Form No. 3401-909 Rev A 4045 Directional Drill with Cab Model No. 23823—Serial No. 314000501 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 Adjusting the Valve Clearance ..................................88 Fuel System Maintenance ...........................................89 Draining Water from the Fuel Filter...........................89 Draining Water from the Fuel Tank ...........................89 Priming the Fuel System ..........................................90 Replacing the Fuel Filters.........................................90 Checking the Fuel Lines and Connections ..................91 Draining and Cleaning the Fuel Tank.
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 • Check for overhead clearances (i.e. branches, doorways, 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: • Use care when driving the machine on soft or unstable electrical wires) before driving under any objects and do not contact them. ground. • Operate the drive pendant alongside the machine outside Note: Soft or uneven ground can reduce stability. of the danger zone (Figure 3).
Drilling Safety Drilling Danger Zone • Always lower the pedestrian safety bar before drilling 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 is reachable by operational movement of the machine, its working devices, auxiliary equipment, or swinging/falling equipment. (Figure 4). • 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 125-6694 1. Tie-down point 125-8473 125-6108 1. Thrown object hazard—read the Operator’s Manual. 10 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.
125-6114 125-6126 1. Stored energy hazard—do not use tools; read the Operator’s Manual. 1. Entanglement hazard—keep away from moving parts. 125-6119 1. Entanglement hazard—keep away from moving objects. 125-6131 1. Warning—stay at least 3 m (10 ft) away from the machine.
5-6128 125-6115 1. High pressure fluid hazard, injection into the body—read the Operator’s Manual before performing maintenance. 1. Crushing hazard—deploy cylinder locks before performing maintenance. 125-6110 1. Crushing hazard—do not stand under any part of the machine. 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 1.8 m (6 ft) away from the sides of the machine.
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 (makeup/breakout wrench) and lower wrenches (stationary wrench). 125-6111 1. Stake up 6. Stake up 2. Stake down 7. Stake spin counterclockwise 8. Stake down 3.
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.
125-6158 Model with Cab only 1. Engine—start 13. With trigger released, rock forward to rotate basket toward pipe cam, rock backward to rotate basket toward drill frame. 2. Press down to stop the engine 14. With trigger released, upper button closes pipe gripper, lower button opens pipe gripper. 3. Pull up to start the engine 15.
125-6142 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. Transmitter-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 (stationary wrench). Mode II—spin drill spindle clockwise. 6.
125-1641 1. Forward left 6. Forward right 2. Increase rpm 7. High 3. Engine speed 8. Track speed 4. Decrease rpm 9. Low 10. Reverse right 5. Reverse left 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 thread-joint compound. 4. Press and hold for maximum drilling fluid pressure; release to stop the flow. 5. Press to turn the drilling-fluid pump on or off. 6.
125-6127 1. Cutting/dismemberment hazard, fan—keep away from moving parts. 0000 0000 0000 125-6129 1. Hot surface—keep away from hot surfaces. 125-6157 125-6141 1. Engine—heating light 4. Engine—start 2. Engine—stop 5. Drill-pendant receptacle 3. Engine—run 6. Drive-pendant receptacle 18 1. Disconnect the battery power. 3. On/Start 2. Off/Stop 4. Read the Operator’s Manual.
125-6113 1. Warning—read the Operator’s Manual. 4. Warning—keep away from moving parts; keep all guards and shields in place. 2. Warning—do not operate the machine unless you are trained. 5. Warning—wear hearing protection. 3. Warning—keep bystanders away from the machine. 6. Explosion hazard, electrical shock hazard; do not dig before calling local utilities. 125-6139 1. Lift point and tie-down point 125-6117 1. Falling hazard—do not stand on the machine while it is moving.
125-1623 1. Forward left track/forward rotary 11. Wrench makeup (for upper wrench) 2. Reverse left track/reverse rotary 12. Raise pipe elevator 3. Drilling fluid pump on 13. Lower pipe elevator 4. Forward right track/forward carriage 14. Reverse cam rotation 5. Reverse right track/reverse carriage 15. Forward (toward operator) cam rotation 6. Tighten lower wrench (stationary wrench) 16. Tighten pipe grip 7. Loosen lower wrench (stationary wrench) 17. Loosen pipe grip 8.
Product Overview Figure 5 1. Drill carriage 6. Front hood 2. Zap-alert strobe 7. Right stabilizer 3. Cab 4. Monitor 5. Track 8. Rear-access door 9. Rear hood 10.
Figure 6 1. Stake-down cage 5. Rear-control panel 2. Pipe holder 6. Left stabilizer 3. Pedestrian safety bar 7. Stake-down plate 4.
Figure 7 1. Cab 5. Upper wrench (makeup/breakout wrench) 2. Thrust frame 6. Lower wrench (stationary wrench) 3. Drill carriage 7. Pipe wiper 4.
Controls Refer to the following sections for the appropriate machine controls: • • • • • • • • • • • • • • Operator Platform Monitor Control Panel Left Joystick—Mode I Left Joystick—Mode II Right Joystick—Mode I Right Joystick—Mode II Exit-Side-Lockout System Rear Control Panel Drill Frame and Stabilizer Controls Figure 9 Drive Pendant Drill Pendant 1. Screws 2.
Control-select Screen When you power up the machine, this is the screen that appears after the start-up screen. The 2 control layouts that the operator can choose from consist of the following: • Mode I—This function places the drilling functions on the right joystick, while the left joystick operates the pipe loader and the wrench functions (Figure 13). Press button number 4 to select this function (Figure 13).
Machine-information Screen Main Operating Screen This screen contains the following information: To access this screen, press button 4 or the down arrow on the Machine-information Screen (page 26). • The machine model and serial number (Figure 14). of re-settable drilling-fluid gallons used (Figure 14). The main operating screen displays the engine-speed (rpm) gauge, the fuel-quantity gauge, the engine-temperature gauge, the rod-row selector, thrust control, and horsepower control (Figure 15).
Main Drill Functions Displayed in Pressure Screen Main Drill Functions Displayed in Torque Screen To access this screen, press the down-arrow button on the Control-select Screen (page 25). To access this screen, press the down arrow on the Main Drill Functions Displayed in Pressure Screen (page 27). This screen provides measurements on rotary pressure in psi, drilling-fluid pressure in psi, carriage pressure in psi, and drilling-fluid flow rate in gpm (Figure 16).
Drill-rotation-speed Screen Thrust-control Screen To access this screen, press the OK button on the Main Operating Screen (page 26). This screen allows the user to increase or decrease the thrust output of the machine. This screen allows the user to increase or decrease the rotation speed of the drill. To access this screen, press button number 3 on the Main Operating Screen (page 26).
Horsepower-control Screen Pipe-row-selector Screen To access this screen, press button number 4 on the Main Operating Screen (page 26). This screen allows you to select the row of pipe(s) that you want to use. The horsepower control allows the user to change the speed setting that the engine can droop to before the horsepower-control system can activate. To access this screen, press button number 8 on the Main Operating Screen (page 26).
Main-selection Screen Lubrication and Maintenance Screens To access this screen, press the down arrow on the Main Drill Functions Displayed in Torque Screen (page 27). To access this screen, press button number 2 on the Main-selection Screen (page 30). This screen allows the user to choose from the following options: These screens provide the user with maintenance schedules at 10-hour, 50-hour, 250-hour, 500-hour, and 1,000-hour increments.
Error Codes Screen To access this screen, press button number 3 on the Main-selection Screen (page 30). This screen displays the number of drill errors and engine errors that have occurred. If more than 1 drill or engine error is shown on the screen, press button 5 to see the next drilling error, button 7 to see the next engine error, or button 8 to see the previous engine error (Figure 28). Note: If there are no drilling errors or engine errors, press the OK button to exit this screen (Figure 28).
Loader-calibration Screen Loader-cam-calibration Screen To access this screen, press button number 6 on the Main-selection Screen (page 30). To access this screen, press button number 1 on the Loader-calibration Screen (page 32). This screen allows you to calibrate the loader cam or to calibrate the loader arm. This screen allows the user to set the row positions for the pipe holder. This screen also allows you to adjust the cam-stop positions, ensuring that the cam is in line with the pipe row.
Loader-arm-calibration Screen Clear-service-reminder Screen To access this screen, press button number 2 on the Loader-calibration Screen (page 32). To access this screen, press button number 7 on the Main-selection Screen (page 30). This screen allows the user to set the loader arm to the In position (fully inward toward the machine), or to the Home position (fully out away from the machine).
Rotary and Carriage-service Screen Auxiliary-activations Screen From the Main Operating Screen (page 26), press button numbers 1 and 5 simultaneously to access this screen. Press the down arrow on the Rotary and Carriage-service Screen (page 34) to access this screen.
Drilling-fluid-information Screen Track-drive-information Screen Press the down arrow on the Auxiliary-activations Screen (page 34) to access this screen. Press the down arrow on the Drilling-fluid-information Screen (page 35) to access this screen.
Control Panel Transmitter-battery-status Light This light (Figure 38) illuminates red when the battery on the exit-side-lockout transmitter is too low to transmit. Stop drilling operations and fix the problem with the transmitter before continuing. Engine-start Button 6 1 Press this button (Figure 38) to start the engine. The key switch on the rear, control panel must be in the On position.
Left Joystick—Mode I Front 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 25) for information on setting the control mode. • Left trigger pressed—press this button to resume the 1 previously set auto-drill speed. Press and hold this button to increase the auto-drill speed. • Left trigger released—press this button to open the pipe gripper.
Left Joystick—Mode II Front 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 25) for information on setting the control mode. • Left trigger pressed—press this button to resume the 1 previously set auto-drill speed. Press and hold this button to increase the auto-drill speed. • Left trigger released—press this button to open the pipe gripper.
Right Joystick—Mode I Lower 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 25) for information on setting the control mode. Press this button to turn the drilling-fluid pump on or off. 1 Trigger Press and hold the trigger to move the drill carriage at high speed up or down the drill frame.
Right Joystick—Mode II Lower 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 25) for information on setting the control mode. Press this button to turn the drilling-fluid pump on or off. 1 Trigger Press and hold the trigger to move the drill carriage at high speed up or down the drill frame.
Exit-side-lockout System Rear Control Panel The exit-side-lockout system provides the individuals working around the machine with a means to disable the drill pipe from rotating and thrusting. 2 1 3 This system consists of a receiver mounted on the machine and a transmitter (Figure 43) that must be held by a designated individual working around the machine.
Drill Frame and Stabilizer Controls Engine Key Switch The key switch has 3 positions as follows (Figure 45): 1 2 3 G0221 15 Figure 45 1. Engine-off position 3. Engine-start position 2. Engine-run position Figure 46 1. Drill-frame tilt lever • Engine-off position—turn the key to this position to stop 3. Right-stabilizer lever 2. Left-stabilizer lever the engine. You cannot start the engine from the operator platform when the key is in this position.
Drive Pendant Operator-presence Switch Refer to Figure 44 for the location of the drive pendant. Press and hold this button to enable the other controls on the drive pendant. The machine will stop moving if you release this button. 1 3 2 4 5 g021855 Figure 47 1. Engine-speed switch 4. Drive-speed switch 2. Drive-direction joystick 5. Operator-presence switch 3. Engine-stop button Engine-stop Button Press this button to immediately stop the engine and all movement/drilling operations.
Drill Pendant Left-track-control Switch/Rotary-control Switch When this switch is connected to the drive-pendant receptacle, move it to control the movement of the left track. WARNING Only an authorized person(s) should operate the drill pendant. Personal injury, harm to others, or damage to the machine could occur if this pendant is misused. • Move the switch forward to move the left track forward. • Move the switch backward to move the left track backward.
Stake-down Levers Drill-spindle-control Switch When this switch is connected to the front drill-pendant receptacle, move it to control the movement of the drill spindle. • Move the switch forward to rotate the drill spindle backward toward the pipe holder. • Move the switch backward to rotate the drill spindle forward toward the operator. Pipe-grip-control Switch When this switch is connected to the front drill-pendant receptacle, move it to control the pipe grip.
Battery-disconnect Switch Handheld unit for the Exit-side-lockout System (cont'd.) Open the rear compartment to access the battery-disconnect switch. Turn the battery-disconnect switch to the On or Off position to perform the following: • To energize the machine electrically, rotate the battery-disconnect switch clockwise to the On position (Figure 50). • To de-energize the machine electrically, rotate the battery-disconnect switch counterclockwise to the Off position (Figure 50).
Operation 4. Drill the bore. You drill the bore in 3 stages: Note: Determine the left and right sides of the machine from the normal operating position. A. Entry 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. After pushing in one or more pipes, you begin drilling down and forward until you reach the desired depth or depth-gauge hole (if used).
Gathering Site Information 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. Planning the Initial Route Before you can begin boring, you need to plan the route that you will bore and prepare as follows: – Ensure that all personnel at the job site wear personal protective equipment including a hard hat, eye protection, and hearing protection.
– Electrical power lines – 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. DANGER Drilling into an electric power line will cause the machine to become electrified and may electrocute you or any bystanders. ◊ Keep bystanders and spectators away from the job site, including the complete bore path.
Planning the Bore Path Before setting up the job site, you need to plan the bore path, including the following: Figure 51 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. This is where you setup the machine and the drill bit enters the ground.
1 g021765 Figure 52 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 3 2 • Entry pitch 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 the same distance back from your beginning-at-depth point 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.
• Insert the first 3 m (10 ft) of drill bit/pipe into the ground The following example illustrates the process given an installation using the machine at an 18% pitch on level ground: with no steering. The end of the drill bit will be 53 cm (21 inches) deep (Figure 56). Figure 56 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 Indicator Light Understanding the Base-unit Transmitter Indicator Lights The following table lists the various states of the indicator lights on the base-unit transmitter (Figure 57) and their meanings: Figure 57 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 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 the machine as follows: • Mark and prepare the bore path Marking and Preparing the Bore Path (page 57). • Test the Zap-Alert system; refer to Testing the Zap-alert System (page 58). • Load the drill pipes into the pipe holder if needed; refer to Loading Drill Pipes into the Pipe Holder (page 60).
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 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 63. 1 g021838 Figure 63 1. Grounding stake If either the audible alarm or the strobe light fail 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 64).
Loading Drill Pipes into the Pipe Holder Before using the machine, fill the pipe holder with up to 40 drill pipes. Figure 65 1. Pipe 2. Male end 3. Clevis pins Adding Fuel 1. Remove the clevis pins from the pipe holder (Figure 65). 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 65). Use only clean, fresh diesel fuel or biodiesel fuels with ultra low (<15 ppm) sulfur content.
• If this is not possible, then refuel such equipment on cold flow characteristics which will ease starting and reduce fuel filter plugging. a truck or trailer from a portable container rather than from a fuel dispenser nozzle. Using summer grade fuel above -7° C (20° F) will contribute toward longer fuel pump life and increased power compared to winter grade fuel.
Checking the Engine-oil Level Note: Be sure to keep this safe distance whenever moving the machine. 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 87). 6. Press and hold the operator presence button on the drive pendant. Checking the Cooling System 7. Use the speed switch on the pendant to increase or decrease the engine speed as desired. 8. Set the desired travel speed using the speed switch.
11. Remove the block from the trailer tires, and stow them with the machine for use when unloading it. 12. After driving a few miles, pull over and check to ensure that all chains are still tight and that the machine has not moved. Note: To unload the machine, reverse the above procedure. Setting up the Machine for Drilling 1.
Figure 70 1. Pedestrian safety bar (lowered position shown) Figure 72 1. Front pin 5. Push down on the rear platform latch securing the operator platform, and swing it out to the desired position, ensuring that it locks in place (Figure 71). 2. Rear pin 7. Load the first pipe and install the sonde and the drill head; refer to Starting the First Pipe (page 67). Note: The operator platform has 4 positions: travel (swung all the way into the machine), full-out, and 2 intermediate positions. 8.
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 it from collapsing on the bore pipe.
Deploying the Zap-alert System 2. Insert the hose from the mixing system over the pump inlet, and secure it with the cam-lock levers. The Zap-alert system is an electric strike-sensing device on the machine that triggers a strobe light and an audible alarm whenever 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.
4. Lower the elevators to load a pipe into the cam. 1 5. Rotate the cam with the pipe facing toward the operator until the cam stops. 6. Rotate the pipe-gripper cam forward until the pipe is in the grippers. 7. Grip the pipe with the pipe grippers. 8. Continue to rotate the pipe-gripper cam toward the operator, until the pipe is aligned with the drill spindle. 9. Rotate the drill spindle clockwise, and move the carriage slowly forward to insert the spindle into the female end of the pipe (Figure 80).
Setting up the Drill Head and the Tracking System The drill head consists of 2 parts, the drill bit and the sonde housing (Figure 81). Figure 81 1. Sonde housing Figure 82 2. Drill bit Drill bits vary in size and type to meet the various soil conditions that you may need to drill through. Some of the possibilities are as follows: 1. Sonde housing 4. Cover holes 2. Bolts 3. Drill bit 5. Cover 3. Insert the sonde beacon with the forward end toward the drill bit into the sonde housing (Figure 83).
Installing the Drill Head 5. Using the lower wrench (stationary wrench), clamp the lead bar, and tighten the drill spindle to full-seat threads. 1. Using the exit-side-lockout transmitter, activate the exit-side lockout to disable the thrust and rotation of the carriage. 6. Double check the drill head and bit to ensure that the fluid ports are clean and free from obstructions. 7.
Adding Drill Pipes Steering the Drill Head 1. Align the pipe joint in the wrench assembly. The drill bit is shaped like a wedge, angled from one side of the bit to the other. When you push the bit through the soil without rotating it, it will veer toward the direction the wedge is pointing. When you rotate the pipe and drill head, it bores through the soil in a straight path. 2. Close the lower wrench (stationary wrench) onto the first pipe.
Backreaming and Pullback Note: This may loosen the obstruction and allow you to push past it. After drilling the initial bore, you attach a reamer to the pipe, which is then connected to a the product that you are installing. The reamer is designed to widen the bore, pack the walls, and lubricate the passage of the product into the bore. 2.
Removing Drill Pipes 12. Rotate the drill spindle counterclockwise, moving rearward slowly until the pipes are separated. 1. Using the exit-side-lockout transmitter, enable the exit side lockout. 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 (makeup/breakout wrench) onto the pipe end, but not on the threads. 2. Install a drill-pipe wiper around the pipe and into the retaining bracket on the front of the machine.
Removing the Last Pipe and the Reamer Using the TJC Applicator Important: Do not pull the drill head into the pipe guide, or you may damage the machine or the drill head. Adjusting the Applicator Nozzle 1. Using the exit-side-lockout transmitter, enable the exit side lockout. You can adjust the applicator nozzle to spray thread-joint compound (TJC) either in a fan-shaped spray or as a stream. 2.
Adjusting the TJC-spray Volume Filling the TJC Applicator 1. Loosen the jam nut on the adjustment bolt located on top of the TJC-applicator piston (Figure 88). 1. Stop the machine and stop the engine. 2. Open the stake-down-guard door. 3. Loosen the wing nuts securing the cover straps to the machine (Figure 89). Figure 88 1. Adjustment bolt 3. TJC-applicator piston 2. Jam nut Figure 89 2. Adjust the bolts as follows: • To increase the applied volume of compound, thread the bolt out (up). 1.
Moving a Disabled Machine Replacing the Pipe Holder 1. Ensure that the 2 upper pins and the 2 lower pins are installed to secure the pipe inside the pipe holder (Figure 91). 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.
Positioning the Cab (Model with Cab only) Opening the Door (Model with Cab only) Open the door from the outside by pulling on the handle, and swing the door to the left (Figure 94). Positioning the Cab for Drilling Operation 1. Push back on the swing rocker switch (until the cab stops) to swing the cab to the drill position (Figure 93). Figure 93 1. Swing rocker switch 2.
Operating the Air Conditioning Operating the Windshield Wipers (Model with Cab only) and Heating (Model with Cab only) Changing the Windshield-wiper Speed Air Conditioning the Cab Turn the windshield-wiper knob (Figure 97) to the right increase the speed of the windshield wipers, or turn the knob to the left to decrease the speed. 1. Push the air-conditioning switch to the right to turn the air conditioning to the On position (Figure 96). Figure 97 1. Windshield-wiper knob Figure 96 1.
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 stakedown planetary-drive oil level (Also, check if external leakage is observed). • Check the rotary motor planetary-drive oil level (Also, check if external leakage is observed). • Check the thrust motor planetary-drive oil. • Check the gearbox drive oil.
Maintenance Service Interval Maintenance Procedure Every 1,000 hours • Drain and clean the fuel tank. • Check the concentration of the coolant before the winter season. • Clean the cooling system. (Clean the cooling system if the coolant becomes dirty or rust colored.) • Check the tension on the engine drive belt. • Change the hydraulic fluid. • Change the high-pressure hydraulic filter (and as needed per the service indicator).
Premaintenance Procedures Opening the Front Hood 1. Park the machine on a level surface, stop the engine, and remove the ignition key. 2. Lift up on the latch as shown in Figure 98. Note: Ensure that the key is in the open (horizontal) position as shown in Figure 98. Figure 100 1. Hood handle Opening the Rear-access Door 1. Park the machine on a level surface, stop the engine, and remove the ignition key. 2.
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 102). 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. Figure 106 Front elevator assembly (top view) 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 109 Rear pipe-loader cam area (6 fittings) Figure 112 Carriage-roller bearings (operator’s side shown; repeat on other side) Figure 110 Hydraulic cylinder and wrench assembly Figure 113 Gearbox float (operator’s side shown; repeat on other side) Figure 114 Stakedown shaft (left side shown; repeat on right side) Figure 111 Stabilizer cylinder and foot (repeat on other side) 83
Engine Maintenance it is necessary only increases the chance of dirt entering the engine when the filter is removed. • Be sure that the cover is seated correctly and seals with Cleaning the Crankcase-vent Tube the air-cleaner body. Checking the Air-cleaner Indicator Service Interval: Before each use or daily—Check the crankcase-vent tube and clean it if necessary. Service Interval: Before each use or daily 1. Start the engine. 1.
Cleaning the Dust Valve Service Interval: Every 50 hours 1. Park the machine on a level surface, stop the engine, and remove the ignition key. 2. Open the rear-access door. 3. Squeeze the sides of the dust valve on the air-cleaner cover to release any collected water, dust, or dirt from the valve. (Figure 117). Note: Ensure that there are no obstructions inside the dust valve. Figure 118 1. Air-cleaner cover latches 6. Pull the air-cleaner cover away from the filter housing and remove the cover. 7.
Servicing the Air-cleaner Filter 6. Insert the new primary filter by applying pressure to the outer rim of the filter to seat it in the air-cleaner cover. Service Interval: Every 250 hours 7. Remove the rubber outlet valve from the cover, clean the cavity, and replace the outlet valve; refer to Cleaning the Dust Valve (page 85). Replace the filters only when the “Check Air Filter” indicator appears on the display screen; refer to Checking the Air-cleaner Indicator (page 84). 8.
Checking the Engine-oil Level B. Service Interval: Before each use or daily—Check the engine oil level. Install the oil-fill cap and the dipstick. Changing the Engine-oil Filter 1. Park the machine on a level surface, stop the engine, and remove the ignition key. Service Interval: Every 250 hours 2. Open the front hood. 1. Park the machine on a level surface, stop the engine, and remove the ignition key. 3. Remove the dipstick (Figure 121), and wipe it clean. 2. Open the front hood. 3.
Changing the Engine Oil Service Interval: Every 250 hours 1. Park the machine on a level surface, stop the engine, and remove the ignition key. WARNING Allow the engine and oil to cool before draining the oil. Hot oil may cause serious injury. Figure 125 2. Ensure that the drain hose (Figure 124) is carefully pulled up and the end of the hose is placed in a drain pan. 1. Filler neck 2. Oil-fill cap 3. Funnel Note: Use a funnel with a flexible, attached hose to direct the engine oil into the engine. 9.
Fuel System Maintenance 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 89). 5. When clean fuel appears, rotate the drain valve clockwise until it is closed. 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.
Priming the Fuel System WARNING The fuel system is under high pressure. Bleeding the system without proper precautions and training could result in injury to you from injected fluid or fire or explosion. Note: Prime the fuel system whenever any of the following occurs: • You drained water from the fuel filter. • You replaced the fuel filter. Read the engine owner’s manual for the proper bleeding procedure or contact your Authorized Toro Dealer.
Replacing the Secondary Fuel Filter Checking the Fuel Lines and Connections 1. Park the machine on a level surface, stop the engine, and remove the ignition key. Service Interval: Every 500 hours/Yearly (whichever comes first)—Inspect the fuel lines and connections. 2. Open the front hood; refer to Opening the Front Hood (page 80). 3. Align a drain pan or several rags under the secondary fuel filter and the fuel-filter adapter (Figure 129).
Electrical System Maintenance A battery contains sulfuric acid, which can cause serious burns; and it can produce explosive gases. Servicing the Battery • Avoid contact with skin, eyes, or clothing; flush affected areas with water. WARNING 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 130). Do not smoke near the battery, and keep sparks and flames away from the battery. Important: Keep the battery fully charged.
Drive System Maintenance Checking the Oil Level for the Stakedown Planetary Drive Service Interval: After the first 100 hours—Check the stakedown planetary-drive oil level (Also, check if external leakage is observed). Every 500 hours—Check the stakedown planetary-drive oil level (Also, check if external leakage is observed). Figure 131 1. Ground point (unpainted bolt) 4. Cover Oil specification: SAE 85W-140 API classification level GL4 2. Jumper-cable clamp (negative) 5.
Checking the Oil Level for the Tracks Planetary Drive Changing the Oil 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). 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). Oil specification: SAE 85W-140 API classification level GL4 Note: Change the oil when it is warm, if possible.
Checking the Oil Level for the Rotary Motor Planetary Drive Checking the Oil for the Thrust Motor Planetary Drive Service Interval: After the first 100 hours—Check the rotary motor planetary-drive oil level (Also, check if external leakage is observed). Service Interval: After the first 100 hours—Check the thrust motor planetary-drive oil. Every 500 hours—Check the thrust motor planetary-drive oil (or yearly, whichever comes first).
Checking the Oil for the Gearbox Drive Changing the Oil for the Gearbox Drive Service Interval: After the first 100 hours—Check the gearbox drive oil. Service Interval: After the first 100 hours—Change the gearbox-drive oil. Every 500 hours—Check the gearbox drive oil (or yearly, whichever comes first). Every 500 hours—Change the gearbox-drive oil (or yearly, whichever comes first). Note: Change the oil when it is warm, if possible. Oil specification: SAE 85W-140 API classification level GL4 1.
Servicing the Tracks 3. Remove the 2 bolts and nuts on the carriage guard (Box B of Figure 137). Service Interval: Before each use or daily—Check the track tension. 4. Remove the 2 bolts and nuts on the side of the carriage guard (Box C of Figure 137). 5. Slide the carriage guard forward (Box D of Figure 137). WARNING 6. Remove the 6 bolts on the gearbox (Box E of Figure 137).
Loosening the Track Tension Cooling System Maintenance If the track seems tight, loosen the track tension as follows: 1. Park the machine on a level surface, stop the engine, and remove the ignition key. Coolant specification: 50/50 solution of ethylene-glycol antifreeze and water or equivalent 2. Remove dirt and debris found around the track-tension grease valve (Figure 139). Engine and Radiator coolant capacity: 16.8 L (17.
Checking the Coolant Level in the Radiator Checking the Condition of Cooling-system Components Service Interval: Before each use or daily Service Interval: Every 300 hours/Yearly (whichever comes first) WARNING Check the condition of the cooling system for leaks, damage, dirt, and loose hoses and clamps. Clean, repair, tighten, and replace the components as necessary. If the engine has been running, the radiator will be pressurized and the coolant inside will be hot.
Draining the Coolant from the System Flushing the Cooling System Important: Do not pour coolant onto the ground or into an unapproved container that can leak. Engine and radiator coolant capacity: 16.8 L (17.7 US qt) 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. Condition the cooling system as follows: 2. Allow the engine to cool. A.
A. Open the filler-neck cap. Filling the System with Coolant B. 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. Fill the radiator with clean water (Figure 143). Important: Use a mixture of 50% ethylene glycol and 50% water mixture or equivalent in the machine. The lowest ambient operating temperature for this mixture is above -37° C (-34° F).
Belt Maintenance 3 Servicing the Engine-drive Belt 2 1 WARNING Contacting a rotating belt can cause serious injury or death. Stop the engine and remove the ignition key before working near belts. G022028 Figure 146 1. Coolant level (at the bottom of the filler neck) Checking the Condition of the Belt 3. Coolant (50/50 ethylene glycol and water or equivalent) Service Interval: Every 250 hours 1. Park the machine on a level surface, stop the engine, and remove the ignition key. 2. Filler neck 2.
Adjusting the Tension of the Belt Checking the Tension of the Belt 1. Park the machine on a level surface, stop the engine, and remove the ignition key. Service Interval: Every 1,000 hours 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. Loosen the nut and bolt at the pivot point for the alternator (Figure 148). 3. Align a straight edge over the drive belt and across the pulleys as shown in Figure 147.
Checking the Hydraulic Fluid Hydraulic System Maintenance Service Interval: Before each use or daily Check the hydraulic fluid as follows: Servicing the Hydraulic Fluid 1. Park the machine on a level surface, stop the engine, and remove the ignition key. The hydraulic reservoir is filled at the factory with approximately 170 L (45 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 Note: Do not overfill. Service Interval: Every 1,000 hours/Yearly (whichever comes first) Changing the Hydrostatic-charge Filter Important: If the fluid becomes contaminated, contact your Authorized Toro Dealer, because the system must be flushed. Contaminated fluid looks milky or black when compared to clean oil. Service Interval: Every 500 hours/Every 6 months (whichever comes first) 1. Park the machine on a level surface, stop the engine, and remove the ignition key.
Changing the High-pressure Hydraulic Filter Changing the Hydraulic-return Filter Service Interval: Every 1,000 hours Service Interval: Every 1,000 hours 1. Park the machine on a level surface, stop the engine, and remove the ignition key. WARNING 2. Open the rear-access door. Ensure that the engine is in the Off position before removing the high-pressure hydraulic filter.
Drilling-Fluid Pump Maintenance Checking the Hydraulic Lines and Hoses 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. Servicing the Drilling-fluid-pump Oil The drilling-fluid pump is shipped with oil in the crankcase; however, check the oil level before and after you first start the engine.
Checking the Drilling-fluid-pump Oil Level Changing the Drilling-fluid-pump Oil Service Interval: Every 500 hours—Change the drilling-fluid pump oil. Service Interval: Before each use or daily—Check the drilling-fluid pump oil level. 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. Allow the engine to cool. 2. Remove the oil-level plug on the crankcase (Figure 154). 3.
Changing the Drilling-fluid-pump, Charge Filter Preparing the Drilling-fluid System for Cold Weather 1. Park the machine on a level surface, stop the engine, and remove the ignition key. Prepare the machine as follows after drilling if the temperature will be below 0° C (32° F). 2. Open the front hood. 1. Park the machine on a level surface, stop the engine, and remove the ignition key. 3. Align a drain pan or several rags under the charge filter (Figure 156). 2.
Figure 161 1. Valve (open position) Figure 159 1. Antifreeze-tank cap D. 2. Antifreeze tank Ensure that the tank is full of antifreeze (Figure 159). C. Start the machine and turn On the drilling-fluid pump. D. Add antifreeze to the tank as needed (Figure 159). E. When the antifreeze comes out of the drill spindle (Figure 157), turn the pump off. 3. Circulate the antifreeze as follows: A. Open the antifreeze valve inside of the rear compartment (Figure 160). 4. Turn the machine off. 5.
Cab Maintenance Changing the Cab Air Filter 1. Open the cab door. 2. Park the machine on a level surface, stop the engine, and remove the ignition key. 3. Remove the screw and the cover that house the air filter (Figure 162). Figure 163 1. Air filter 2. Air-filter cover 3. Screw Filling the Windshield-washer Fluid Tank 1. Open the cab door. 2. Open the cap of the windshield-washer-fluid tank (Figure 164). Figure 162 1. Screw 2. Air-filter cover 4.
Cleaning 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. Figure 166 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 84). 4. Grease the machine; refer to Greasing the Machine (page 82). 5. Charge the battery; refer to Charging the Battery (page 93). 6.
Troubleshooting Problem The starter does not crank. The engine cranks, but does 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, 47–48 A Accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Adding drill pipes . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Adding fuel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Air conditioning the cab . . . . . . . . . . . . . . . . . . . 77 Air filter Cab Changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 Air-cleaning system Checking the air-cleaner indicator. . . . .
Adding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Loading into the pipe holder . . . . . . . . . . . 60 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Starting the first . . . . . . . . . . . . . . . . . . . . . . . . . 67 Wiper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Drill spindle Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Spin clockwise . . . . . . . . . . . . . . . . . . . . . .
J Labels ( See Decals ) Latch Operator-platform. . . . . . . . . . . . . . . . . . . . . . . 24 Lead bar Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Left joystick Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Mode I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Mode II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pipe-clamp-control switch . . . . . . . . . . . . . . . . 45 Pipe-elevator-control switch . . . . . . . . . . . . . . 45 Pipe-grip-control switch . . . . . . . . . . . . . . . . . . . 45 Pipe-row-selector screen . . . . . . . . . . . . . . . . . 29 Pipes Loading into the pipe holder . . . . . . . . . . . 60 Pipr holder Replacing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Pitch Setting the thrust frame . . . . . . . . . . . . . . . . 63 Planetary drive Changing the oil . . . . . . . .
Safety Alert. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2, 4 T Temperature Sonde. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Testing the Zap-alert system . . . . . . . . . . . . . 58 Thread joint compound Applicator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Applicator nozzle Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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.
