANT: To prevent damage to hydraulic motor, DO NOT hit wheel hub or motor with a hammer during wheel hub removal or installation.

3. If rear wheel motor was removed, slide parking latch link through parking latch bar and secure with hair pin (Fig. 36).

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 woodruff key from motor shaft.

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.

4. Clean wheel motor and hydraulic connections. Label hydraulic lines for assembly purposes.

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.

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 parking latch support.

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 machine.

5. Install hydraulic lines to hydraulic fittings on wheel motor. Tighten connections.

6. Make sure that wheel motor shaft and wheel hub taper 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 hub assembly includes wheel hub, bearing plate and wheel studs.

B. Rear hub assembly includes wheel hub, bearing plate, parking latch disc and wheel studs.

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).

9. Follow Hydraulic System Start–up procedures.

System

Hydraulic

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.

Installation (Fig. 35)

1. If removed, install hydraulic fittings with new o–rings into the wheel motor. Orientate the fittings as noted during disassembly.

2. Position and support wheel motor to the frame.

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 Hydraulic SystemPage 4 – 43

1. Parking latch link

2. Hair pin

3. Parking latch bar

Figure 36

4. Parking latch support

5. Wheel motor shaft

Page 78

Wheel Motor Service

Figure 37

1. Dust seal

2. Housing

3. O–ring

4. Shaft seal

5. Axial needle bearing

6. Bearing race

7. Needle bearing

8. Shaft

9. O–ring

10. Spring washer

11. Balance plate

12. Disc valve

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 different displacement than the rear motors and has a counter–clockwise direction for the forward direction. The right and left rear wheel motors have the same displacement (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 counter–clockwise direction. Displacement and primary rotation (forward) direction are identified on the motor name plate.

16. Cardan shaft

17. O–ring

18. Gearwheel set

19. End cover

20. Name plate

21. Washer (7 used)

22. Cap screws (7 used)

NOTE: For repair of the wheel motors, see the SAUER

DANFOSS OMEW HYDRAULIC MOTOR SERVICE MANUAL at the end of this chapter.

ProCore 648Hydraulic System Page 4 – 44

Page 79

This page is intentionally blank.

System

Hydraulic

ProCore 648 Page 4 – 45 Hydraulic System

Page 80

Hydraulic Lift Control Manifold

RIGHT

FRONT

1. Main frame

2. Cap screws (2 used)

Figure 38

3. Hydraulic lift control manifold

4. Hydraulic oil filter

5. Flange nut (2 used)

ProCore 648Hydraulic System Page 4 – 46

Page 81

Removal (Fig. 38)

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. Remove caps or plugs that were put on any hydraulic lines or fittings during disassembly.

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

Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil. See Relieving Hydraulic System Pressure in the General Information section of this chapter.

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).

2. Disconnect solenoid valve electrical connectors.

NOTE: The hydraulic reservoir will drain when the hydraulic oil filter is removed from the hydraulic manifold.

3. Clean area around hydraulic filter mounting area. Remove filter from hydraulic manifold and drain reservoir into a suitable container. Discard filter.

4. Clean manifold and hydraulic connections. Disconnect hydraulic lines. Label all connections for assembly.

5. Allow hydraulic lines to drain into a suitable container. Put caps or plugs on disconnected hoses and fittings to prevent contamination. Discard any removed o– rings.

6. Remove two (2) cap screws and flange nuts that secure hydraulic manifold to the frame mounting bracket.

7. Remove hydraulic manifold from the machine.

6. Secure hydraulic manifold by tightening two (2) cap screws and flange nuts.

7. Reconnect solenoid valve electrical connectors.

8. Follow Hydraulic System Start–up procedures.

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)

System

Hydraulic

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 fittings are clean.

ProCore 648 Hydraulic SystemPage 4 – 47

Page 82

Hydraulic Lift Control Manifold Service

5 ft–lb

(6.8 N–m)

20 ft–lb

(27.1 N–m)

5 ft–lb (6.8 N–m)

25 ft–lb

(33.9 N–m)

20 ft–lb

(27.1 N–m)

120 in–lb

(13.6 N–m)

20 ft–lb

(27.1 N–m)

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

7. Relief valve (R1 port)

8. Solenoid valve (SVQ port)

9. Nut

10. Solenoid valve (SVR port)

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).

11. Pres. compensating valve (PV port)

12. #4 plug (zero leak)

13. Orifice plug

14. Check valve

15. Plug

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 designed 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 before using an allen wrench to remove the plug: the impact 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).

ProCore 648Hydraulic System Page 4 – 48

Page 83

Hydraulic Manifold Service

1. Make sure the manifold is clean before removing any cartridge valve.

2. If solenoid cartridge is being serviced, remove nut securing solenoid to the cartridge valve. Carefully slide solenoid off the valve.

CAUTION

Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil. See Relieving Hydraulic System Pressure in the General Information section of this chapter.

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.

CAUTION

Abrupt movement of internal spools can cause stored fluid to be released suddenly.

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 extremely careful not to damage cartridge. Use compressed air for cleaning.

7. Reinstall the cartridge valve:

A. Lubricate new seal kit components with clean hydraulic 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 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.

5. Visually inspect cartridge valve for damaged sealing surfaces and contamination.

A. Contamination may cause valves to stick or hang up. Contamination can become lodged in small valve orifices or seal areas causing malfunction.

B. If valve sealing surfaces appear pitted or damaged, the hydraulic system may be overheating or there may be water in the system.

CAUTION

Use eye protection such as goggles when using compressed air for cartridge valve cleaning.

B. Thread cartridge valve carefully into correct manifold port. The valve should go in easily without binding.

C. Torque cartridge valve using a deep socket to values identified in Figure 40.

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).

9. After assembly, if problems still exist, remove valve and clean again or replace valve.

System

Hydraulic

ProCore 648 Page 4 – 49 Hydraulic System

Page 84

Lift Cylinder

RIGHT

FRONT

Figure 41

1. Main 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)

7. Clevis pin (4 used)

8. Hair pin (4 used)

9. Retaining ring

10. Thrust washer

11. Cylinder pin

12. Spacer (2 used)

Removal (Fig. 41)

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 rear hood (see Operator’s Manual).

3. Remove tine heads from stomper arms to allow coring head to be fully lowered.

CAUTION

The extension spring is under tension and may cause personal injury during removal. Use caution when disconnecting spring from machine.

13. Lift cylinder

14. O–ring

15. Hydraulic fitting

16. O–ring

17. Hydraulic hose

18. Coring head frame

4. Disconnect the lower end of one extension spring (item 2) from frame:

A. Remove service latch from coring head. Turn key switch to ON (engine not running). Move traction lever to forward direction and depress lower switch on handle to fully lower coring head.

B. Loosen, but do not remove, both flange nuts (item

6) that secure the spring plate (item 5) for one of the extension springs.

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).

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.

ProCore 648Hydraulic System Page 4 – 50

Page 85

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

Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil. See Relieving Hydraulic System Pressure in the General Information section of this chapter.

6. Release hydraulic pressure in lift cylinder:

A. Turn key switch to ON (engine not running).

B. Move traction lever to forward direction and depress lower switch on handle to lower coring head onto service latch.

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 container.

8. Plug disconnected hose and fitting to prevent contamination.

9. Remove one retaining ring from the upper cylinder pin. Pull upper cylinder pin from the lift cylinder and coring head frame. Locate and retrieve spacer and thrust washer from each side of cylinder pivot (Fig. 43).

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.

7. Install disconnected extension spring to machine in reverse order of disassembly.

8. Install rear hood.

9. Install tine heads to stomper arms (see Operator’s Manual).

10.Follow Hydraulic System Start–up procedures.

Figure 42

1. Extension spring 3. Lower carriage screw

2. Upper carriage screw 4. 1/2” drive hole

System

Hydraulic

11. Remove lift cylinder from the machine.

12.If needed, remove hydraulic fitting and o–ring from the lift cylinder. Discard o–ring.

Installation (Fig. 41)

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.

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 retaining ring (Fig. 43). Secure with retaining ring.

ProCore 648 Page 4 – 51 Hydraulic System

1. Lift cylinder shaft 3. Cylinder pin

2. Thrust washer 4. Spacer

Figure 43

Page 86

Lift Cylinder Service

Figure 44

1. Retaining ring

2. Cylinder tube

3. Rod

4. O–ring

5. Backup ring

6. Retaining ring

Disassembly (Fig. 44)

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.

IMPORTANT: Prevent damage when clamping the lift cylinder into a vise; clamp on the pivot only. Do not close vise enough to distort tube.

2. Mount lift cylinder in a vise so that the shaft end tilts up slightly.

7. Seal

8. Head

9. Wiper

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.

6. Remove and discard o–ring (item 4), backup ring (item 5), seal (item 7) and wiper (item 9) from the head.

Spanner wrench

3. Rotate head (item 8) with a spanner wrench and remove retaining ring (item 6) as shown in Figure 45.

4. Grasp end of rod; extract rod and head by carefully twisting and pulling on the rod.

IMPORTANT: Do not clamp vise jaws against rod surface. Protect rod surface before mounting in vise.

Retaining ring

Figure 45

ProCore 648Hydraulic System Page 4 – 52

Page 87

Inspection

CAUTION

Use eye protection such as goggles when using compressed air

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.

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 sealing components to the head.

IMPORTANT: Do not clamp vise jaws against rod surface. Protect rod surface before mounting in vise.

Spanner wrench

Retaining ring

(Offset end against left side of barrel groove after installing)

Figure 46

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 slightly.

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 Figure 46.

System

Hydraulic

ProCore 648 Page 4 – 53 Hydraulic System

Page 88

Hydraulic Reservoir

FRONT

RIGHT

Figure 47

1. Hydraulic reservoir

2. Dipstick

3. Cap

4. Shoulder screw

5. Tank strap

6. Cap screw

7. J clip

8. Flat washer

9. Frame

10. O–ring

11. Hydraulic adapter

12. O–ring

13. Hydraulic tube

Inspecting Reservoir (Fig. 47)

1. Clean hydraulic reservoir with solvent.

2. Inspect reservoir for leaks, cracks or other damage.

14. Hydraulic tube

15. Suction hose

16. Hose clamp

17. Hydraulic barb fitting

18. Hydraulic tee fitting

19. O–ring

3. Replace any hydraulic hose, tube or fitting if damaged or leaking.

4. Make sure cap screw (item 6) that secures tank strap is tight.

ProCore 648Hydraulic System Page 4 – 54

Page 89

Table of Contents

Chapter 5

Electrical System

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)

Charging System Test

Check Operation of Interlock Switches

COMPONENT TESTING . . . . . . . . . . . . . . . . . . . . . . 13

Ignition Switch

Engine Oil Pressure Indicator Light

Hour Meter

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

. . . . . . . . . . . . . . . . . . . . . . . 11

. . . . . . . . . . . . . . . 11

. . . . . . . . 12

. . . . . . . . . . . 14

Electrical Diagrams

The electrical schematic, electrical circuit drawings and wire harness drawings for the ProCore 648 are located in Chapter 8 – Electrical Diagrams.

Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Manual Raise/Lower Switch Ground Follow Switch Lift Reset Switch Solenoid Valve Coil Head Low and Head High Limit Switches Fuses Proximity Switches Aerator Control Module Electric Clutch Diode Assemblies

SERVICE AND REPAIRS

Battery Storage Battery Care Battery Service Electric Clutch Solenoid Valve Coil

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

. . . . . . . . . . . . . . . . . . . . . . . . . . . 18

. . . . . . . . . . . . . . . . . . . . . . . . . 19

. . . . . . . . . . . . . . . . . . . . . . . . . 22

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

. . . . . . . . . . . . . . . . . . . . . . . . . . 27

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

. . . . . . . . . . . . . . . . . . . . . . . . . 34

. . . . . . . . . . . . . . . . . 16

. . . . . . . . . . . . . . . . . . . . . . 17

. . . . . . 20

. . . . . . . . . . . . . . . . . . . . . 24

. . . . . . . . . . . . . . . . . . . . . 28

ProCore 648

Page 5 – 1

Electrical System

System

Electrical

Page 90

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 operation.

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.

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 allows 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.

Begin Aerating (Traction Lever in Forward)

To begin aerating, the operator moves the traction lever to the forward direction which opens the reverse proximity 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.

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.

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.

Electrical System

Page 5 – 2

ProCore 648

Page 91

GROUND

TRACTION LEVER IN NEUTRAL OR REVERSE

TO IGNITION

SWITCH

TERMINAL ”L”

CONTROL MODULE

”OK TO LOWER” LED

IS NOT ILLUMINATED

TO AERATOR CONTROL MODULE OK TO LOWER

GROUND

(IN RAISE POSITION)

(ENERGIZED)

BEGIN AERATING (TRACTION LEVER IN FORWARD)

(PRESSED TO LOWER)

(2 AND 3 CLOSED, 5 AND 6 CLOSED)

(NOT ENERGIZED)

(ENERGIZED)

LOCKOUT

CIRCUIT

TO IGNITION

SWITCH

TERMINAL ”L”

LOCKOUT

CIRCUIT

TO AERATION #3 PROX. SWITCH

CONTROL MODULE

”OK TO LOWER” LED

IS ILLUMINATED

TO AERATOR CONTROL MODULE OK TO LOWER

TO AERATION #3 PROX. SWITCH

GROUND

ProCore 648

AERATING (TRACTION LEVER IN FORWARD)

(IN MIDDLE/AERATE POSITION)

(2 AND 3 CLOSED)

(NOT ENERGIZED)

Figure 1

Page 5 – 3

(ENERGIZED)

TO IGNITION

SWITCH

TERMINAL ”L”

LOCKOUT

CIRCUIT

AERATION #3 PROX. SWITCH

CONTROL CURRENT OK TO LOWER

Electrical System

CONTROL MODULE ”OK TO LOWER” LED

IS ILLUMINATED

TO AERATOR CONTROL MODULE OK TO LOWER

System

Electrical

Page 92

Lockout Circuit (Fig. 2)

The lockout circuit is used on the ProCore to provide current 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 aerator control module to allow energizing of the solenoid valves. Lockout circuit protection is provided by fuse F3.

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.

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 solenoid valves so the coring head cannot be raised. Pressing 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.

Electrical System

Page 5 – 4

ProCore 648

Page 93

GROUND

(NOT PRESSED)

CORING HEAD RAISED

TO IGNITION SWITCH

TERMINAL ”A”

(ENERGIZED)

TO IGNITION SWITCH TERMINAL ”L”

(ENERGIZED)

TO ELECTRIC CLUTCH

TO AERATOR

CONTROL

MODULE

GROUND

(NOT PRESSED)

CORING HEAD STRANDED

AERATING

TO IGNITION SWITCH

TERMINAL ”A”

(ENERGIZED)

TO IGNITION SWITCH TERMINAL ”L”

(ENERGIZED)

TO ELECTRIC CLUTCH

TO AERATOR

CONTROL

MODULE

TO AERATOR

CONTROL

MODULE

System

Electrical

(PRESSED)

ProCore 648

TO IGNITION SWITCH

TERMINAL ”A”

(ENERGIZED)

Figure 2

Page 5 – 5

(ENERGIZED)

TO ELECTRIC CLUTCH

CONTROL CURRENT POWER CURRENT

Electrical System

Page 94

Electric Clutch Circuit (Fig. 3)

The electric clutch circuit is used on the ProCore to provide current for the electric clutch which rotates the coring 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 operation 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.

Not Aerating (Clutch not Engaged)

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.

TO IGNITION SWITCH TERMINAL ”L”

GROUND

NOT AERATING (CLUTCH NOT ENGAGED)

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 begins.

The clutch will continue to be energized until either:

A. The coring head is raised which opens the aeration #3 proximity switch.

B. The “OK to lower” circuit opens (e.g. the operator releases the traction lever while aerating).

TO OK TO LOWER CIRCUIT

TO IGNITION SWITCH TERMINAL ”L”

GROUND

(NOT ENERGIZED)

AERATING (CLUTCH ENGAGED)

(ENERGIZED)

(HEAD LOWERED)

Figure 3

TO OK TO LOWER CIRCUIT

(NOT ENERGIZED)

(ENERGIZED)

CONTROL CURRENT CLUTCH CURRENT

Electrical System

Page 5 – 6

ProCore 648

Page 95

Special Tools

Multimeter

The multimeter can test electrical components and circuits 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 meter in the voltage mode will make sure that excess current is not allowed through the meter. This excess current can cause damage to circuits not designed to carry it.

Battery Terminal Protector

Figure 4

Battery Terminal Protector (Toro Part No. 107–0392) is an aerosol spray that should be used on battery terminals to reduce corrosion problems. Apply terminal protector after battery cable has been secured to battery terminal.

Battery Hydrometer

Use the Battery Hydrometer when measuring specific gravity of battery electrolyte. Obtain this tool locally.

Figure 5

System

Electrical

ProCore 648

Page 5 – 7

Figure 6

Electrical System

Page 96

Troubleshooting

For effective troubleshooting and repairs, you must

CAUTION

Remove all especially rings and watches, before doing any electrical troubleshooting or testing. Disconnect the battery cables unless the test requires battery voltage.

jewelry,

Starting Problems

Problem Possible Causes

have a good understanding of the electrical circuits (see Chapter 8 – Electrical Diagrams) and components used on this machine.

If the machine has any interlock switches by–passed, they must be reconnected for proper troubleshooting and safety.

Starter solenoid clicks, but starter will not crank (if solenoid clicks, problem is not in safety interlock system).

Nothing happens when start attempt is made (traction lever must be in neutral position for successful start).

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.

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).

Electrical System

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.

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ProCore 648

Page 97

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 Neutral proximity switch is out of adjustment or faulty. out of the neutral position.

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).

System

Electrical

ProCore 648

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Electrical System

Page 98

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

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ProCore 648

Page 99

Electrical System Quick Checks

Battery Test (Open Circuit Test)

Use a multimeter to measure the voltage between the battery terminals.

Set the multimeter to the DC volts setting. The battery should be at a temperature of 60 C). The ignition key should be in the OFF position and all accessories turned off. Connect the positive (+) meter lead to the positive battery post and the negative (–) meter lead to the negative battery post.

NOTE: This test provides a relative condition of the battery. Load testing of the battery will provide additional and more accurate information.

to 100o F (16o to 38

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.

Tool required: Digital multimeter set to DC volts.

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 connected and record the battery voltage.

Voltage Measured

12.68 v (or higher) Fully charged (100%)

12.45 v 75% charged

12.24 v 50% charged

12.06 v 25% charged

11.89 v 0% charged

Start the engine and run at 3400 RPM (high idle). Allow the battery to charge for at least 3 minutes. Record the battery voltage.

Test results should be (example):

At least 0.50 volt over initial battery voltage.

Initial Battery Voltage = 12.25 v

Battery Voltage after 3 Minute Charge = 12.80 v

Battery Charge Level

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.

Difference = +0.55 v

System

Electrical

ProCore 648

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Electrical System

Page 100

Check Operation of Safety Interlock System

CAUTION

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.

The Safety Interlock System of the ProCore 648 ensures the following operations:

1. The engine should crank only when the traction lever is in the neutral position.

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.

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 Component Testing section of this Chapter. Testing of individual interlock switches is included in the Component Testing section of this Chapter.

3. If the coring head is stranded in the lowered position, the coring head will not raise unless the lift reset switch is depressed.

Electrical System

Page 5 – 12

ProCore 648

Toro 648 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Preface

Table Of Contents

Safety Instructions

Before Operating

While Operating

Maintenance and Service

Jacking Instructions

Safety and Instruction Decals

Product Records

Maintenance

Equivalents and Conversions

Torque Specifications

Fastener Identification

Standard Torque for Dry, Zinc Plated and Steel Fasteners (Inch Series)

Standard Torque for Dry, Zinc Plated and Steel Fasteners (Metric Fasteners)

Other Torque Specifications

Conversion Factors

Introduction

Specifications

General Information

Fuel Shutoff Valve

Adjustments

Adjust Choke Control

Adjust Engine Speed

Service and Repairs

Cooling System

Fuel System

Exhaust System

Engine

Belt Tensioners

Specifications

General Information

Hydraulic Hoses

Hydraulic Fitting Installation

Pushing/Pulling Machine

Check Hydraulic Fluid

Relieving Hydraulic System Pressure

Hydraulic Schematic

Hydraulic Flow Diagrams

Traction Circuit (Forward Shown)

Coring Head Raise/Lower Circuits

Special Tools

Hydraulic Pressure Test Kit

Hydraulic Tester (Pressure and Flow)

Hydraulic Test Fitting Kit

Wheel Hub Puller

Troubleshooting

Testing

Charge Pressure Test (Using Pressure Gauge)

Coring Head Raise/Lower Relief (R1) Pressure Test (Using Pressure Gauge)

Traction (Piston) Pump (P1) Flow Test (Using Tester With Flow Meter and Pressure Gauge)

Traction Circuit Relief Pressure Test (Using Tester With Flow Meter and Pressure Gauge)

Gear Pump (P2) Flow Test (Using Tester With Flow Meter and Pressure Gauge)

Wheel Motor Efficiency Test (Using Tester With Flow Meter and Pressure Gauge)

Service and Repairs

General Precautions for Removing and Installing Hydraulic System Components

Check Hydraulic Lines and Hoses

Flush Hydraulic System

Hydraulic Pump Drive Belt

Hydraulic Pump Control Assembly

Hydraulic (Traction/Charge) Pump

Hydraulic (Traction/Charge) Pump Service

Wheel Motors

Wheel Motor Service

Hydraulic Lift Control Manifold

Hydraulic Lift Control Manifold Service

Lift Cylinder

Lift Cylinder Service

Hydraulic Reservoir

Electrical Diagrams

Circuit Operation

Special Tools

Multimeter

Battery Terminal Protector

Battery Hydrometer

Troubleshooting