Form No. 3402-239 Rev A 2024 Directional Drill Model No. 23800—Serial No. 313000501 and Up Register at www.Toro.com.
You may contact Toro directly at www.Toro.com for product and accessory information, help finding a dealer, or to register your product. This product complies with all relevant European directives; for details, please see the separate product specific Declaration of Conformity (DOC) sheet. Whenever you need service, genuine Toro parts, or additional information, contact an Authorized Service Dealer or Toro Customer Service and have the model and serial numbers of your product ready.
Contents Priming the Fuel System ..........................................87 Replacing the Fuel Filters.........................................87 Checking Fuel Lines and Connections .......................88 Draining and Cleaning the Fuel Tank.........................88 Electrical System Maintenance ....................................89 Servicing the Battery...............................................89 Charging the Battery ...............................................90 Jump-starting the Machine..
Preparation Safety • Evaluate the terrain to determine what accessories and Improper use or maintenance by the operator or owner can result in injury. To reduce the potential for injury, comply with these safety instructions, and pay attention to the safety alert symbol , which means Caution, Warning, or Danger—“personal safety instruction.” Failure to comply with the instructions may result in personal injury or death. attachments are needed to properly and safely perform the job.
Driving Safety • Use care when loading or unloading the machine onto a You drive the machine to and from the work site with the use of a tethered remote. When driving the machine, observe the following safety precautions: • Watch for traffic when crossing roadways. trailer. • Check for overhead clearances (i.e. branches, doorways, electrical wires) before driving under any objects and do not contact them. • Operate the drive pendant alongside the machine outside of the danger zone (Figure 3).
Drilling Safety Drilling Danger Zone • Always lower the safety bar before drilling (Figure 4). The danger zone is the area within and around the machine where a person is exposed to the risk of injury. This proximity includes where a person can be reached by operational movement of the machine, its working devices, auxiliary equipment, or swinging/falling equipment. • Ensure that no one approaches a pipe while it is spinning. The pipe can snag on clothing and cause amputation or death.
Utility Line Color Refer to the following table for the proper utility line and the corresponding utility line color (USA and Canada).
Maintenance and Storage – Do not refuel the machine indoors. • Do not touch parts which may be hot from operation. – Do not store the machine or fuel container inside where there is an open flame, such as near a water heater or furnace. Allow them to cool before attempting to maintain, adjust, or service. – Do not fill a container while it is inside a vehicle, trunk, pick-up bed, or any surface other than the ground. • Lower the thrust frame, stop the engine, and remove the key.
Safety and Instructional Decals Safety decals and instructions are easily visible to the operator and are located near any area of potential danger. Replace any decal that is damaged or lost. Battery Symbols Some or all of these symbols are on your battery 1. Explosion hazard 6. Keep bystanders a safe distance from the battery. 2. No fire, open flame, or smoking. 7. Wear eye protection; explosive gases can cause blindness and other injuries 3. Caustic liquid/chemical burn hazard 4.
125-6137 125-6108 1. Thrown object hazard—read the Operator’s Manual. 125-6694 125-6121 1. Engine—heating light 5. Fluid pump on 2. Engine—stop 6. Fluid pump off 3. Engine—run 7. Drill-pendant receptacle 4. Engine—start 8. Drive-pendant receptacle 1.
125-6119 125-8473 1. Explosion hazard—wear eye protection. 3. Fire hazard—keep open flames away. 2. Caustic liquid/chemical burn hazard—rinse affected area and seek medical assistance. 4. Poison hazard—do not tamper with the battery. 1. Entanglement hazard—keep away from moving objects. 125-6126 1. Entanglement hazard—keep away from moving parts. 125-6114 1. Stored energy hazard—do not use tools; read the Operator’s Manual.
5-6110 1. Crushing hazard—do not stand under any part of the machine. 125-6128 125-6131 1. High pressure fluid hazard, injection into the body—read the Operator’s Manual before performing maintenance. 1. Warning—stay at least 3 m (10 ft) away from the machine. 125-6115 1. Crushing hazard—deploy cylinder locks before performing maintenance. 125-6130 1. Warning—read the Operator’s Manual; stay at least 3 m (10 ft) away from the front and rear of the machine and 1.
125-6123 1. Load pipes from back row first. 125-6109 1. Electrical shock hazard—when the Zap-Alert system is activated by a power strike, do not leave the operator’s position or touch the ground and the machine at the same time; the machine will be energized with electrical power. 125-6124 1. Center the pipe joint between the upper and lower wrenches. 125-6111 1. Stake up 6. Stake up 2. Stake down 7. Stake spin counterclockwise 8. Stake down 3. Stake spin counterclockwise 4. Stake spin clockwise 5.
125-6140 1. Rotate the chair. 125-6107 1. Crushing hazard of hand and foot—keep hands and feet away. 125-6152 1. Move seat forwards and backwards. 125-6116 1. Falling hazard—do not move the machine when someone is in the operator’s position.
125-6112 1. Exit-side lockout—reset light 14. Work lights—Off 2. Exit-side lockout—drill-enabled light 15. Press and hold to increase engine speed. 3. Receiver-battery-status light 16. Engine speed 4. Engine—start 17. Press and hold to decrease engine speed. 5. Press down to stop the engine; pull up to start the engine. 18. Mode I—left trigger released, extends pipe gripper toward drill frame; left trigger pressed, opens lower wrench. Mode II—spin drill spindle clockwise. 6.
125-1645 1. Pull back drill carriage 6. Wrench controls on 2. Reverse left track 7. Drill spindle clockwise spin 3. Forward left track 8. Forward right track 4. Forward drill carriage 9. Reverse right track 5. Drill fluid pump on 10. Drill spindle counterclockwise spin 125-6125 1. Warning—read the Operator’s Manual. 2. Explosion hazard; electrical shock hazard—do not dig before calling local services. 3. Press to apply tread-joint compound. 4.
125-1622 1. Pull up to start the engine. 2. Push down to stop the engine. 125-6127 1. Cutting/dismemberment hazard, fan—keep away from moving parts. 125-6129 1. Hot surface—keep away from hot surfaces. 114-9600 1. Read the Operator's Manual.
Product Overview Figure 5 1. Drill carriage 6. Front hood 2. Zap-Alert strobe 7. Right stabilizer 3. Operator seat 8. Rear hood 4. Control panel 9. Thrust frame 5.
Figure 6 1. Stake-down cage 5. Rear-control panel 2. Pipe holder 6. Left stabilizer 3. Safety bar 7. Stake-down plate 4.
Figure 7 4. Upper wrench 1. Thrust frame 2. Drill carriage 5. Lower wrench 3. Drill spindle 6.
Controls Operator-controls Covers Refer to the following sections for the appropriate machine controls: The covers protect the operator controls from adverse weather conditions, such as rain, wind, sunlight, etc. Remove them before using the machine and replace them before leaving the machine for the day. Each cover is secured with 2 screws as shown in Figure 9.
Monitor To release the platform and swing it out or in, press up on the front platform latch (Figure 11). Start-up Screen When you power up the machine, this is the first screen that appears (Figure 12). The start-up screen appears whenever you press the ESC button (found in the bottom-left corner of the screen) from the first 3 pages of the display. Note: No keys are active from this screen. 1 5 2 6 Figure 11 1.
Control-select Screen Machine-information Screen When you power up the machine, this is the screen that appears after the start-up screen. This screen contains the following information: The 2 control layouts that the operator can choose from consist of the following: • The number of engine hours for the machine (Figure 14). • The machine model and serial number (Figure 14).
Main Operating Screen Main Drill Functions Displayed in Pressure Screen To access this screen, press button 4 or the down arrow on the Machine-information Screen (page 23). To access this screen, press the down arrow on the Main Operating Screen (page 24). The main operating screen displays the engine-rpm gauge, the fuel-quantity gauge, and the engine-temperature gauge (Figure 15).
Main Drill Functions Displayed in Torque Screen Drill-rotation-speed Screen To access this screen, press the down arrow on the Main Drill Functions Displayed in Pressure Screen (page 24). To access this screen, simultaneously press the OK button and the left and right arrow buttons on the Main Operating Screen (page 24). This screen provides measurements on rotary torque in ft-lbs, drilling-fluid pressure in psi, carriage force in lbs, and drilling-fluid flow rate in gpm (Figure 17).
Horsepower-control Screen Clear-service-reminder Screen The horsepower control allows the user to change the engine-speed (rpm) setting that the engine can droop to before the horsepower-control system can activate. To access this screen, press button number 4 as shown in Figure 20. The horsepower control allows the operator to function the unit at low rpm levels, so that the engine can stall under heavy loads.
Lubrication and Maintenance Screens After entering the 8-digit PIN, the following screen will appear stating that the maintenance reminder has been cleared (Figure 22). These screens provide the user with maintenance schedules at 10-hour, 50-hour, 250-hour, 500-hour, and 1,000-hour increments. Note: Press the OK button to exit this screen.
Figure 24 10-Hour and 50-Hour Maintenance Screen Figure 27 1000-Hour Maintenance Screen Figure 25 250-Hour Maintenance Screen Figure 26 500-Hour Maintenance Screen 28
Error Codes Screen The following figure is an example of how an error code appears. This screen displays the number of drill errors that have occurred. Notice that the text before the occurrence count entails what the actual error is. If more than 1 drill error is shown on the screen, press button 6 to see the next drilling error (Figure 28). Note: If there are no drilling errors, press the OK button to exit this screen (Figure 28). Figure 30 1. Number of errors and number of reset errors 2.
Rotary and Carriage-service Screen Auxiliary-activations Screen From the Main Operating Screen (page 24), press button numbers 1 and 5 simultaneously to access this screen. Press the down arrow on the Rotary and Carriage-service Screen (page 30) to access this screen.
Drilling-fluid-information Screen Track-drive-information Screen Press the down arrow on the Auxiliary-activations Screen (page 30) to access this screen. Press the down arrow on the Drilling-fluid-information Screen (page 31) to access this screen.
Control Panel Engine-start Button Press this button (Figure 36) to start the engine. The key switch on the rear, control panel must be in the On position. Engine-stop Button 1 2 3 6 Press this button (Figure 36) to immediately stop the engine and all drilling operations. You must pull this button out before you can start the engine again.
Left Joystick—Mode I Rear Button Note: The joystick controls vary depending on the control mode you select when powering up the machine. There are 2 control modes: Mode I and Mode II; refer to the Control-select Screen (page 23) for information on setting the control mode. • Left trigger pressed—press this button to set the auto 1 drill speed. Press and hold this button to decrease the auto-drill speed. • Left trigger released—press this button to close the pipe gripper.
Left Joystick—Mode II Rear Button Note: The joystick controls vary depending on the control mode you select when powering up the machine. There are 2 control modes: Mode I and Mode II; refer to the Control-select Screen (page 23) for information on setting the control mode. • Left trigger pressed—press this button to set the auto 1 drill speed. Press and hold this button to decrease the auto-drill speed. • Left trigger released—press this button to close the pipe gripper.
Right Joystick—Mode I Joystick—Forward Note: The joystick controls vary depending on the control mode you select when powering up the machine. There are 2 control modes: Mode I and Mode II; refer to the Control-select Screen (page 23) for information on setting the control mode. Push the joystick forward to thrust the drill carriage forward. 1 Joystick—Rearward Pull the joystick rearward to pull the drill carriage rearward. 2 Joystick—Left Push the joystick left to spin the drill spindle clockwise.
Right Joystick—Mode II Joystick—Forward Note: The joystick controls vary depending on the control mode you select when powering up the machine. There are 2 control modes: Mode I and Mode II; refer to Control-select Screen (page 23) for information on setting the control mode. Push the joystick forward to thrust the drill carriage forward. Joystick—Rearward Pull the joystick rearward to pull the drill carriage rearward. 1 2 Joystick—Left • Left trigger pressed—opens the lower wrench.
Exit-side-lockout System (Standard Range) The exit-side-lockout system provides the individuals working around the machine with a means to disable the drill pipe from rotating and thrusting. This system consists of a receiver mounted on the machine and a transmitter (Figure 41) that must be held by a designated individual working around the machine.
Rear Control Panel • Engine-run position—turn the key to this position after 2 1 starting the engine. Turning the key to this position also enables the engine start button from the operator platform. 3 • Engine-start position—turn the key to this position to start the engine. Release the key to the Run position once the engine has started. Fluid-pump Switch Use this switch to turn on the fluid pump to use the spray gun when cleaning the machine.
Drill-frame Tilt Lever Drive Pendant Use the drill-frame tilt lever to tilt the drill frame to place the stake-down plate on the ground or to return the frame to the travel position. Refer to Figure 43 for location. Note: The Drive/Drill switch on the operator panel must be switched to the Drive position for this function to work. 1 3 2 4 5 g021855 Figure 46 1. Engine-speed switch 4. Drive-speed switch 2. Drive-direction joystick 5. Operator-presence switch 3.
Operator-presence Switch Center Switch Press and hold this button to enable the other controls on the drive pendant. The machine will stop moving if you release this button. Move this switch to the left to enable the pipe loader and wrench operation; move the switch to the center to turn off the drilling fluid.
Battery-disconnect Switch Specifications Open the front hood to access the battery-disconnect switch; refer to Opening the Front Hood (page 75). Note: Specifications and design are subject to change without notice. The battery-disconnect switch is located to the right of the engine; it is used to electrically disconnect the battery from the machine. Machine Turn the battery-disconnect switch to the On or Off position to perform the following: Width 131 cm (51.
Operation Handheld unit for the Exit-side-lockout System (Long Range) Batteries 3 AAA Low battery warning 3.
Gathering Site Information Refer to Preparing the Job Site and the Machine (page 55) for instructions on preparing the job site and the machine. Planning the Initial Route 4. Drill the bore. Before you can begin boring, you need to plan the route you will bore and prepare as follows: You drill the bore in three stages: A. Entry B. • Create a basic plan for the bore, mapping out the In the entry phase of the bore, you push the drill bit and head into the ground at an angle of up to 16 degrees.
– Electrical power lines DANGER Contacting underground hazards with the machine while drilling or reaming can cause explosion, electrocution, breathing problems, severe trauma, and death to you or bystanders. DANGER Drilling into an electric power line will cause the machine to become electrified and may electrocute you or any bystanders. – Ensure that all personnel at the job site wear personal protective equipment including a hard hat, eye protection, and hearing protection.
– Crystalline silica and other dust If you will be drilling through or cutting concrete, sand, or other substances that create dusts or fumes, you need to ensure that you and all workers wear breathing protection to protect your lungs from the dust.
Planning the Bore Path Before setting up the job site, you need to plan the bore path, including the following: 1 4 3 2 5 g021764 Figure 50 1. Bore entry 4. Obstacle 2. Beginning-of-bore-at-depth point 5. End-of-bore-at-depth point and bore exit 3. Bore depth • Bore entry needed for steering the drill to the surface, typically 9 to 15 m (30 to 50 ft) from the end-of-the-bore-at-depth point. The is the location where you setup the machine and the drill bit enters the ground.
1 g021765 Figure 51 1. 20 cm (8 inches) This flexibility is often rated in materials as a minimum bend radius, which is the radius of the circle formed if the material or pipes, connected together, were bent to form a giant circle. The minimum radius of a circle made with the pipe used with this machine is 36.6 m (102 ft). 1 2 • Entry pitch g021767 The entry pitch is the angle at which the machine enters the ground.
Note: The depths given in the following table are for 3 m (10 ft) of combined drill head and pipe. As you steer up, the pitch of the steered section will change and can be monitored with the receiver. Use the following table to identify how many lengths of pipe will be necessary to insert and steer to the beginning point and help you choose an entry point.
Given the above information, you can calculate the number of rods required to reach your beginning point at the appropriate depth. Toro recommends that you start the entry point a distance back from your beginning-at-depth point by the same distance as the length of pipes you will need to reach that point. This will ensure that you have enough extra space so you will not need to over-steer and damage the pipes.
• You insert the first 3 m (10 ft) of drill bit/pipe into the The following example illustrates the process given an installation using the machine at an 18% pitch on level ground: ground with no steering. The end of the drill bit will be 53 cm (21 inches) deep (Figure 55). 6 1 2 3 4 5 g021769 Figure 55 1. 18% pitch 3. 96 cm (38 inches 5. 119 cm (47 inches) 2. 53 cm (21 inches) 4. 114 cm (45 inches) 6. 10.
Understanding and Using the Exit-side-lockout System (Standard Range) Understanding and Using the Handheld Transmitter (Standard Range) The individual holding the transmitter can push the Lock Drill (Off) button to stop the drill rotation and thrust.
8. Release the On button. The Red light turns off and the Green light flashes for a few seconds. Disassociating all Handheld Transmitters from the Base Unit (Standard Range) Important: Completing this procedure will disassociate all transmitters from the base unit, which will need to be associated again before they will function. 1. Ensure that the machine is turned off. 2. Ensure that the handheld transmitter is not active (i.e., no lights are on). Figure 59 1. Handheld transmitter 2. AAA batteries 3.
Understanding and Using the Exit-side-lockout System (Long Range) Indicator Light Understanding the Base-unit Transmitter Indicator Lights (Long Range) The following table lists the various states of the indicator lights on the base-unit transmitter (Figure 60) and their meanings: Figure 60 1. Polarity-reversal indicator 2. 3. 4. 5. 6. +V1 +V2 +V3 RTX RRX 7. Over temperature/voltage 8. 9. 10. 11. 12.
Understanding and Using the Handheld Transmitter Indicator Lights (Long Range) Meaning Indicator Light State The individual holding the transmitter can push the Lock Drill (Off) button to stop the drill rotation and thrust.
Preparing the Job Site and the Machine Important: Ensure that you install the batteries in the correct polarity orientation or you could damage the transmitter. Before drilling, prepare the job site and machine as follows: • Mark and prepare the bore path Marking and Preparing the Bore Path (page 55). • Test the Zap-Alert system; refer to Testing the Zap-Alert System (page 56). • Load the drill pipes into the pipe holder if needed; refer to Loading Drill Pipes into the Pipe Holder (page 58).
Testing the Zap-Alert System The Zap-Alert system is an electric strike sensing device on the machine that triggers a strobe light and audible alarm in the event that the drill bit, reamer, or stake breaks into an energized power line. In the event of an electric strike, the machine will become energized, setting off the alarm. DANGER If the Zap-Alert system activates while drilling, the machine, except for the operator’s platform, will become energized.
7. Disconnect the alligator clips from the grounding stud and the machine. 8. Store the grounding stake in the holder on the operator platform as shown in Figure 66. 1 g021838 Figure 66 1. Grounding stake If either the audible alarm or the strobe light failed to trigger when you pressed the test button, have them repaired before drilling with the machine. Mounting a Fire Extinguisher Mount your fire extinguisher below the operator seat (Figure 67).
Loading Drill Pipes into the Pipe Holder Before using the machine, fill the pipe holder with up to 40 drill pipes. Figure 68 1. Pipe 2. Male end 3. Clevis pins Adding Fuel 1. Remove the clevis pins from the pipe holder (Figure 68). Service Interval: Before each use or daily—Check the fuel level. 2. Insert the pipes from the top with the male threaded pipe ends toward the front of the machine (Figure 68).
Use of summer grade fuel above -7° C (20° F) will contribute toward longer fuel pump life and increased power compared to winter grade fuel. • If this is not possible, then refuel such equipment on Important: Do not use kerosene or gasoline instead of diesel fuel. Failure to observe this caution will damage the engine. • If a fuel dispenser nozzle must be used, keep the nozzle in a truck or trailer from a portable container, rather than from a fuel dispenser nozzle.
Adjusting the Carriage Pressure Checking the Engine-oil Level To hydraulically adjust the carriage pressure, do the following: Before you start the engine and use the machine, check the oil level in the engine crankcase; refer to Checking the Engine-oil Level (page 83) in Engine Maintenance. 1. Press button 7 on the screen to turn the carriage pressure to the On position (green), as shown in Figure 70.
Loading and Unloading the Machine 4. Using the drive pendant, set the engine speed to slow and the drive speed to slow. WARNING 5. Using the drive pendant, carefully drive the machine forward or rearward up the ramp and into position on the trailer. Moving a machine of this size on a trailer over public roads carries risks to those around the machine if it should come loose, be involved in an accident, hit a low hanging structure, etc. 6. Lower the stake-down plate to the deck of the trailer. 7.
Setting Up the Drill Head and Tracking System The drill head consists of two parts, the drill bit and the sonde housing (Figure 74). Figure 74 1. Sonde housing Figure 75 2. Drill bit 3. Insert the sonde beacon with the forward end toward the drill bit into the sonde housing (Figure 76). Drill bits vary in size and type to meet the various soil conditions you may need to drill through. Some of the possibilities are as follows: • Straight blade—Used in a wide range of medium density soils.
Setting up the Machine for Drilling Note: The operator platform has 4 positions: travel (swung all the way into the machine), full-out, and 2 intermediate positions. 1. Using the drive pendant, drive the machine to the location that you have prepared for it, ensuring that the front of the machine is the proper distance back from entry point and the drill frame is in line with the bore path. 2. Drive up to the location and make sure that all utilities are located and marked prior to drilling. 3.
Connecting to a Drilling-fluid Source When drilling and reaming, you pump a mixture of bentonite clay, water, and sometimes other ingredients, collectively called drilling fluid or “Mud”, through the pipe and into the bore. This drilling fluid, or “Mud”, does the following for your bore: • Lubricates the drill head • Loosens the soil into which the drill is cutting • Penetrates and binds loose soil to keep them from collapsing on the bore pipe.
Setting Up the Pump to Use a Natural Water Source Deploying the Zap-Alert System To set up a pump to use a natural water source, you must ensure that you use the Y-screen to filter all materials other than water. The Zap-Alert system is an electric strike sensing device on the machine that triggers a strobe light and audible alarm in the event that the drill bit, reamer, or stake breaks into an energized power line.
4. Lower the pipe elevators to load a pipe into the pipe gripper. 1 5. Rotate the pipe gripper with the pipe toward the drill frame, and extend the pipe until the pipe is centered over the frame and in front of the spindle on the drill carriage. 6. Rotate the drill spindle clockwise and move the carriage slowly forward to insert the spindle into the female end of the pipe (Figure 87). g021838 Figure 85 1. Grounding stake 2.
Installing the Drill Head 5. Using the upper wrench, clamp the lead bar and tighten it to full machine torque. 1. Using the exit-side-lockout transmitter, enable the exit side lockout. 6. Using the exit-side-lockout transmitter, enable the exit-side lockout. WARNING 7. Double check the drill head and bit to ensure that the fluid ports are clean and free from obstructions.
Note: This will allow the carriage to float, and will not damage the pipe threads. transmitter temperature, and orientation in the soil. The remote console is a screen that remains near you (the drill operator) to show you the information from the receiver while drilling so you can make steering decisions. 4. Rotate the drill head counterclockwise until the spindle is completely removed from the pipe.
Exiting the Ground Backreaming and Pullback As you approach the end of the bore, steer the drill head to the exit point, keeping the steering limits in mind as you do so. Before exiting the ground, ensure that everyone is away from the exit point. As soon as you break through, stop the drilling-fluid flow. Extend the drill forward until the entire drill head is out of the ground. After drilling the initial bore, you attach a reamer to the pipe which is then connected to a the product you are installing.
Removing Drill Pipes 13. Move the drill carriage back until the male-pipe threads just clear the female end of the lower pipe, then close the upper wrench onto the pipe end, but not on the threads. 1. Using the exit-side-lockout transmitter, enable the exit side lockout. 2. Install a drill-pipe wiper around the pipe and into the retaining bracket on the front of the machine. 14. Rotate the drill spindle counterclockwise until the upper-pipe joint is loose but not separated.
6. Leave the lead bar clamped in the lower wrench, but do not connect the drill spindle to the lead bar. Using the TJC Applicator 7. Remove the reamer from the end of the lead bar as directed by the reamer manufacturer. Adjusting the Applicator Nozzle You can adjust the applicator nozzle to spray thread-joint compound (TJC) either in a fan-shaped spray or as a stream. 8. Release the lower wrench and pull the lead bar out of the pipe guide.
Adjusting the TJC-spray Volume Filling the TJC Applicator 1. Stop the machine and stop the engine. To adjust the volume of thread-joint compound that is delivered by the applicator, complete the following: 2. Open the stake-down-guard door. 1. Loosen the jam nut on the adjustment bolt located on top of the TJC-applicator piston (Figure 92). 1 2 3. Loosen the wing nuts securing the cover straps to the machine (Figure 93). 3 1 2 3 4 5 g021846 g021845 Figure 93 Figure 92 1. Adjustment bolt 3.
Moving a Disabled Machine Whenever the machine is stopped and the engine is not running, the hydrostatic brakes automatically engage. Do not attempt to tow the machine if it cannot move under its own power. If possible, repair the machine at the site. If this is not possible, use a crane and a spreader bar to lift the machine onto a trailer, using the lift points shown in Figure 94. Figure 94 Repeat lift points on other side 1. Spreader bar 2.
Maintenance Note: Determine the left and right sides of the machine from the normal operating position. Recommended Maintenance Schedule(s) Maintenance Service Interval Maintenance Procedure After the first 100 hours • Check the gearbox drive oil. • Change the gearbox-drive oil. After the first 250 hours • Adjust the valve clearance. • Change the planetary-drive oil. Before each use or daily • • • • • • • • • • Check the fuel level. Grease the machine. (Grease immediately after every washing).
CAUTION If you leave the key in the ignition switch, someone could accidently start the engine and seriously injure you or other bystanders. Remove the key from the ignition before you do any maintenance. WARNING Improperly servicing or repairing the machine may cause injury or death. If you do not understand the service procedures for this machine, contact your dealer or see the service manual for this machine. WARNING Raised equipment on the machine without an operator may cause injury or death.
Opening the Rear Hood 3. Lift up the handle as shown in Figure 98. 1. Park the machine on a level surface, stop the engine, and remove the ignition key. 2. Pull the hood latch out (Figure 97). Figure 98 1. Hood handle Figure 97 1.
Removing and Storing the Cylinder Lock Using the Cylinder Lock WARNING 1. Start the engine. The thrust frame may lower when it is in the raised position, causing serious injury or death. 2. Lower the thrust frame to the fully lowered position. 3. Stop the engine. Install the cylinder lock before performing maintenance that requires the thrust frame to be raised. 4. Remove the cotter pin and the clevis pin that secure the cylinder lock (Figure 99). 5. Remove the cylinder lock. 6.
Lubrication Greasing the Machine Service Interval: Before each use or daily (Grease immediately after every washing). Grease type: General-purpose grease. 1. Park the machine on a level surface, stop the engine, and remove the ignition key. 2. Clean the grease fittings with a rag. 3. Connect a grease gun to each fitting. 4. Pump grease into the fittings until grease begins to ooze out of the bearings (approximately 3 pumps). 5. Wipe up any excess grease.
Figure 106 Rear-pipe elevator (operator’s side) Figure 109 Carriage-roller bearings (operator’s side shown; repeat on other side) Figure 107 Front-pipe elevator (operator’s side) Figure 110 Gearbox float (operator’s side shown; repeat on other side) Figure 108 Stakedown motors 79
Figure 111 Track roller (operator’s side shown; repeat on other side) Engine Maintenance Cleaning the Crankcase-vent Tube Service Interval: Before each use or daily—Check the crankcase-vent tube and clean it if necessary. 1. Park the machine on a level surface, stop the engine, and remove the ignition key. Figure 112 Rear-cam bearing (operator’s side) 2. Open the front hood. 3. Gently pull the crankcase-vent tube out (Figure 114). 4. Clean the end of the crankcase-vent tube (Figure 114).
Servicing the Air-cleaning System B. Important: Do not remove the elements from the machine to check for dirty filters; use the following procedure instead. Repeat steps 1 and 2; if the restricted air-cleaner indicator is still shown on the display screen, replace the secondary, air-cleaner filter; refer to Servicing the Air-cleaner Filter (page 82).
Servicing the Air-cleaner Cover Service Interval: Every 50 hours—Remove air cleaner cover and clean out debris. Do not remove the filter. Removing the Air-cleaner Cover 1. Park the machine on a level surface, stop the engine, and remove the ignition key. 2. Open the front hood. 3. Clean the outside of the air-cleaner canister with a clean, damp cloth. 4. Check the air-cleaner canister for damage which could cause an air leak. Replace a damaged air cleaner body. Figure 118 1.
Servicing the Engine Oil and Filter Important: Do not clean the used filter. 2 4 3 The engine is shipped with oil in the crankcase; however, check the oil level before and after you first start the engine. Crankcase capacity: 7.5 L (8 US qt) with the filter. Use only high-quality SAE 15W-40 heavy-duty engine oil with an API classification of CH-4 or higher.
Changing the Engine-oil Filter Service Interval: Every 250 hours 1. Park the machine on a level surface, stop the engine, and remove the ignition key. 2. Open the front hood. 3. Align a drain pan or several rags under the oil filter and the oil-filter adapter (Figure 124). Figure 122 Operator’s side 1. Dipstick Figure 124 4. Insert the dipstick into the oil fill tube, pull the dipstick out again, and read the oil level on the dipstick. 1. Oil-filter adapter 2.
Changing the Engine Oil Note: Use a funnel with a flexible, attached hose to direct the engine oil into the engine. Service Interval: Every 250 hours 1. Park the machine on a level surface, stop the engine, and remove the ignition key. 2. Remove the drain plug (Figure 125). 9. Fill the crankcase with approximately 7.5 L (8 US qt) of the specified engine oil; refer to Servicing the Engine Oil and Filter (page 83). 10. Install the oil-fill cap. 11.
Fuel System Maintenance and drain any water and sediment from the fuel filter (Figure 127). Note: If the fuel-water separator has any water or sediment, also drain the water and sediment from the fuel tank; refer to Draining Water from the Fuel Tank (page 86). DANGER Under certain conditions, diesel fuel and fuel vapors are highly flammable and explosive. A fire or explosion from fuel can burn you and others and can cause property damage. 5.
Priming the Fuel System Replacing the Fuel Filters Note: Prime the fuel system whenever any of the following occur: • You drained water from the fuel filter. • You replaced the fuel filter. • You ran the engine until the fuel tank is empty or drained the fuel tank. 1. Park the machine on a level surface, stop the engine, and remove the ignition key. 2. Open the front hood. 3. Ensure that the engine and the exhaust system are cool. 4. Ensure that the fuel tank is at least 1/4 full. 5.
4. Start the engine and check for leaks at the fuel filters. Checking Fuel Lines and Connections Service Interval: Every 500 hours/Yearly (whichever comes first)—Inspect the fuel lines and connections. Inspect the fuel lines and connections for deterioration, damage, or loose connections. Draining and Cleaning the Fuel Tank Service Interval: Every 1,000 hours/Yearly (whichever comes first)—Drain and clean the fuel tank. Figure 130 1. Filter adapter 6. Hose clamp 2. Secondary-filter element 7.
Electrical System Maintenance WARNING A battery contains sulfuric acid, which can cause serious burns; and they can produce explosive gases. Servicing the Battery • Avoid contact with skin, eyes, or clothing; flush affected areas with water. Service Interval: Every 50 hours—Check the battery condition • If taken internally, drink large quantities of water or milk. Do not induce vomiting. Seek medical attention immediately.
Charging the Battery Battery-charger Table WARNING Charging the battery produces gasses that can explode. Charger setting Charging time 4 to 6 amperes 30 minutes 25 to 30 amperes 10 to 15 minutes 8. When the battery is fully charged, unplug the charger from the electrical source, then disconnect the charger leads from the battery posts (Figure 131). Do not smoke near the battery and keep sparks and flames away from battery. Important: Keep the battery fully charged.
Drive System Maintenance Checking the Oil Level for the Tracks Planetary Drive Service Interval: Every 50 hours—Check the tracks rotary motor planetary-drive oil level (Also, check if external leakage is observed). Oil specification: SAE 85W-140 API classification level GL4 Figure 132 1. Jumper-cable clamp (positive) 4. Ground point (unpainted bolt) 2. Jump post 5. Jumper-cable clamp (negative) Planetary-drive oil capacity: approximately 1.4 L (1.
Changing the Oil for the Tracks Planetary Drive Service Interval: After the first 250 hours—Change the planetary-drive oil. Every 800 hours—Change the planetary-drive oil (or yearly, whichever comes first). Note: Change the oil when it is warm, if possible. 1. Park the machine on a level surface. 2. Clean the area around the oil-level plug (Figure 133). 3. Rotate the planetary drive until the oil-drain plug is directly below the oil-level plug (Figure 133). 4. Stop the engine and remove the key.
9. Place the guard back into place and install the 2 bolts (Box A of Figure 135). 10. Install the 2 other bolts securing the lid onto the gearbox (Box A of Figure 135). 11. Torque the bolts to 23 to 29 N∙m (17 to 21 ft-lb). Servicing the Tracks Service Interval: Before each use or daily—Check the track tension. WARNING Grease in the hydraulic track is highly pressurized; ensure that the track-tension grease valve is not loosened more than one revolution at a time.
Cooling System Maintenance 5. Remove excess grease from around the valve. 6. Install the cover and retaining bolts. 7. Repeat steps 2 through 6 to tighten the track tension on the other side. Coolant specification: 50/50 solution of ethylene-glycol antifreeze and water or equivalent Loosening the Track Tension Engine and Radiator coolant capacity: 16.77 L (17.7 US qt) If the track seems tight, loosen the track tension as follows: 1.
Checking the Coolant Level in the Reservoir 1. Park the machine on a level surface, stop the engine, and remove the ignition key. 2. Allow the engine to cool. Service Interval: Before each use or daily 3. Open the front hood and rear hood. Important: Do not remove the radiator filler cap during this procedure. 1. Park the machine on a level surface, stop the engine, and remove the ignition key. 2. Allow the engine to cool. 3. Open the front hood. 4. Check the coolant level in the reservoir (Figure 138).
Checking the Concentration of the Coolant 6. Open the drain plug for the radiator and allow the coolant system to drain completely. Note: Dispose of the used coolant properly according to local codes. Service Interval: Every 1,000 hours/Yearly (whichever comes first)—Check the concentration of the coolant before the winter season. 7. Clean the threads on the drain plug and apply 3 layers of PTFE sealing tape. Test the concentration of ethylene glycol-based antifreeze in the coolant .
Filling the System with Coolant E. Open the drain plug for the radiator, and drain the cleaning solution into a drain pan. F. Clean the threads on the drain plug and apply 3 layers of PTFE sealing tape. G. Close the drain plug. Important: You must fill the cooling system properly to prevent air locks in the cooling passages. Failing to vent the cooling system properly can severely damage the cooling system and engine.
Belt Maintenance Checking the Tension of the Belt Service Interval: Every 1,000 hours Servicing the Engine-drive Belt 1. Park the machine on a level surface, stop the engine, and remove the ignition key. 2. Open the front hood. 3. Align a straight edge over the drive belt and across the pulleys as shown in Figure 144. WARNING Contacting a rotating belt can cause serious injury or death. Stop the engine and remove the ignition key before working near belts.
Adjusting the Tension of the Belt Hydraulic System Maintenance 1. Park the machine on a level surface, stop the engine, and remove the ignition key. 2. Open the front hood. Servicing the Hydraulic Fluid 3. Loosen the nut and bolt at the pivot point for the alternator (Figure 145). The hydraulic reservoir is filled at the factory with approximately 102 L (27 US gallons) of high-quality hydraulic fluid. Check the level of the hydraulic fluid before the engine is first started and daily thereafter.
Changing the Hydraulic-fluid Return Filter Checking the Hydraulic Fluid Service Interval: Before each use or daily Service Interval: Every 500 hours/Every 6 months (whichever comes first) Check the hydraulic fluid as follows: 1. Park the machine on a level surface, stop the engine, and remove the ignition key. 1. Park the machine on a level surface, stop the engine, and remove the ignition key. 2. Open the front hood. 2. Open the front hood. 3.
Changing the Hydraulic-pressure Filter WARNING Service Interval: Every 500 hours/Every 6 months (whichever comes first) Raising the rear of the unit relying solely on mechanical or hydraulic jacks could be dangerous. The mechanical or hydraulic jacks may not be enough support or may malfunction allowing the unit to fall, which could cause injury or death. 1. Park the machine on a level surface, stop the engine, and remove the ignition key. 2. Open the front hood. 3. Place a drain pan under the filter.
Checking the Hydraulic Lines and Hoses Drilling-fluid Pump Maintenance Service Interval: Every 2 years—Replace moving hoses. Inspect the hydraulic lines and hoses daily for leaks, kinked lines, loose mounting supports, wear, loose fittings, weather deterioration, and chemical deterioration. Make all necessary repairs before operating.
Preparing the Drilling-fluid System for Cold Weather 4. Ensure that the oil is at the oil-fill line as shown in Figure 149. Note: If the oil is below the oil-fill line, refer to step 8 of Changing the Drilling-fluid Pump Oil (page 103) and add the necessary amount of oil. Prepare the machine as follows after drilling if the temperature will be below 0° C (32° F). Changing the Drilling-fluid Pump Oil 1. Park the machine on a level surface, stop the engine, and remove the ignition key.
Cleaning 1 Cleaning with the Spray-hose Attachment Service Interval: Before each use or daily The machine comes with a spray-hose attachment that you can use to clean the machine and pipes. Important: Do not spray any electronic component of the machine and ensure that the hood is down before cleaning the machine with the spray-hose attachment.
7. Turn the drilling-fluid pump to the On position through the display screen; refer to Main Drill Functions Displayed in Pressure Screen (page 24). 8. Using the spray-hose attachment, hold down the lever and spray down the machine and pipes. Cleaning Plastic and Resin Parts Avoid using gasoline, kerosene, paint thinner, etc. when cleaning plastic windows, the console, the instrument cluster, the monitor, gauges, etc. Use only water, mild soap , and a soft cloth when you clean these parts. Figure 156 1.
Storage 1. Stop the engine and remove the key. 2. Remove dirt and grime from the entire machine. Important: You can wash the machine with mild detergent and water. Avoid excessive use of water, especially near the control panel, engine, hydraulic pumps, and motors. 3. Service the air cleaner; refer to Servicing the Air-cleaning System (page 81). 4. Grease the machine; refer to Greasing the Machine (page 78). 5. Charge the battery; refer to Charging the Battery (page 90). 6.
Troubleshooting Problem The starter does not crank. The engine cranks, but will not start. Possible Cause Corrective Action 1. The battery-disconnect switch is in the Off position. 1. Turn the battery-disconnect switch to the On position. 2. The electrical connections are corroded or loose. 3. A fuse is blown or loose. 4. The battery is discharged. 5. The relay or switch is damaged. 6. A starter or starter solenoid is damaged. 7. The internal engine components have seized. 2.
Problem The engine starts, but does not keep running. Possible Cause 1. The fuel tank vent is restricted. 1. Loosen the cap. If the engine runs with the cap loosened, replace the cap. 2. Dirt or water is in the fuel system. 2. Drain and flush the fuel system; add fresh fuel. 3. Replace the fuel filter. 4. Bleed the nozzles and check for air leaks at fuel hose connections and fittings between the fuel tank and engine. 5. Drain the fuel system and replace the fuel filter.
Problem The engine overheats. Possible Cause 1. More coolant is needed. 1. Check and add coolant. 2. There is restricted air flow to the radiator. 3. The crankcase oil level is incorrect. 4. There is excessive loading. 2. Inspect and clean the side panel screens with every use. 3. Fill or drain to the full mark. 4. Reduce the load and use a lower ground speed. 5. Drain and flush the fuel system; add fresh fuel. 6. Contact your Authorized Service Dealer. 7. Contact your Authorized Service Dealer. 8.
Index 811 ............................. 4, 42–43 A Accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Adding drill pipes . . . . . . . . . . . . . . . . . . . . . . . . . . 67 Adding fuel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Air-cleaning system Checking the air-cleaner indicator. . . . . 82 Cleaning the dust valve . . . . . . . . . . . . . . . . 81 Cover latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 Installing the cover. . . .
Horizontal shaft . . . . . . . . . . . . . . . . . . . . . . . . . 68 Setting up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Starting the first pipe . . . . . . . . . . . . . . . . . . . 66 Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Drilling danger zone. . . . . . . . . . . . . . . . . . . . . . . . .6 Drilling fluid Pump Changing the oil . . . . . . . . . . . . . . . . . . . . . 103 Checking the oil level . . . . . . . . . . . . . . .
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Mode I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Mode II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Left-stabilizer lever . . . . . . . . . . . . . . . . . . . . . . . . 38 Length. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Lever Drill-frame tilt . . . . . . . . . . . . . . . . . . . . . . . . 38–39 Left-stabilizer. . . . . . . . . . . . .
R Reamer Carbide step-wing cutter . . . . . . . . . . . . . . . 69 Cast cone packer . . . . . . . . . . . . . . . . . . . . . . . 69 Connecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Fluted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Rear button Left joystick. . . . . . . . . . . . . . . . . . . . . . . . . . 33–34 Right joystick . . . . . . . . . . . . . . . . . . . . . . . .
Valve clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Vent tube Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Vibration information . . . . . . . . . . . . . . . . . . . . . . . .8 W Water as drilling fluid. . . . . . . . . . . . . . . . . . . . . . 65 Water lines Safety precautions. . . . . . . . . . . . . . . . . . . . . . . .7 Weight. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Width . . . . . . . . . . . . . . . . . . .
International Distributor List Distributor: Agrolanc Kft Asian American Industrial (AAI) B-Ray Corporation Brisa Goods LLC Casco Sales Company Ceres S.A. CSSC Turf Equipment (pvt) Ltd. Cyril Johnston & Co. Cyril Johnston & Co. Fat Dragon Femco S.A. FIVEMANS New-Tech Co., Ltd ForGarder OU G.Y.K. Company Ltd. Geomechaniki of Athens Golf international Turizm Hako Ground and Garden Hako Ground and Garden Hayter Limited (U.K.) Hydroturf Int. Co Dubai Hydroturf Egypt LLC Irrimac Irrigation Products Int'l Pvt Ltd.
Underground Equipment The Toro Underground Warranty A Limited Warranty Conditions and Products Covered The Toro Company and its affiliate, Toro Warranty Company, pursuant to an agreement between them, jointly warrant your Toro Underground Equipment (“Product”) to be free from defects in materials or workmanship. Where a warrantable condition exists, we will repair the Product at no cost to you including diagnostics, labor, and parts.
