Toro ProCore 648 Bedienungsanleitung

Form No. 04129SL Rev D

ProCore®648

Original Instructions (EN)

Revision History

Revision

Date

Description

2004

Initial Issue.

2006

Updated Engine chapter.

2009

Updated Hydraulic System chapter.

2009

Updated Hydraulic System chapter.

02/2018

Added revision history.

THE TORO COMPANY 2018

This document and all information contained herein is the sole property of The Toro Company (and/or its affiliated companies). No

intellectual property rights are granted by the delivery of this document or the disclosure of its content. This document shall not be

reproduced by a third party without the express written consent of The Toro Company (and/or the appropriate affiliated company).

Reader Comments

The Toro Company Technical Assistance Center maintains a continuous effort to improve the quality

and usefulness of its publications. To do this effectively, we encourage user feedback.

Please comment on the completeness, accuracy, organization, usability, and readability of this manual

by an e-mail to [email protected]

or Mail to:

Technical Publication Manager, Commercial

The Toro Company

8111 Lyndale Avenue South

Bloomington, MN 55420-1196

Phone: +1 952-887-8495

NOTES _

Part No. 04129SL (Rev. D)

Service Manual

ProCoreR648

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 OP-

ERATING, MAINTENANCE AND ADJUSTMENT

INSTRUCTIONS. Space is provided in Chapter 2 of this

book to insert the Operator’s Manuals and Parts Cata-

logs for your machine. Replacement Operator’s Manu-

als and Parts Catalogs are available on the internet at

www.toro.com.

The Toro Company reserves the right to change product

specifications or this publication without notice.

This safety symbol means DANGER, WARNING,

or CAUTION, PERSONAL SAFETY INSTRUC-

TION. When you see this symbol, carefully read

the instructions that follow. Failure to obey the

instructions may result in personal injury.

NOTE: ANOTE will give general information about the

correct operation, maintenance, service, testing or re-

pair of the machine.

IMPORTANT: The IMPORTANT notice will give im-

portant instructions which must be followed to pre-

vent damage to systems or components on the

machine.

EThe Toro Company -- 2004, 2006, 2009, 2018

This page is intentionally blank.

ProCore 648

Table Of Contents

Chapter 1 – Safety

Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . 1 – 2

Jacking Instructions . . . . . . . . . . . . . . . . . . . . . . . . . 1 – 4

Safety and Instruction Decals . . . . . . . . . . . . . . . . 1 – 5

Chapter 2 – Product Records and Maintenance

Product Records . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 – 1

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 – 1

Equivalents and Conversions . . . . . . . . . . . . . . . . 2 – 2

Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . 2 – 3

Chapter 3 – Kohler Engine

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 2

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 3

General Information . . . . . . . . . . . . . . . . . . . . . . . . 3 – 4

Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 5

Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . . 3 – 7

KOHLER ENGINE SERVICE MANUAL

Chapter 4 – Hydraulic System

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 – 2

General Information . . . . . . . . . . . . . . . . . . . . . . . . 4 – 4

Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . 4 – 7

Hydraulic Flow Diagrams . . . . . . . . . . . . . . . . . . . . 4 – 8

Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 – 12

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 – 14

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 – 17

Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . 4 – 30

HYDRO–GEAR BDP–10A/16A/21L HYDROSTATIC

PUMPS SERVICE AND REPAIR MANUAL

DANFOSS GROUP 2 GEAR PUMPS AND

MOTORS SERVICE MANUAL

DANFOSS OMEW HYDRAULIC MOTOR

SERVICE MANUAL

Chapter 5 – Electrical System

Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 1

Circuit Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 2

Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 7

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 8

Electrical System Quick Checks . . . . . . . . . . . . . 5 – 11

Component Testing . . . . . . . . . . . . . . . . . . . . . . . . 5 – 13

Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . 5 – 28

Chapter 6 – Chassis

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 2

Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 3

Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . . 6 – 4

Chapter 7 – Coring Head

General Information . . . . . . . . . . . . . . . . . . . . . . . . 7 – 2

Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . . 7 – 4

Chapter 8 – Electrical Diagrams

Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . 8 – 3

Electrical Circuit Drawings . . . . . . . . . . . . . . . . . . . 8 – 4

Wire Harness Drawings . . . . . . . . . . . . . . . . . . . . 8 – 11

SafetyProduct Records

and Maintenance

Kohler

Engine

Hydraulic

System

Electrical

System

ChassisCoring HeadElectrical

Diagrams

ProCore 648

This page is intentionally blank.

ProCore 648

Chapter 1

Safety

Table of Contents

SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . 2

Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

While Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Maintenance and Service . . . . . . . . . . . . . . . . . . . . 3

JACKING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . 4

SAFETY AND INSTRUCTION DECALS . . . . . . . . . . 5

Safety

ProCore 648 Page 1 – 1 Safety

Rev. C ProCore 648

Page 1 -- 2

Safety

Safety Instructions

The ProCore 648 is designed and tested to offer safe

service when operated and maintained properly. Al-

though hazard control and accident prevention partially

are dependent upon the design and configuration of the

machine, these factors are also dependent upon the

awareness, concern and proper training of the person-

nel involved in the operation, transport, maintenance

and storage of the machine. Improper use or mainte-

nance of the machine can result in injury or death. To re-

duce the potential for injury or death, comply with the

following safety instructions.

WARNING

To reduce the potential for injury or death,

comply with the following safety instructions.

Before Operating

1. Read and understand the contents of the Operator’s

Manual before starting and operating the machine. Be-

come familiar with the controls and know how to stop the

machine and engine quickly. Additional copies of the

Operator’s Manual are available on the internet at

www.Toro.com.

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 NEU-

TRAL and coring head is DISENGAGED.

4. Since gasoline is highly flammable, handle it careful-

ly:

A. Store fuel in containers specifically designed for

this purpose.

B. Do not remove machine fuel tank cap while en-

gine is hot or running.

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.

While Operating

1. Operator should be standing at the side console

when starting the engine and at the handle when operat-

ing the machine. Stay away from the coring head when

it is engaged.

2. Before starting the engine:

A. Engage the parking brake.

B. Make sure traction lever is in neutral.

3. After engine is started, release parking brake and

apply no pressure to traction lever. Machine must not

move. If movement is evident, the traction linkage is ad-

justed incorrectly. Shut engine off and adjust traction

linkage until machine does not move when traction lever

is released (see Operator’s Manual).

4. Do not run engine in a confined area without ade-

quate ventilation. Exhaust fumes are hazardous and

could possibly be deadly.

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.

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.

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