Toro 23803 Operator's Manual

Download

FormNo.3414-730RevA

2226DirectionalDrill

ModelNo.23803—SerialNo.400000000andUp

Registeratwww.T oro.com. OriginalInstructions(EN)

*3414-730*A

WARNING

CALIFORNIA

Proposition65Warning

Thisproductcontainsachemical

orchemicalsknowntotheStateof

Californiatocausecancer,birthdefects,

orreproductiveharm.

Dieselengineexhaustandsomeofits constituentsareknowntotheStateof

Californiatocausecancer,birthdefects,

andotherreproductiveharm.

g217463

Figure1

ItisaviolationofCaliforniaPublicResourceCode Section4442or4443touseoroperatetheengineon anyforest-covered,brush-covered,orgrass-covered landunlesstheengineisequippedwithaspark arrester,asdenedinSection4442,maintainedin effectiveworkingorderortheengineisconstructed, equipped,andmaintainedforthepreventionofre.

Introduction

Thismachineisadirectionaldrillintendedfor undergrounddrillingandpullbackoperationforutility linesincluding:electrical,gas,communication, water,etc.Itisdesignedtooperateawidevariety ofattachmentseachofwhichperformaspecialized function.Thismachineistobeusedintemperatures of17to37°C(0to100°F).

Beforestartingoroperatingthemachine,readthis informationcarefullytolearnhowtooperateand maintainyourproductproperlyandtoavoidinjuryand productdamage.Y ouareresponsibleforoperating theproductproperlyandsafely.

YoumaycontactTorodirectlyatwww.Toro.com forproductsafetyandoperationtrainingmaterials, accessoryinformation,helpndingadealer,orto registeryourproduct.

1.Modelandserialnumberlocation

ModelNo.

SerialNo.

Thismanualidentiespotentialhazardsandhas safetymessagesidentiedbythesafetyalertsymbol (Figure2),whichsignalsahazardthatmaycause seriousinjuryordeathifyoudonotfollowthe recommendedprecautions.

g000502

Figure2

1.Safetyalertsymbol

Thismanualuses2wordstohighlightinformation. Importantcallsattentiontospecialmechanical informationandNoteemphasizesgeneralinformation worthyofspecialattention.

Wheneveryouneedservice,genuineToroparts,or additionalinformation,contactanAuthorizedService DealerorToroCustomerServiceandhavethemodel andserialnumbersofyourproductready.Figure1 identiesthelocationofthemodelandserialnumbers ontheproduct.Writethenumbersinthespace provided.

Contactusatwww.Toro.com.

PrintedintheUSA

AllRightsReserved

Contents

Safety.......................................................................4

GeneralSafety...................................................4

TrammingSafety................................................5

DrillingSafety.....................................................6

SafetyandInstructionalDecals..........................8

ProductOverview...................................................24

Controls...........................................................27

OperatorPlatform.........................................27

FrontControlPanel.......................................29

RearControlPanel........................................33

TravelPendant..............................................33

Specications..................................................34

BeforeOperation.................................................35

BeforeOperationSafety...................................35

UnderstandingHorizontalDirectional

Drilling...........................................................35

GatheringSiteInformation................................36

PlanningtheBorePath.....................................39

PreparingtheJobSiteandtheMachine

......................................................................44

MarkingandPreparingtheBorePath...............44

CheckingtheSafety-InterlockSwitches............44

TestingtheZap-AlertSystem............................45

MountingaFireExtinguisher............................46

LoadingtheDrillPipes......................................46

FillingtheFuelTank..........................................46

PerformingDailyMaintenance..........................47

StartingandShuttingOfftheEngine.................47

TrammingtheMachine.....................................48

LoadingandUnloadingtheMachine.................48

SettingUptheDrillHeadandTracking

System..........................................................50

SettinguptheMachineforDrilling.....................51

DeployingtheZap-AlertSystem.......................51

LoweringtheStakes.........................................52

ConnectingtoaDrilling-FluidSource................52

DuringOperation.................................................54

DuringOperationSafety...................................54

DieselParticulateFilterRegeneration...............55

DrillingtheBore................................................57

BackreamingandPullback...............................60

AfterOperation....................................................62

AfterOperationSafety......................................62

FinishingtheJob..............................................63

UsingtheTJCApplicator..................................63

MovingaDisabledMachine..............................64

Maintenance...........................................................65

RecommendedMaintenanceSchedule(s)...........65

Pre-MaintenanceProcedures..............................67

Pre-MaintenanceSafety...................................67

AccessingInternalComponents.......................67

UsingtheCylinderLock....................................68

Lubrication..........................................................68

GreasingtheMachine.......................................68

EngineMaintenance...........................................72

EngineSafety...................................................72

ServicingtheAirCleaner..................................72

ServicingtheEngineOil....................................74

AdjustingtheEngine-ValveClearance..............76

CleaningtheEngineEGRCooler......................76

InspectingtheEngineCrankcase-Breather

System..........................................................76

CheckingandReplacingFuelHosesand

Engine-CoolantHoses..................................76

LappingorAdjustingtheEngineIntakeand

ExhaustValves.............................................76

InspectingandCleaning

Engine-Emission-ControlComponents

andTurbocharger.........................................77

FuelSystemMaintenance...................................77

ServicingtheFuelSystem................................77

ServicingtheWaterSeparator.........................77

ReplacingtheFuelFilterElement.....................78

ElectricalSystemMaintenance...........................79

BatterySafety...................................................79

ServicingtheBattery.........................................79

ChargingtheBattery.........................................80

Jump-StartingtheMachine...............................80

DriveSystemMaintenance..................................81

CheckingthePlanetaryDriveOilLevel

PlanetaryDrive.............................................81

ChangingthePlanetaryDriveOil.....................82

CheckingtheRotaryGearboxDrive

Oil.................................................................82

ChangingtheRotaryGearboxDrive

Oil.................................................................83

ServicingtheTracks.........................................84

CoolingSystemMaintenance..............................85

CoolingSystemSafety.....................................85

CheckingtheCoolantLevelinthe

Reservoir......................................................85

CheckingtheCoolantLevelinthe

Radiator........................................................86

CheckingtheConditionofthe

Cooling-SystemComponents.......................86

CheckingtheConcentrationofthe

Coolant.........................................................86

CleaningtheCoolingSystem............................87

BeltMaintenance................................................89

ServicingtheEngine-DriveBelt........................89

HydraulicSystemMaintenance...........................90

HydraulicSystemSafety...................................90

ServicingtheHydraulicFluid............................90

Drilling-uidPumpMaintenance...........................94

ServicingtheDrilling-Fluid-PumpOil................94

PreparingtheDrilling-FluidSystemforCold

Weather........................................................95

ControlsMaintenance..........................................97

CalibratingtheJoysticksandtheTravel

Pendant........................................................97

Cleaning..............................................................97

CleaningwiththeSpray-Hose

Attachment....................................................97

CleaningPlasticandResinParts......................98

Storage...................................................................99

Troubleshooting....................................................100

Index.....................................................................103

Safety

Important:Thismachinewasmanufactured

accordingtotheappropriateregulatorystandards. Modifyingthismachineinanywaymaycauseit tobeoutofcompliancewiththosestandardsand withtheinstructionsinthisOperator’sManual. Modicationstothismachineshouldonlybe madebyonlythemanufactureroranAuthorized ServiceDealer.

Important:Beforeoperatinginanareawith

high-voltagelinesorcables,contacta“One-Call SystemDirectory”service.IntheUSA,call811 oryourlocalutilitycompany.Ifyoudonotknow yourlocalutilitycompany’sphonenumber,call thenationalnumber(USAandCanadaonly)at 1-888-258-0808.InAustralia,call1100forthe nationwidemarkingservice.Also,contactany utilitycompaniesthatarenotparticipantsofthe “One-CallSystemDirectory”service.Pleaserefer toDrillingNearUtilityLines(page6)formore information.

GeneralSafety

Thisproductiscapableofamputatinghandsand feetandofthrowingobjects.Alwaysfollowallsafety instructionstoavoidseriouspersonalinjury.

Usingthisproductforpurposesotherthanitsintended usecouldprovedangeroustoyouandbystanders.

•Readandunderstandthecontentsofthis

Operator’sManualbeforestartingtheengine.

•Donotputyourhandsorfeetnearmoving

componentsofthemachine.

•Donotoperatethemachinewithoutallguards

andothersafetyprotectivedevicesinplaceand workingonthemachine.

•Keepbystandersandpetsasafedistanceaway

fromthemachine.

•Neverallowchildrentooperatethemachine.

•Stopthemachineandshutofftheenginebefore

servicingorfuelingthemachine.

Improperlyusingormaintainingthismachinecan resultininjury.Toreducethepotentialforinjury, complywiththesesafetyinstructionsandalwayspay attentiontothesafety-alertsymbol,whichmeans Caution,Warning,orDanger—personalsafety instruction.Failuretocomplywiththeseinstructions mayresultinpersonalinjuryordeath.

Youcanndadditionalsafetyinformationwhere neededthroughoutthisOperator’sManual.

TrammingSafety

Youmovethemachinetoandfromtheworksitewith theuseofatravelpendant.Whentramming(moving themachinewiththependant),observethefollowing safetyprecautions:

•Operatethetravelpendantalongsidethemachine

outsideofthedangerzone(Figure3).

•Moveslowlywhenusingthependantfortramming.

•Usecarewhenloadingorunloadingthemachine

ontoatrailer.

•Watchfortrafcwhencrossingroadways.

•Checkforoverheadclearances(i.e.,doorways,

branches,electricalwires)beforetrammingunder anyobjectsanddonotcontactthem.

•Keepallbystandersawaywhiletrammingthe

machine.

•Donotcarrypassengersonthemachine.

•Watchfortheturning-radiussweepofthedrill

frame,asthecenteroftheturningradiusisthe endofthetrack.

•Whentrammingonaslope,youshouldbeuphill

fromthemachine.

Usethefollowingillustrationtoensurethatbystanders donotenterthedangerzonewhileyouaretramming themachine.

Figure3

DrivingDangerZone

1.1.8m(6ft)safetydistance3.Turning-radiuscenter(endofthetrack)

2.Operator4.2.4m(8ft)safetydistance

g217464

DrillingSafety

•Alwayslowerthepipeloadingguardbeforedrilling

(Figure4).

•Alwaysengagetheexitsidelockoutbefore

operating.

•Keepbystandersandpetsasafedistanceaway

fromthemachine.

•Stopoperatingthemachineifanyoneentersthe

drillingdangerzone.

•Ensurethatnooneapproachesapipewhileitis

spinning.

DrillingDangerZone

Thedangerzoneistheareawithinandaroundthe machinewhereapersonisexposedtotheriskof injury.

Thedangerzonedenestheamountofspaceneeded forsafedrillingoperation,includingmovementofthe carriage.

Usethefollowingillustrationtoensurethatbystanders donotenterthedangerzonewhileyouaredrilling.

Figure4

DrillingDangerZone

1.3m(10ft)safetydistance2.1.8m(6ft)safetydistance

DrillingNearUtilityLines

Important:Beforeoperatinginanareawithhigh-voltagelinesorcables,contacta“One-CallSystem

Directory”service.IntheUSA,call811oryourlocalutilitycompany .Ifyoudonotknowyourlocal utilitycompany’sphonenumber,callthenationalnumber(USAandCanadaonly)at1-888-258-0808.In Australia,call1100forthenationwidemarkingservice.Also,contactanyutilitycompaniesthatarenot participantsofthe“One-CallSystemDirectory”service.

g217462

UtilityLineColor

Refertothefollowingtablefortheproperutilityline andthecorrespondingutilitylinecolor(USAand Canada).

UtilityLine

ElectricRed

Telecommunication,alarmorsignal, cables,orconduit

Naturalgas,oil,steam,petroleum,or othergaseousorammablematerial

SeweranddrainGreen

DrinkingwaterBlue

Reclaimedwater,irrigation,and slurrylines

TemporarysurveymarkingsPink

ProposedexcavationlimitsWhite

UtilityLineColor

Orange

Yellow

Purple

ElectricalandCommunication LineSafety

•Thealarmwillsoundifthedrillcontactsan

electricalpowersource.

•Donotattempttoleavethemachine.

Note:Youwillbesafeaslongasyoudonotleave

theseatofthemachine.

•Touchinganypartofthemachinemaygroundyou.

•Donotallowanotherindividualtotouchor

approachthemachinewhencharged.

•Thealarmmaysoundifacommunicationline

isbroken,butuntilyouarecertain,youmust considerthealarmtobeanelectricstrike.

GasLineSafety

WARNING

Ifyoudamageagasline,animmediate explosionandrehazardcouldoccur. Leakinggasisbothammableandexplosive andmaycauseseriousinjuryordeath.

•Donotsmokewhileoperatingthemachine.

WARNING

Ifyouleavetheseatofthemachineortouch anypartofthemachinewhenitischarged withelectricity,seriousinjuryordeathcould result.

Donotleavetheseatofthemachineifthe machineischargedwithelectricity.

CAUTION

Ifyoudamagetheber-opticcableandlook intotheexposedhighly-intenselight,youmay harmyoureyes.

•Shutoffthemachineandremovethekey.

•Removeallindividualsfromtheworkarea.

•Immediatelycontacttheproperemergency andutilityauthoritiestosecurethearea.

Intheeventofanelectricstrikethatchargesthe machine,theZap-Alertalarmsystemwillsoundforas longasthemachineischargedwithpower.

•Shutoffthemachineandremovethekey.

•Removeallindividualsfromtheworkarea.

•Immediatelycontacttheproperemergency andutilityauthoritiestosecurethearea.

WaterLineSafety

Ifyoudamageawaterline,apotentialood hazardcouldoccur.

•Shutoffthemachineandremovethekey.

•Removeallindividualsfromtheworkarea.

•Immediatelycontacttheproperemergencyand

utilityauthoritiestosecurethearea.

Note:Immediatelycontacttheproperemergency

andutilityauthoritiestosecuretheareaincasethe machineischargedandyoucannotleavetheseat ofthemachine.

Note:Itispossibletostrikeautilitylinewithoutthe

machinebecomingcharged.

SafetyandInstructionalDecals

Safetydecalsandinstructionsareeasilyvisibletotheoperatorandarelocatednearanyarea ofpotentialdanger.Replaceanydecalthatisdamagedormissing.

BatterySymbols

Someorallofthesesymbolsareonyourbattery

1.Explosionhazard

2.Nore,opename,or smoking.

3.Causticliquid/chemical burnhazard

4.Weareyeprotection9.Flusheyesimmediately

5.ReadtheOperator's

Manual.

6.Keepbystandersasafe

7.Weareyeprotection;

8.Batteryacidcancause

10.Containslead;donot

decalbatterysymbols

distancefromthebattery.

explosivegasescan causeblindnessandother injuries

blindnessorsevereburns.

withwaterandgetmedical helpfast.

discard.

g228534

Figure5

1.137-7160

137-7160

1.Emergencyenginestop—release

2.Emergencyenginestop—engage

3.Setupoperatorpresence—on

4.Setupoperatorpresence—off

5.Trammingoperatorpresence—on/off

6.Enginespeed—decrease

7.Enginespeed—increase

8.Trammingdirection—forward-left17.Leftstabilizerfoot—raise/lower

9.Trammingdirection—forward18.Rightstabilizerfoot—raise/lower

10.Trammingdirection—forward-right

11.Trammingspeed—fast

12.Trammingspeed—slow

13.Trammingdirection—backward-right

14.Trammingdirection—backward

15.Trammingdirection—backward-left

16.Thrustframe—raise/lower

decal137-7160

g228521

Figure6

1.125-61303.125-6115

2.125-6128

125-6130

1.Warning—readtheOperator’sManual;stayatleast3m(10ft)awayfromthefrontandrearofthemachineand1.8m(6ft) awayfromthesidesofthemachine.

decal125-6130

125-6128

1.Highpressureuidhazard,injectionintothebody—read theOperator’sManualbeforeperformingmaintenance.

decal125-6128

decal125-6115

125-6115

1.Crushinghazard—deploycylinderlocksbeforeperforming maintenance.

g228523

Figure8

1.137-7167

g228522

Figure7

1.137-7166

decal137-7167

137-7167

137-7166

1.Crushinghazard—donotstandunderthemachine.

1.Thrownobjecthazard—keepbystandersawayfromthe machine.

decal137-7166

g228524

Figure9

1.137-7168

g228525

Figure10

1.137-7172

decal137-7168

137-7168

1.Electrocutionhazard—donottouchthemachinewhenthe alarmissounding.

decal137-7172

137-7172

1.Runover/backoverhazard—readtheOperator’sManual.

Figure11

1.125-61273.137-7164

2.125-61294.137-7174

125-6127

1.Cutting/dismembermenthazard,fan—keepawayfrom movingparts.

g228526

decal137-7164

137-7164

1.ReadtheOperator’sManual—rotatecounterclockwise todisconnectthebattery;rotateclockwisetoconnectthe battery;thenegativepostislocatedbelowtheswitch;the positivepostislocatedtothesideoftheswitch.

decal125-6127

decal137-7174

137-7174

125-6129

1.Hotsurface—keepawayfromhotsurfaces.

1.ReadtheOperator’s

8.Operatorplatform Manualforinformationon fuses.

2.Emergencyenginestop

9.Display button

3.Electric

decal125-6129

4.Keyswitch

10.Cam

11.Stake

5.Headlights12.Autodrill

6.Enginecontrolunit13.Airhammer

7.Worklights

decal137-7175

137-7175

1.125-61523.137-7175

2.137-7171

1.Moveseatforwardandbackward.

Figure12

125-6152

g231766

decal125-6152

1.Rotatetheoperatorplatform.

g228528

Figure13

1.125-6694

137-7171

1.Fallinghazard—donotrideonthemachinewhileitis moving.

decal125-6694

125-6694

1.Tie-downlocation

decal137-7171

Figure14

1.137-71792.137-7178

137-7179

1.Warning—hazardousarea;keepatleast3m(10ft)away fromthemachineduringoperation.

g228532

g228533

Figure15

1.125-61972.125-4967

decal137-7179

decal125-6197

125-6197

1.Maxweightlimit—1342kb(2,958lb)

137-7178

1.Entanglementhazard—keepawayfrommovingparts.

decal137-7178

decal125-4967

125-4967

1.Liftpoint

decal125-8473

125-8473

Figure16

1.137-71803.125-6119

2.125-8473

1.Explosionhazard—wear eyeprotection.

2.Causticliquid/chemical burnhazard—rinse

3.Firehazard—keepopen amesaway.

4.Poisonhazard—donot tamperwiththebattery.

affectedareaandseek medicalassistance.

g228531

decal125-6119

125-6119

1.Entanglementhazard—keepawayfrommovingobjects.

137-7180

1.Impacthazard—donotuseapipewrench;refertothe Operator’sManual.

decal137-7180

1.117-27182.137-7161

decal117-2718

117-2718

g228960

Figure17

1.Engine—stop5.Headlights

2.Engine—run

3.Engine—start

4.Spraygun

decal137-7161

137-7161

6.On

7.Off

1.125-61403.137-7182

2.137-71834.125-6124

decal125-6140

125-6140

1.Rotatethechair.

g228527

Figure18

1.ReadtheOperator’sManual.

decal137-7183

137-7183

137-7182

1.Loadpipesfrombackrowrst.

125-6124

1.Centerthepipejointbetweentheupperandlower wrenches.

decal137-7182

decal125-6124

1.137-71654.137-7170

2.125-84835.127-1829

3.137-7169

decal137-7165

137-7165

1.Antifreeze

g228530

Figure19

decal125-8483

125–8483

1.Hydraulicuid;readtheOperator’sManual.

137-7169

1.Warning—readtheOperator’sManual.4.Warning—keepawayfrommovingparts;keepallguardsand

2.Warning—alloperatorsmustbetrainedbeforeoperatingthe machine.

3.Warning—keepbystandersawayfromthemachine.

coversinplace.

5.Warning—hearingprotectionmustbeworn.

6.Explosionandelectricalshockhazard—donotdig;callyour localutilitycompany.

decal137-7169

137-7170

1.Fallinghazard—donotclimbonthemachinewhileitis moving.

127-1829

1.Oildrain

decal137-7170

g228520

Figure20

1.125-6107

decal127-1829

125-6107

1.Crushinghazardofhandandfoot—keephandsandfeet away.

decal125-6107

1.137-71773.125-6193

2.137-71764.125-6194

g231767

Figure21

137-7177

1.Mud—On/Off8.Carriagethrustspeed—high

2.Upperwrench—open/close9.Mudow—high

3.Lowerwrench—open/close10.Thrustthecarriageforward(drillmodeIandII);lowerthe stake(setupmode)

4.Mudow—increase11.Rotatethedrillspindleclockwise(drillmodeI);rotatethe stakecounterclockwise(setupmode)

5.Mudow—decrease12.Rotatethestakeclockwise(setupmode);rotatethedrill spindlecounterclockwise(drillmodeI)

6.Rotatethewrenchclockwiseandcounterclockwise(make

andbreakrotation)

13.Raisethestake(setupmode);pullthecarriageback(drill modeIandII)

7.Autodrill—set14.Rightstakecontrols

decal137-7177

decal137-7176

137-7176

1.Engine—start10.Rotatethecamassembly.

2.Enginespeed—increase11.Movetothenext

3.Enginespeed—decrease

4.Pipegripperarm—retract

5.Pipegripperarm—extend14.Rotatestakecounter

6.Applytread-joint compound.

7.Elevator—raise

8.Elevator—lower

9.Pipegripper—open/close

orpreviousstepin SmartTouch™mode.

12.Camoverridefunctionto rotatethecamassembly.

13.Lowerthestake(setup mode);rotatedrillspindle counterclockwise(drill modeII)

clockwise(setupmode)

15.Rotatethestakeclockwise (setupmode)

16.Raisethestake(setup mode);rotatedrillspindle clockwise(drillmodeII)

17.Leftstakecontrols

125-6193

1.Exit-sidelockout—reset5.Trammingandsetup

2.Exit-sidelockoutswitch6.Drilling

3.Ground-strike—reset

7.Worklights—on

4.Ground-strikeswitch8.Worklights—off

125-6194

1.Exit-side-lockoutreceiverbattery-statuslight4.Emergencyenginestop—engage

2.Exit-sidelockoutdrill-enabledlight5.Emergencyenginestop—release

3.Exit-sidelockoutstandbylight

decal125-6193

decal125-6194

ProductOverview

g218957

Figure22

LeftSideView

1.Pipebox

2.Safetybar

3.Stabilizerfoot

Figure23

RearView

1.Rearcontrolpanel3.Zap-alertstake

2.Drilling-uid-sourceconnection

g218958

Figure24

RightSideView

1.Carriage6.Thrustframe

2.Zap-alertstrobe

3.Fronthood8.Rearhood

4.Frontcontrolpanel9.Tracks

5.Operatorseat

7.Stabilizerfoot

g218959

Figure25

Topview

g218960

1.Carriage

5.Lowerwrench

2.Drillspindle6.Pipewiper

3.Thrustframe7.Stake-downtube

4.Upperwrench

Controls

Refertothefollowingsectionsfortheappropriate machinecontrols:

•OperatorPlatform(page27)

•TheSoftwareGuide

•FrontControlPanel(page29)

•JoysticksinSetupMode(page30)

•LeftJoystick(page31)

•RightJoystick(page32)

•ExitSideLockout(page33)

•RearControlPanel(page33)

•TravelPendant(page33)

•Battery-DisconnectSwitch(page34)

OperatorPlatform

Theoperatorplatform,locatedontheright,front cornerofthemachine,containsmostofthecontrols youusetooperatethedrillingfunctionsofthe machine.

Operator-PlatformLatch

Theoperatorplatformswingsoutawayfromthe machine,makingroomforyoutosit.Ithas5positions: travel(swungallthewayintothemachine),full-out, and3intermediatepositions.Returntheplatformto theTRA VELpositionbeforemovingthemachine.

Tomovetheplatform,pushupontherearplatform latchorpushdownonthefrontplatformlatch(Figure

27).

g218956

Figure27

Figure26

1.Frontcontrolpanel3.Rightjoystick

2.Leftjoystick4.Operatordisplay

Operator-ControlsCovers

Thecoversprotecttheoperatorcontrolsfromadverse weatherconditions,suchasrain,wind,sunlight,etc. Removethembeforeusingthemachineandreplace thembeforeleavingthemachinefortheday.

Toreleasetheplatformandswingitoutorin,pushup onthefrontplatformlatch(Figure27).

g218950

AdjustingtheOperatorConsoleBolts

Tightentheconsoleboltstoaddfrictiontotheconsoles;refertoFigure28.

Theleftconsolecanrotate10degreesin.

Therightconsolecanrotate10degreesinand45degreesout.

Figure28

g230008

FrontControlPanel

Figure29

1.Engine-speedswitch6.Exit-side

2.Engine-startbutton7.Exit-side-lockouthandheld

3.Work-lightsswitch8.Exit-side-lockout—reset

4.Emergencyenginestop button

5.Exit-sidelockout—standby light(orange)

lockout—drill-enabled light(green)

battery-statuslight(red)

switch

9.Ground-strike-resetswitch

10.Drill/setupswitch

EmergencyEngineStopButton

Pushthisbutton(Figure29)toimmediatelyshutoff theengineandalldrillingoperations.Youmustpull thisbuttonoutbeforeyoucanstarttheengineagain.

Exit-SideLockout—StandbyLight

Thislight(Figure29)illuminatesorangewhenthe exit-sidelockoutisturnedoff,indicatingthatyoumay resetthesystem.

Exit-SideLockout—Drill-enabledLight

Thislight(Figure29)illuminatesgreenwhenthe exit-side-lockoutsystemhasbeenresetandthe machineisreadytodrill.

Exit-Side-LockoutBattery—StatusLight

Thislight(Figure29)illuminatesredwhenthebattery ontheexit-side-lockouttransmitteristoolowto transmit.Stopdrillingoperationsandreplacethe batteriesinthetransmitterbeforecontinuing.

g218968

Exit-SideLockout—ResetSwitch

Pushthisswitch(Figure29)toenabledrilling operationwhentheyellowresetlightilluminates.

Ground-Strike-ResetSwitch

Pushthisswitch(Figure29)toresettheZap-Alert systemafteragroundstrikehasoccurredandbeen xed;refertoDeployingtheZap-AlertSystem(page

51).

Drill/SetupSwitch

Engine-SpeedSwitch

•Pushandholdthetopofthisswitchtoincrease

theenginespeed.

•Pushandholdthebottomofthisswitchto

decreasetheenginespeed.

•Releasetheswitchtomaintainthecurrentengine

speed.

Engine-StartButton

Pushthisbutton(Figure29)tostarttheengine.The keyswitchontherear,controlpanelmustbeintheON position.Ensurethatbothemergencystopswitches areintheraisedposition.

Work-lightsSwitch

Pushthetopofthisswitch(Figure29)toturnthe machinelightsonorthebottomoftheswitchtoturn themoff.

Pushthetopofthisswitch(Figure29)toenablethe setupcontrolsorthebottomoftheswitchtoenable drillandpipe-loaderfunctions.

JoysticksinSetupMode

Themachinemustbeinsetupmode(Figure29)andyoumustbeintheseattousethesefunctions.

Figure30

Joysticks–SetupMode

g225942

1.Lowertheleftstakedown

2.Rotatetheleftstakeclockwise

3.Raisetheleftstakeup

4.Rotatetheleftstakecounterclockwise

LeftJoystickinSetupMode

•Forward:Pushthejoystickforwardtolowerthe

leftstakedown.

•Rearward:Pullthejoystickrearwardtoraisethe

leftstakedown.

•Left:Movethejoysticktothelefttorotatetheleft

stakecounterclockwise.

•Right:Movethejoysticktotherighttorotatethe

leftstakeclockwise.

5.Lowertherightstakedown

6.Rotatetherightstakeclockwise

7.Raisetherightstakeup

8.Rotatetherightstakecounterclockwise

RightJoystickinSetupMode

•Forward:Pushthejoystickforwardtolowerthe

rightstakedown.

•Rearward:Pullthejoystickrearwardtoraisethe

rightstakedown.

•Left:Movethejoysticktothelefttorotatetheright

stakecounterclockwise.

•Right:Movethejoysticktotherighttorotatethe

rightstakeclockwise.

LeftJoystick

g226145

Figure31

LeftJoystickinDRILLmode

1.Raisetheelevator

2.Lowertheelevator7.Retractthepipegripperarm

3.Open/Closethepipegripper

4.Rotatethecamassembly9.Applytread-jointcompound

5.GotothepreviousstepinSmartT ouch™mode

6.GotothenextstepinSmartTouch™mode

8.Extendthepipegripperarm

Figure32

LeftJoystick—DirectionalControls

g226143

1.Rotatethedrillspindlecounterclockwise(DrillModeII)3.Rotatethedrillspindleclockwise(DrillModeII)

2.Noaction4.Noaction

Pushthejoystickleftandholdthecamrockerswitchatthesametimetousethecamoverridefunction.

Important:Thisoverridestheanti-crashpreventionwarningandcouldcausedamagetothemachine.

Pushthecamrockerswitchforwardtorotatethecamassemblyout.

Pushthecamrockerswitchbackwardtorotatethecamassemblyin.

RightJoystick

Thejoystickcontrolsvarydependingonthecontrolmodeyouselectwhenpoweringupthemachine.Thereare 2controlmodes:DrillModeIandDrillModeII;refertotheControl-SelectScreenintheSoftwareGuidefor informationonsettingthecontrolmodes.

Figure33

RightJoystick

1.Turnthemudonoroff4.OpenandClosetherearwrench7.Settheautodrillonoroff

2.Increasethemudowmomentarily5.Openandclosethefrontwrench8.Setthecarriagetohighspeed

3.Deceasethemudowmomentarily

6.Rotatethewrenchclockwiseand counterclockwise(makeandbreak rotation)

9.Maxowofmud

g226146

RightJoystick—DrillModeI

Figure34

RightJoystick—DrillModeI

1.Thrustthecarriageforward

2.Rotatethedrillspindle counterclockwise

3.Pullthecarriageback

4.Rotatethedrillspindle clockwise

RightJoystick—DrillModeII

g226144

Figure35

RightJoystick—DrillModeII

1.Thrustthecarriageforward

2.Noaction4.Noaction

3.Pullthecarriageback

ExitSideLockout

Theexit-side-lockoutsystemprovidestheindividuals workingaroundthemachinewithameanstodisable thedrillpipefromrotatingandthrusting.

Formoreinformationandinstructions,refertothe Operator’sManualfortheExit-side-lockoutsystem.

•Engine-offposition—turnthekeytothispositionto

shutofftheengine.Theenginecannotbestarted fromtheoperatorplatformwhenthekeyisinthis position.

•Engine-runposition—turnthekeytothisposition

afterstartingtheengine.Turningthekeytothis positionalsoenablestheenginestartbuttonfrom theoperatorplatform.

RearControlPanel

Figure36

1.Travelpendantbracket3.Engine,keyswitch

2.Fluid-pumpswitch

4.OK-to-Startlight

•Engine-startposition—turnthekeytothisposition

tostarttheengine.ReleasethekeytotheRUN positiononcetheenginehasstarted.

Fluid-PumpSwitch

Usethisswitchtoturnontheuidpumptousethe spraygunwhencleaningthemachine.

TravelPendant

RefertoFigure36forlocation.

g229102

OK-to-StartLight

Thegreenlightilluminateswhenthemachineisready tostart.

Ifthelightdoesnotilluminate,checkthe2emergency stopbuttons.Theyneedtobedisengagedbeforethe machinecanstart.

Engine,KeySwitch

Thekeyswitchhas3positionsasfollows(Figure36):

Figure37

1.Engine-offposition

2.Engine-runposition

3.Engine-startposition

g225940

Figure38

1.Operatorpresenceswitch (tramming)

2.Enginespeedswitch

3.Tramming-Direction Joystick

4.Errorindicatorlight(when blinking)

g220853

5.Trammingspeedswitch10.Emergencyenginestop

6.Thrustframeswitch

7.Rightstabilizerfootswitch

8.Leftstabilizerfootswitch

9.Operatorpresenceswitch (setup)

button

Usethecorrespondingoperatorpresenceswitchto operatethesetupandtrammingfunctions.

Ifyoureleasetheoperatorpresenceswitchwhile operating,youwillneedtoreleaseallofthecontrols beforeresumingoperation.

OperatorPresenceSwitch

Pushandholdthisbuttontoenabletheothercontrols onthetravelpendant.Themachinestopsmoving whenyoureleasethisbutton.

EngineSpeedSwitch

Battery-DisconnectSwitch

Openthefronthoodtoaccessthe BATTERY-DISCONNECTswitch;refertoOpening

theFrontandRearHoods(page67).

TheBA TTERY-DISCONNECTswitchislocatedtotheright oftheengine;itisusedtoelectricallydisconnectthe batteryfromthemachine.

Important:Donotusethebattery-disconnect

switchtoturnofftheengine.

•Pushthetopofthisswitchtoincreasetheengine

speedin100rpmincrements.Holdtheswitchto rapidlyincreasetohighidle.

•Pushthebottomofthisswitchtodecreasethe

enginespeedin100rpmincrements.Holdthe switchtorapidlydecreasetolowidle.

•Releasetheswitchtomaintainthecurrentengine

speed.

TrammingDirectionJoystick

Usethejoysticktocontrolthedirectionofthemachine. Themachinewilltravelinthedirectionyoumovethe joystick.

ErrorIndicatorLight

Thislightlightsupwhenthe2-speedbuttonispushed. Thelightwillblinkthereisaninternalerrorwiththe travelpendant.

Drive-SpeedSwitch

Theswitchsetsthespeedatwhichthemachine travels.Pushtheswitchtoalternatebetweenhigh andlowspeed.

TurntheBA TTERY-DISCONNECTswitchtotheONorOFF positiontoperformthefollowing:

•T oenergizethemachineelectrically,rotatethe

BATTERY-DISCONNECTswitchclockwisetotheON

position(Figure39).

•T ode-energizethemachineelectrically,rotatethe

BATTERY-DISCONNECTswitchcounterclockwiseto

theOFFposition(Figure39).

g218942

Figure39

Specications

Note:Specicationsanddesignaresubjectto

changewithoutnotice.

ThrustFrameSwitch

Usethisswitchtoraiseandlowerthethrustframe.

RightStabilizerFootSwitch

Usethisswitchtoraiseandlowertherightstabilizer foot.

LeftStabilizerFootSwitch

Usethisswitchtoraiseandlowertheleftstabilizer foot.

EmergencyEngineStopButton

Pushthisbuttontoimmediatelyshutofftheengine andallmovement/drillingoperations.Youmustpull thisbuttonoutbeforeyoucanstarttheengineagain.

Machine

Width

Length Height Weight

147cm(58inches)

521cm(205inches)

198cm(78inches)

4,302kg(9,485lb)

Operation

UnderstandingHorizontal

Determinetheleftandrightsidesofthemachinefrom thenormaloperatingposition.

BeforeOperation

BeforeOperationSafety

GeneralSafety

•Theownermustensurethatalloperatorsare

welltrainedandcompetenttosafelyoperatethe machine.

•Neverallowchildrenoruntrainedpeopleto

operateorservicethemachine.Localregulations mayrestricttheageoftheoperator.

•Becomefamiliarwiththesafeoperationofthe

equipment,operatorcontrols,andsafetysigns.

•Knowhowtostopthemachineandshutoffthe

enginequickly.

•Checkthatoperator-presencecontrols,safety

switches,andshieldsareattachedandfunctioning properly.Donotoperatethemachineunlessthey arefunctioningproperly.

DirectionalDrilling

Horizontaldirectionaldrillingisaprocessusedfor drillingahorizontalborethroughthesoilandunder obstructionssuchasroads,buildings,bodiesofwater, etc.Onceyoudrillthebore,pullbacktheutilitylinesor pipesthroughtheboreandconnectthemasneeded. Becauseitdoesnotrequireverymuchdisturbanceof thesurface,installationofutilitiesusingdirectional drillingpreservestheenvironmentandsavesboth timeandmoneyovertraditionalinstallationmethods suchastrenching.

Wheninstallingcablingorpipeusingadirectionaldrill, completethefollowingsteps:

1.Gathersiteinformation.

Beforeoperatinginanareawithhigh-voltage linesorcables,contacta“One-CallSystem Directory”service.IntheUSA,call811oryour localutilitycompany.Ifyoudonotknowyour localutilitycompany’sphonenumber,callthe nationalnumber(USAandCanadaonly)at 1-888-258-0808.InAustralia,call1100forthe nationwidemarkingservice.Also,contactany utilitycompaniesthatarenotparticipantsofthe “One-CallSystemDirectory”service.Please refertoDrillingNearUtilityLines(page6)for moreinformation.

•Inspecttheareawhereyouwillusethemachine

andremoveallobjectsthatthemachinecould throw.

•Keepthemanual(s)withthemachine.Goto

www.T oro.comforareplacementmanual.

FuelSafety

•Useextremecareinhandlingfuel.Itisammable

anditsvaporsareexplosive.

•Extinguishallcigarettes,cigars,pipes,andother

sourcesofignition.

•Useonlyanapprovedfuelcontainer.

•Donotremovethefuelcaporllthefueltank

whiletheengineisrunningorhot.

•Donotaddordrainfuelinanenclosedspace.

•Donotstorethemachineorfuelcontainerwhere

thereisanopename,spark,orpilotlight,such asonawaterheaterorotherappliance.

•Ifyouspillfuel,donotattempttostarttheengine;

avoidcreatinganysourceofignitionuntilthefuel vaporshavedissipated.

Beforefullyplanningtheborepath,gather informationaboutthejobsitesuchasthe locationofotherutilities,obstaclesatthesite, andwhatregulationsandpermitsyouneed tocompletethejob;refertoGatheringSite

Information(page36).

2.Plantheborepath.

Beforedrilling,plantheborepathbasedonthe informationyougathered.RefertoPlanningthe

BorePath(page39).

3.Preparethejobsiteandthemachine.

Beforedrilling,preparethejobsitewithanentry point,depth-gaugehole(optional),andanexit hole.Drivethemachinetothejobsite,setitup fordrilling,andconnectittoadrilling-uidmixer.

Note:Whendrilling,connectthemachine

toadrilling-uidmixerthatmixeswaterwith bentoniteclayandotheringredients.The machinepumpsthismixture,referredtoas drillinguidor“mud,”throughthedrillpipeand outofthedrillbit.Thedrillinguidlubricatesthe drillbit,helpstoholdtheboreopenwhiledrilling, andmixeswiththespoils,ushingthemoutof theborethroughtheentrypoint.

RefertoPreparingtheJobSiteandthe

Machine(page44)forinstructionsonpreparing

thejobsiteandthemachine.

4.Drillthebore.

Drilltheborein3stages:

A.Entry

Intheentryphaseofthebore,pushthedrill bitandheadintothegroundatanangle ofupto16degrees.Afterpushinginone ormorepipes,begindrillingdownand forwarduntilyoureachthedesireddepthor depth-gaugehole(ifused).

B.HorizontalReach

Afterreachingthedesireddepth,pushthe bitforward,steeringthebittoahorizontal depth.Thesondeemitsaradiosignal fromthesondehousing,allowingthe locating-equipmentoperatoronthesurface totrackthelocationanddepthofthehead usingthesondereceiverasyoudrilland steeritalongaplannedpath..

C.Exit

Onceyouhaveattainedtheplanned horizontalreach,steertheheadupatan angle,similartoyourentryangle,bringing thebitintotheexitholeortrench.

RefertoDrillingtheBore(page57).

5.Backreamtheboreandpullbackthecabling

orpipe.

Afterenteringtheexithole,acrewmember detachesthedrillbitandsondehousingfromthe drillpipe.Attachareamingbitandtheendof thecableorpipetobepulledthroughthebore. Thereamingbitisdesignedtoenlargethebore asyoupullitback.Pumpdrillinguidthrough thepipetothereamingbitasyoupullthecable orpipebackthroughtheboretolubricatethe reamerandallowthecableorpipetoslideeasily throughthebore.Continuepullingthepipeback untilthereamerreachesthedepth-gaugehole orexitsattheentrypoint.Removethereamer andproductfromthedrillpipe,pullingthepipe therestofthewaybacktothemachine.

RefertoBackreamingandPullback(page60) forinstructionsonbackreamingandpulling cableorpipe.

6.Finishtheboreandleavethejobsite.

Aftercompletingtheoperation,disconnectand cleanthemachine,andloaditonthetrailer; refertoFinishingtheJob(page63).

GatheringSiteInformation

PlanningtheInitialPath

Beforedrilling,planthepathyouwillboreandprepare asfollows:

•Createabasicplanforthebore,mappingoutthe

proposedpath.

–Noteanyobstacleswhichmayaffectthebore

suchaslargetrees,bodiesofwater,buildings, etc.

–Planthepathoftheboretoavoidasmany

obstaclesaspossible.

–Determinethedepthofanybodiesofwaterto

becrossedtoensurethatyoucangetdeep enoughtogounderthem.

•Determinethedepthyouneedtoinstallthe

materialatandtheminimumbendradiusofboth thedrillpipeandthematerialbeinginstalled.This willaffecthowlongtheboreneedstobeand atwhatangleyoucanenterandexit;referto

PlanningtheBorePath(page39).

•Havetheareaoftheborepathmarkedforutility

lines(intheUScall811).Ensurethatalllinesare markedonyourblueprints/boreplanaswell.

•Contactthelocalauthoritiestoarrangeforany

permitsandtrafccontrolthatyouwillneedto conductthejob.

InspectingtheProposedJobSite

Physicallyinspectthesiteasfollows:

•Notetheterrain,slopes,valleys,hills,andany

featuresnotplannedforpreviously.

Determinethedegreeofslopeatboththe proposedentrypointandexitpoint.

•Determinewhatthesoiltypesareintheareaand,

ifpossible,andwhattheyareatthedepthyou willbeboring.Youmayneedtodigtestholesat intervalsalongtheborepathtofullydeterminethis.

•Walktheareaoftheborepathlookingfor

anypossibleunmarkedobstructions.Lookfor manholes,pedestals,oldfoundations,etc.

•Identifyallhazardsofwhichyouwillbepassing

within3m(10ft).

Commonhazardsincludethefollowing:

–Gaslines

–Electricalpowerlines

–Crystallinesilicaandotherdust

Ifyouwillbedrillingthroughorcuttingconcrete, sand,orothersubstancesthatcreatedusts orfumes,youneedtoensurethatyouandall workerswearbreathingprotectiontoprotect yourlungsfromthedust.

DANGER

Contactingundergroundhazardswith themachinewhiledrillingorreaming cancauseexplosion,electrocution, breathingproblems,severetrauma,and deathtoyouorbystanders.

◊Ensurethatallpersonnelatthe

jobsitewearpersonalprotective equipmentincludingahardhat,eye protection,electricallyinsulated safetybootsandgloves,andhearing protection.

◊Keepbystandersandspectators

awayfromthejobsite,includingthe completeborepath.

◊Locateandexposeallelectricand

gaslinesthatyouwillbecrossingby carefulhanddigging.

◊EnsurethatyouusetheZap-Alert

systemwheneveroperatingthe machine.

DANGER

Drillingintoanelectricpowerline willcausethemachinetobecome electriedandmayelectrocuteyouor anybystanders.

◊Keepbystandersandspectators

awayfromthejobsite,includingthe completeborepath.

◊Locateandexposeallelectriclines

thatyouwillbecrossingbycareful handdigging.

◊Havetheelectriccompanyturnoff

thepowertoanylinesyouwillbe crossingbeforedrilling.

◊Usethereceivertotracktheexact

positionofthedrillheadwhen approachingelectriclines.

◊Beforedrilling,setupandusethe

Zap-Alertsystemwhichisdesigned tonotifyinthecaseofanelectric strike.IftheZap-Alertalarmtriggers, stopwhatyouaredoinganddo notleavetheoperator’sposition. RefertoDeployingtheZap-Alert

System(page51)fordetailed

instructionsonusingtheZap-Alert system.

DANGER

Drillingintoagaslinecancausean explosionorre,burning,injuring,or killingyouorothersinthevicinityof thebreak.

◊Donotsmokeorhaveanysourceof

ameneargaslinesorateitherend ofaborethatwillbecrossingagas line.

◊Keepbystandersandspectators

awayfromthejobsite,includingthe completeborepath.

◊Locateandexposeallgaslinesthat

youwillbecrossingbycarefulhand digging.

◊Havethegascompanyturnoffthe

gastoanylinesyouwillbecrossing beforedrilling.

◊Usethereceivertotracktheexact

positionofthedrillheadwhen approachinggaslines.

WARNING

Machiningorhandlingstone,masonry, concrete,metal,andothermaterials cangeneratedust,mists,andfumes containingchemicals,suchassilica, knowntocauseseriousorfatalinjury orillness,suchasrespiratorydisease, silicosis,cancer,birthdefects,orother reproductiveharm.

◊Controldust,mist,andfumesatthe

sourcewherepossible.Watershould beusedfordustsuppressionwhen feasible.

◊Usegoodworkpracticesand

followtherecommendationsofthe manufacturerorsuppliers,OSHA, andotheroccupationalandtrade associations.

◊Whenthehazardsfrominhalation

cannotbeeliminated,theoperator andanybystandersshouldweara respiratorapprovedbyOSHAforthe materialbeinghandled.

WARNING

SilicosisWarning:Grinding,cutting, ordrillingstone,masonry,concrete, metal,andothermaterialswithsilica intheircompositionmaygiveoff dustormistcontainingcrystalline silica.Silicaisabasiccomponent ofsand,quartz,brick,clay,granite, andnumerousothermineralsand rocks.Repeatedand/orsubstantial inhalationofairbornecrystallinesilica cancausefatalrespiratorydiseases, includingsilicosis.Inaddition,some otherauthoritieshavelistedrespirable crystallinesilicaasasubstance knowntocausecancer.Whencutting suchmaterials,followrespiratory precautions.

PlanningtheBorePath

Beforesettingupthejobsite,youneedtoplantheborepath,includingthefollowing:

Figure40

g218955

1.Boreentry

2.Beginningofbore-at-depthpoint5.Endofbore-at-depthpointandboreexit

3.Boredepth

•Boreentry

Thisisthelocationwhereyousetupthemachine andthedrillbitenterstheground.Depending onconditions,thiswilltypicallybesetback 9to15m(30to50ft)fromthebeginningof the-bore-at-depthpoint.

•Beginningofbore-at-depthpoint

Thisisthepointwhereyouwanttheutilityline orpipetoendafterinstallationiscomplete.Itis typicallythepointatwhichtheborelevelsout andbeginstoborehorizontally.Thismaybethe sameastheentrypoint,oryoumaydigaseparate depth-gaugeholeatthispoint(Figure40).

•Boredepth

Thisthedepthatwhichyouwanttoinstallthe utilitylineorpipe.

•Obstaclesinthepath

Youwillneedtosteeraroundorunderobstacles. Itisimportanttoknowwheretheseobstacleswill bebeforestartingsothatyoucanplanwhereto beginsteeringpriortoreachingtheobstacle.

•Endofbore-at-depthpoint

Thisisthepointwhereyouwanttheutilitylineor pipetobeginafterinstallationiscomplete.Often thiswillalsobetheboreexit.

•Boreexit

Thisisthelocationwherethedrillheadwillexit thegroundandthepointatwhichyouwillpullthe utilitylinesorpipeintothebore.Ifthispointwill beatthesurfaceinsteadofatinstallationdepth,

4.Obstacle

youwillneedtodeterminethedistancefromthe end-of-bore-at-depthlocationneededforsteering thedrilltothesurface,typically9to15m(30to50 ft)fromtheend-of-the-bore-at-depthpoint.

DeterminingtheBoreEntryPoint

Oneofthemorechallengingaspectsofplanningthe borepathistodeterminetheentrypointofthebore. Youneedtotakethefollowingtraitsintoaccountwhen determiningthelocationoftheentrypoint:

•Boredepth

Thisthedepthatwhichyouwanttoinstalltheutility lineorpipe.Thismachineisdesignedprimarilyfor installationsbetween1and3m(3.5to10ft).

•Pipeandmaterialexibility

The3m(10ft)pipesusedonthismachinecan extoan8%pitchoverthelengthofthepipe; thisequatestoabendofnomorethan20cm(8 inches)offofastraightpath(Figure41).

Important:Ifyousteerthepipetobend

sharperthan20cm(8inches)perpipe,you maydamagethepipesandtheirconnections. Youmustalsomakesteeringchanges graduallyovertheentirelengthofeachpipe. Ifyousteerthewhole20cm(8inches)in only25to50cm(1to2ft)oftravel,youcan permanentlydamagethepipes.

Figure41

1.20cm(8inches)

Thisexibilityisoftenratedinmaterialsasa minimumbendradius,whichistheradiusofthe circleformedifthematerialorpipes,connected together,werebenttoformagiantcircle.The minimumradiusofacirclemadewiththepipe usedwiththismachineis31m(101ft).

•Entrypitch

Theentrypitchistheangleatwhichthedrillbit enterstheground.Withthetracksonlevelground, thestabilizersdown,andthestake-downplate ontheground,thedrillframeangleisabout15 degreesora27%pitch.Thispitchwillchange dependingontheslopeofthegroundandother factorsofthejobsite.Y oucanalsoreducethis pitchabitbybuildingupthegroundunderthe stake-downplatebeforepositioningthemachine. Youcandeterminetheactualpitchofthedrill framebyplacingthedrillbitandsondehousing ontheframeandthenusethereceivertodisplay thepitch.

g021765

g218953

Figure43

1.18%pitch3.53cm(21inches)

2.3m(10ft)

Thesteeperyourentrypitchis,thedeeperyour boremustbeduetothelimitationsofthepipe exibility.Typically ,youneedtoinsertthedrillbit andatleast1/3ofapipeintothegroundbefore youcanstartsteeringtowardthebeginningofthe borepoint.Figure42,Figure43,andthefollowing tableillustratetherelationshipbetweenentrypitch anddepth.

Figure42

g218953

1.26%pitch3.76cm(30inches)

2.3m(10ft)

Note:Thedepthsgiveninthefollowingtablearefor3m(10ft)ofcombineddrillheadandpipe.As

yousteerup,thepitchofthesteeredsectionchangesandcanbemonitoredwiththereceiver.Usethe followingtabletoidentifyhowmanylengthsofpipewillbenecessarytoinsertandsteertothebeginning pointandhelpyouchooseanentrypoint.

Pitch

1%2cm(1inch)26%76cm(30inches) 2%5cm(2inches)27%79cm(31inches) 3%10cm(4inches)28%81cm(32inches) 4%13cm(5inches)29%84cm(33inches) 5%15cm(6inches)30%86cm(34inches) 6%18cm(7inches)31%91cm(36inches) 7%20cm(8inches)32%94cm(37inches) 8%25cm(10inches)33%97cm(38inches)

9%28cm(1 1inches)34%99cm(39inches) 10%30cm(12inches)35%102cm(40inches) 11%33cm(13inches)36%104cm(41inches) 12%36cm(14inches)37%107cm(42inches) 13%39cm(15inches)38%109cm(43inches) 14%43cm(17inches)39%112cm(44inches) 15%46cm(18inches)40%114cm(45inches) 16%48cm(19inches)41%117cm(46inches) 17%51cm(20inches)42%117cm(46inches) 18%53cm(21inches)43%119cm(47inches) 19%56cm(22inches)44%122cm(48inches) 20%61cm(24inches)45%124cm(49inches) 21%64cm(25inches)46%127cm(50inches) 22%66cm(26inches)47%130cm(51inches) 23%69cm(27inches)48%133cm(52inches) 24%71cm(28inches)49%135cm(53inches) 25%74cm(29inches)50%137cm(54inches)

Allmeasurementsareapproximateandwillvarydependingonsoilconditions.

DepthChangeper10feet

Pitch

DepthChangeper10feet

Note:RefertotheguidancesystemOperator’sManualformoreinformation.

Giventheinformationinthetable,youcancalculatethenumberofpipesrequiredtoreachyourbeginning pointattheappropriatedepth.Tororecommendsthatyoustarttheentrypointadistancebackfromyour beginning-at-depthpointbythesamedistanceasthelengthofpipesyouwillneedtoreachthatpoint.Thiswill ensurethatyouhaveenoughextraspacesoyouwillnotover-steeranddamagethepipes.

Thefollowingexampleillustratestheprocessgivenaninstallationusingthemaximumentrypitchofthe machine(26%)onlevelground:

Figure44

1.26%pitch4.185cm(73inches)7.14.7m(45ft)

2.76cm(30inches)5.203cm(80inches)

3.142cm(56inches)6.208cm(82inches)

•Y ouinserttherst3m(10ft)ofdrillbit/pipeinto

thegroundwithnosteering.Theendofthedrillbit is76cm(30inches)deep(Figure44).

g218954

•Y oubeginsteeringupforthenext3m(10ft),

pushingthepipesinatthemaximumpitchchange of8%.Thisresultsinachangeofpitchfrom26% atthebeginningofthe3m(10ft)to18%atthe endofthe3m(10ft)foranaveragepitchof22%. Giventhat,thedrillheadlowersanother66cm(26 inches)andisnow142cm(56inches)deep.

•Continuingsteeringupforthenext3m(10ft)at

an8%pitchchange,yourpitchchangesfrom18% to10%foranaveragepitchof14%.Giventhat, thedrillheadlowersanother43cm(17inches) andisnow185cm(73inches)deep.

•Continuingsteeringupforthenext3m(10ft)at

an8%pitchchange,yourpitchchangesfrom10% to2%foranaveragepitchof6%.Giventhat,the drillheadlowersanother18cm(7inches)andis now203cm(80inches)deep.

•Levelingthedrillheadfrom2%to0%takesless

than1.5m(5ft)moreforanaldepthof208cm (82inches).Reachingthisnalpointtook4and ahalf,3m(10ft)pipes.Soforthisexampleyour entrypointshouldbe14.7m(45ft)backfromthe beginning-at-depthpointofyourinstallation.

Thefollowingexampleillustratestheprocessgivenaninstallationusingthemachineatan18%pitchon levelground:

Figure45

1.18%pitch3.96cm(38inches)5.119cm(47inches)

2.53cm(21inches)4.114cm(45inches)6.10.6m(35ft)

g218952

•Y ouinserttherst3m(10ft)ofdrillbit/pipeinto

thegroundwithnosteering.Theendofthedrillbit is53cm(21inches)deep(Figure45).

•Y oubeginsteeringupforthenext3m(10ft),

pushingthepipesinatthemaximumpitchchange of8%.Thisresultsinachangeofpitchfrom18% atthebeginningofthe3m(10ft)to10%atthe endofthe3m(10ft)foranaveragepitchof14%. Giventhat,thedrillheadlowersanother43cm(17 inches)andisnow96cm(38inches)deep.

•Continuingsteeringupforthenext3m(10ft)at

an8%pitchchange,yourpitchchangesfrom10% to2%foranaveragepitchof6%.Giventhat,the drillheadlowersanother18cm(7inches)andis now114cm(45inches)deep.

•Levelingthedrillheadfrom2%to0%takesless

than1.5m(5ft)moreforanaldepthof119cm (47inches).Reachingthisnalpointtook3anda half,3m(10ft)pipes.Soforthisexample,your entrypointshouldbe10.6m(35ft)backfromthe beginning-at-depthpointofyourinstallation.

Important:Youcanusetheinformationcontained

inthissectiontodetermineboththespaceneeded tosteeruptotheexitpointifneededandalsoto steeraroundobstacles.

MappingtheBorePath

Withtheinformationyougatheredpreviously ,mapout thepathofthebore,identifyingthefollowingsothat youcanmarkthesitelater:

•Entrypoint

•Locationofthemachineandsupportingequipment

•Beginningofbore-at-depth

•Anyobstaclesthatyouneedtosteeraroundand

thelocationswhereyouneedtostartsteeringto getaroundorunderthem

•Anyutilitylinesyouwillneedtocross

•Slopeandsoilchangesalongthepaththatwill

affectthebore

•Endofthebore-at-depth

•Exitlocationifitisdifferentthantheendofthebore

PreparingtheJobSiteand

Checkingthe

theMachine

Beforedrilling,preparethejobsiteandmachineas follows:

•MarkingandPreparingtheBorePath(page44)

•T estingtheZap-AlertSystem(page45)

•LoadingtheDrillPipes(page46)

•FillingtheFuelTank(page46)

•CheckingtheEngine-OilLevel(page74)

•CheckingtheCoolantLevelintheRadiator(page

86)

•CheckingtheHydraulicFluid(page91)

•CheckingtheDrilling-Fluid-PumpOilLevel(page

94)

•LoadingandUnloadingtheMachine(page48)

•UnderstandingHorizontalDirectionalDrilling(page

35)

•ConnectingtoaDrilling-FluidSource(page52)

•SettingUptheDrillHeadandTracking

System(page50)

•SettinguptheMachineforDrilling(page51)

•DeployingtheZap-AlertSystem(page51)

Safety-InterlockSwitches

CheckingtheOperatorPresence Safety-InterlockFunctionsonthe OperatorPlatform

1.Starttheengine.

2.Withtheenginerunning,risefromtheseatand pressajoystickfunction.

Note:Thedrillfunctionsshouldnotengage.

Iftheydoengage,thereisamalfunctioninthe interlocksystemthatyoushouldcorrectbefore resumingoperation.

CheckingtheOperatorPresence Safety-InterlockFunctionsonthe TravelPendant

Youwillneed2peopleforthisprocedure.

1.Starttheengine.

2.Withtheenginerunning,have1personsitin theseat.

3.Usingthetravelpendant,pressthecontrolsto tramthemachine.

MarkingandPreparingthe BorePath

1.Walktheborepath,markingitontheground withmarkingpaintsothatthereceiveroperator willbeabletofollowthepath.

2.Handdigtoexposeanyburiedutilitylines, previouslymarked,thattheborepathwillbe crossing.Thiswillallowthereceiveroperatorto knowexactlywheretheyare.

3.Ifyouareexitingtheboreatgroundleveland notinanexistingtrench,diganangledholeinto whichthebitwillenterattheendofthebore.

4.Ifdesired,digaholetothebeginning-of-the-bore pointwhereyoucandisconnectthepipeorlines afterpullingthemback.

Note:Thetrammingfunctionsshouldnot

engage.Iftheydoengage,thereisamalfunction intheinterlocksystemthatyoushouldcorrect beforeresumingoperation.

4.Withtheenginerunning,usethetravelpendant andpressthecontrolstolowerthestabilizerfeet whilenotholdingtheoperatorpresencebutton.

Note:Thestabilizerfeetfunctionsshould

notengage.Iftheydoengage,thereisa malfunctionintheinterlocksystemthatyou shouldcorrectbeforeresumingoperation.

5.Withtheenginerunning,usethetravelpendant andpressthecontrolstotramthemachinewhile

notholdingtheoperatorpresencebutton.

Note:Thetrammingfunctionsshouldnot

engage.Iftheydoengage,thereisamalfunction intheinterlocksystemthatyoushouldcorrect beforeresumingoperation.

CheckingthePipeLoadGuard SafetyInterlockFunctions

Youwillneed2peopleforthisprocedure.

audiblealarmintheeventthatthedrillbit,reamer, orstakebreaksintoanenergizedpowerline.Inthe eventofanelectricstrike,themachinebecomes energized,settingoffthealarm.

1.Starttheengine.

2.Lowerthepipeloadguard.

3.Withtheenginerunning,have1personsitinthe seatandbeginthedrillingprocess.

4.Raisethepipeloadguard.

Note:Thecamassemblyshouldnotengage.

Ifitdoesengage,thereisamalfunctioninthe interlocksystemthatyoushouldcorrectbefore resumingoperation.

TestingtheZap-Alert System

DANGER

IftheZap-Alertsystemactivateswhiledrilling, themachinewillbecomeenergized.Ifyou stepoffoftheoperatorplatformorifsomeone touchesthemachineorwetgroundnearthe machineorinthebore,youortheycouldbe electrocuted,causingseriousinjuryordeath.

•TesttheZap-Alertsystembeforedrilling.

•Deploythegroundingstakebeforedrilling. Ensurethatthestakeisfullyinsertedinto moistsoil.

TesttheZap-Alertsystembeforeusingthedrilleach day,asfollows:

1.Removethegroundcablefromitsstorage positionattherearofthemachine(Figure49).

2.Laythegroundingstakeatonthegroundaway fromthemachine.Donotdrivethestakeinto theground.

Important:Donotallowthestaketotouch

anypartofthemachine.

3.Openthefronthood;refertoOpeningtheFront

andRearHoods(page67).

4.ConnectanalligatorclipfromtheZap-Alert testertothegroundingstudontheZap-Alert system(Figure46andFigure47).

g218967

Figure46

•IftheZap-Alertistriggered:

–Stayintheseatanddonottouchthe

groundoranyotherpartofthemachine untilthepowerhasbeenturnedoff. Donotpourliquidsorurinatefromthe operatorplatformontotheground.

–Stopdrilling,stopthedrilling-uidow,

andretractthedrilloutoftheground.

–Keepeveryoneawayfromthemachine.

–Keepstandingorrunningwaterand

drillinguidcontainedclosetothe machine.Keepwateranddrillinguid sourcesawayfromthebrokenline.

–Contacttheutilitycompanytohave

powershutofftothebrokenline.Do notresettheZap-Alertsystemuntilthe powerhasbeenturnedoff.

TheZap-Alertsystemisanelectricstrikesensing deviceonthemachinethattriggersastrobelightand

g230010

Figure47

5.Connecttheotheralligatorcliptoametal componentofthemachineframe.

6.PushtheTESTbuttonontheZap-Alerttester (Figure48).

TheZap-Alertalarmshouldsound,andthe strobeontopofthefronthoodshouldash.

MountingaFire Extinguisher

Mountyourreextinguisherbelowtheoperatorseat (Figure50).

Note:Areextinguisherisnotprovidedwiththe

machine.

Figure48

7.PushtheZAP-ALERTRESETbuttontostopthe alarm(Figure29).

8.Disconnectthealligatorclipsfromthegrounding studandthemachine.

9.Storethegroundingstakeintheholderatthe rearofthemachine(Figure49).

g230009

Therecommendedreextinguisherisadrychemical reextinguisherapprovedforclassBandCres.

Operateandmaintainthereextinguisherperthe instructionsonthereextinguisher.

g218948

Figure50

LoadingtheDrillPipes

Figure49

Ifeithertheaudiblealarmorthestrobelightfailed totriggerwhenyoupushedtheTESTbutton,have themrepairedbeforedrillingwiththemachine.

RefertotheSoftwareGuidefortheprocedureon loadingdrillpipesintothepipeboxorontothedrill string.

g218966

FillingtheFuelTank

FuelTankCapacity

114L(30USgallons)

FuelSpecication

Important:Useonlyultra-lowsulphurdiesel

fuel.Fuelwithhigherratesofsulfurdegrades thedieseloxidationcatalyst(DOC),whichcauses operationalproblemsandshortenstheservicelife ofenginecomponents.

Failuretoobservethefollowingcautionsmay damagetheengine.

•Neverusekeroseneorgasolineinsteadofdiesel

fuel.

•Nevermixkeroseneorusedengineoilwiththe

dieselfuel.

•Neverkeepfuelincontainerswithzincplatingon

theinside.

•Donotusefueladditives.

PetroleumDiesel

Cetanerating:45orhigher

Sulfurcontent:Ultra-lowsulfur(<15ppm)

FuelTable

Dieselfuelspecication

ASTMD975

No.1-DS15

No.2-DS15

EN590EuropeanUnion

ISO8217DMX

JISK2204GradeNo.2

KSM-2610

Location

USA

International

Japan

Korea

•Useonlyclean,freshdieselfuelorbiodieselfuels.

•Purchasefuelinquantitiesthatcanbeusedwithin

180daystoensurefuelfreshness.

Usesummer-gradedieselfuel(No.2-D)at temperaturesabove-7°C(20°F)andwinter-grade fuel(No.1-DorNo.1-D/2-Dblend)belowthat temperature.

Note:Useofwinter-gradefuelatlowertemperatures

provideslowerashpointandcoldowcharacteristics whicheasesstartingandreducesfuellterplugging.

Usingsummer-gradefuelabove-7°C(20°F) contributestowardlongerfuelpumplifeandincreased powercomparedtowinter-gradefuel.

Biodiesel

Thismachinecanalsouseabiodieselblendedfuelof uptoB20(20%biodiesel,80%petroleumdiesel).

Sulfurcontent:Ultra-lowsulfur(<15ppm)

Biodieselfuelspecication:ASTMD6751or

EN14214

Blendedfuelspecication:ASTMD975,EN590, orJISK2204

Important:Thepetroleumdieselportionmust

beultra-lowsulfur.

Observethefollowingprecautions:

•Biodieselblendsmaydamagepaintedsurfaces.

•UseB5(biodieselcontentof5%)orlesserblends

incoldweather.

•Monitorseals,hoses,gasketsincontactwithfuel

astheymaybedegradedovertime.

•Fuellterpluggingmaybeexpectedforatime

afterconvertingtobiodieselblends.

•ContactyourAuthorizedServiceDealerformore

informationonbiodiesel.

AddingFuel

1.Movethemachinetoalevelsurface.

2.Positionthethrustframeinthehorizontal position.

3.Shutofftheengine.

4.Cleanaroundthefuel-tankcapandremovethe cap.

g218946

Figure51

5.Addfuelandinstallthefuel-tankcap.Wipeup anyspilledfuel.

PerformingDaily Maintenance

Beforestartingthemachineeachday,perform theEachUse/Dailyprocedureslistedinthe

RecommendedMaintenanceSchedule(s)(page65).

StartingandShuttingOff theEngine

Tostarttheengine,dothefollowing:

1.Openthefronthood;refertoOpeningtheFront

andRearHoods(page67).

2.Turnthebatterydisconnectswitchtothe ONposition;refertoBattery-Disconnect

Switch(page34).

3.Closeandlatchthehood.

4.Openthedoorontherearcontrolpanel.

5.TurnthekeytotheRUNposition.

Ensurethatok-to-startlightisilluminated.If thelightisnotilluminated,ensurethatthe

emergency-engine-stopbuttonsarereleased (Figure29andFigure38).

6.TurnthekeytotheST ARTpositionuntilthe enginestarts,thenreleaseit.

Toshutofftheengine,turnthekeytotheOFFposition.

Inanemergency,youcanalsoshutoffthe engineandallprocessesbypushingthe EMERGNECY-ENGINE-STOPbuttononeitherthetravel pendantorthecontrolpanel.

TrammingtheMachine

RefertoTrammingSafety(page5).

1.Raisetheelevators.

2.Installthelowerpipeboxpins.

3.Lowertheelevators.

4.SwitchthedrillintoSETUPmode(Figure29).

LoadingandUnloadingthe Machine

WARNING

Movingamachineofthissizeonatrailerover publicroadscarriesriskstothosearoundthe machineifitshouldcomeloose,beinvolved inanaccident,hitalowhangingstructure, etc.

•Followthetie-downproceduresdescribed inthissectionwhenmovingthemachine.

•Followalllocaltrafcregulations governingthehaulingoflargeequipment. Thismanualcannotadequatelycoverall lawsandsafetyregulations;itisyour responsibilitytoknowandfollowthelaws andregulationsthatpertaintoyou.

5.Walkaroundthemachinetoensurethatnoone isnearit.Ensurethatallbystandersareclearof theareawhereyouwillbemovingthemachine.

6.Removethetravelpendantfromtherearcontrol panel.

7.Withthetravelpendantinhand,walkatleast 6feettothesideofthemachine.Besureto keepthissafedistancewhenevermovingthe machine.

8.PushandholdtheOPERATOR-PRESENCEbutton onthetravelpendant.

9.Usethespeedswitchonthependanttoincrease ordecreasetheenginespeedasdesired.

10.Setthedesiredtravelspeed,usingthespeed switch.

11.Usethejoysticktomovethemachineasdesired.

Note:Formoreinformationonthetravelpendant,

refertoTravelPendant(page33).

WARNING

Themachinecanslipandfallfromatraileror ramp,crushinganyonecaughtbeneathitand causingseriousinjuryordeath.

•Keepallbystandersawayfromthemachine andtrailer.

•Ensurethatthetrailerandramparenot slipperyandarefreeofice,grease,oil,etc.

•Movethemachineontotherampatslow speedwiththeengineatslowspeed.

•Ensurethatyouhavethemachinecentered ontherampandtrailer.

1.Ensurethattherampandthetrailerortruckbed cansupporttheweightofthemachine.

2.Ensurethattheupperpipeboxstrapsandlower pipeboxpinsareinstalled(Figure52).

g218951

Figure52

1.Upperstraps

2.Lowerpins

3.Placeablockatthefrontandrearofthetrailer and/ortrucktires.

7.Lowerthestabilizersuntilthestabilizerfeet contactthetraileroor.

4.Usingthetravelpendant,settheengineandthe tramspeedtoslow.

5.Usingthetravelpendant,carefullytramthe machineforwardorrearwarduptherampand intopositiononthetrailer.

6.Lowerthestake-downtubetothedeckofthe trailer.

8.Turnofftheengine.

9.Useappropriatelyratedchainsandbinders tosecuretheringsontheleftandrighttrack framesandthroughthetubeonthestake-down platetothetrailer(Figure53).

1.Tie-downpoints(onlyleftsideshown)

10.Measurethedistancefromthegroundtothe highestpointonthemachineforreferenceto ensurethatyoudonotcollidewithlowhanging obstacles.

11.Removetheblockfromthetrailertires,andstow themwiththemachineforusewhenunloadingit.

12.Aftertrammingafewmiles,pulloverandcheck toensurethatallchainsarestilltightandthat themachinehasnotmoved.

Tounloadthemachine,reversetheaboveprocedure.

g239626

Figure53

SettingUptheDrillHead andTrackingSystem

Thedrillheadconsistsof2parts,thedrillbitandthe sondehousing(Figure54).

Figure54

1.Sondehousing

2.Drillbit

Drillbitsvaryinsizeandtypetomeetthevarioussoil conditionsyoumayneedtodrillthrough.Someofthe possibilitiesareasfollows:

•Straightblade—Usedinawiderangeofmedium

densitysoils.

•Bentblade—Usedinmediumtosoftsoils.This

bithasanadded20°bendtoincreasesteering performanceinsoftsoils.

•Trianglepointblade—Useinhardandrocky

soils.Thisbithascarbideedgestoreducewear.

Alloftheabovebitscomeinvaryingwidths.A widerbladeincreasesyourabilitytosteerinsoft soils.Anarrowerblademovesthroughhardsoils better.ContactyourAuthorizedServiceDealerfora completelistofavailableblades.

Thesondesandreceiversareessentialtotrack thepositionofthedrillheadthroughoutthedrilling operation.Thesondehousingonthedrillheadopens uptoacceptthesondebeaconwhichworkswiththe receivertotrackthelocation,pitch,direction,head orientation,andmoreofthedrillhead.Refertothe TrackingSystemOperator’sManualforinstructions onusingthesystem.

g023076

1.Sondehousing

2.Screws

3.Drillbit

Figure55

4.Housingcover

5.Housing

g023073

3.Insertthesondebeaconwiththeforwardend towardthedrillbitintothesondehousing(Figure

56).

g218969

Figure56

1.Sondehousing

2.Sonde

3.Drillbit

4.Installthehousingcoverandsecureitwiththe screws(Figure55).

Toinstallthesondebeaconintothesondehousingon thedrillhead,completethefollowing:

1.Replacethebatteriesinthesondebeaconas describedintheTrackingSystemOperator’s Manual.

2.Loosenthescrewssecuringthehousingcover tothehousingandremovethecover(Figure55).

SettinguptheMachinefor

DeployingtheZap-Alert

Drilling

1.Usingthetravelpendant,tramthemachine tothelocationthatyouhavepreparedforit, ensuringthatthefrontofthemachineisthe properdistancebackfromentrypointandthe drillframeisinlinewiththeborepath.

2.Driveuptothelocationandmakesurethatall utilitiesarelocatedandmarkedpriortodrilling.

3.Removetheconsolecovers.

Note:Storethemsomeplacesafefortheday.

4.Lowerthepipeloadingguard(Figure57).

System

TheZap-Alertsystemisanelectricstrikesensing deviceonthemachinethattriggersastrobelightand audiblealarmintheeventthatthedrillbit,reamer, orstakebreaksintoanenergizedpowerline.Inthe eventofanelectricstrike,themachinebecomes energized,settingoffthealarm.

DANGER

IftheZap-Alertsystemactivateswhile drilling,themachine,includingtheoperator’s platform,willbecomeenergized.Ifyou stepofftheoperatorplatformorifsomeone touchesthemachineorwetgroundnearthe machineorinthebore,youortheycouldbe electrocutedcausingseriousinjuryordeath.

•TesttheZap-Alertsystembeforedrilling.

•Deploythegroundingstakebeforedrilling. Ensurethatthestakeisfullyinsertedinto moistsoil.

•IftheZap-Alertistriggered:

Figure57

5.Pushdownontheoperatorplatformlatchand swingtheplatformouttothedesiredposition, ensuringthatitlocksinplace(Figure58).

Note:Theoperatorplatformhas5positions:

travel(swungallthewayintothemachine), full-out,and3intermediatepositions.

–Stayintheseatanddonottouchthe

g230516

groundoranyotherpartofthemachine untilthepowerhasbeenturnedoff. Donotpourliquidsorurinatefromthe operatorplatformontotheground.

–Stopdrilling,stopthedrilling-uidow,

andretractthedrilloutoftheground.

–Keepeveryoneawayfromthemachine,

wetgroundnearthemachineorrunning fromthemachine,andanyopen sourcesofwater/mudthatisinthebore andcontactingthebrokenline.

–Contacttheutilitycompanytohave

powershutofftothebrokenline.Do notresettheZap-Alertsystemuntilthe powerhasbeenturnedoff.

1.Removethegroundingstakefromtheholderon thesideoftheoperatorplatform(Figure59).

Figure58

g218956

Figure60

1.Thrustframe2.Stake-downplate

3.Lowertherearstabilizersuntiltheycontactthe groundrmly,oruntilthedesiredentryangleis achieved(Figure61).

g218964

Figure59

2.Movethestakedirectlyawayfromthemachine, perpendiculartothedrillframeanddriveitinto thegrounduntilthehandletouchestheground.

3.Ifthegroundisdrywhereyouputthestake, soakitwithwaterbeforeusingthemachineto ensuregoodelectricalcontact.

LoweringtheStakes

PreparingtheMachinetoLower theStakes

1.Movetheoperatorstationtothedesiredangle, switchtheDRILL/SETUPswitchtotheDRILL position,andraisethepipeelevators,sothatthe pipeisrestingontheelevators;refertoStarting

theFirstPipe(page57).

2.Removethepipeboxtransportpins.

3.Powerontheexit-sidelockoutsystem.

4.Loadtherstpipeandinstallthesondeandthe drillhead;refertoStartingtheFirstPipe(page

57).

5.Placethedrillheadonthedrillframe,andtake apitchreadingusingthereceiver;refertothe TrackingSystemOperator’sManual.

LoweringtheStakes

1.Movetheoperatorstationtothedesiredangle, switchtheDRILL/SETUPswitchtotheDRILL position,andraisethepipeelevators,sothatthe pipeisrestingontheelevators;refertoStarting

theFirstPipe(page57).

2.SwitchtheDRILL/SETUPswitchtotheSETUP position,lowerthethrustframe,tiltingthedrill frameuntiltheplatecontactstheground(Figure

60).

g218966

Note:Therearofthetracksshouldjuststartto

liftofftheground.

Note:Ifthegroundissoft,placetimberbelow

thestabilizersandlowerthestabilizers.

g218941

Figure61

4.Deploythezap-alertsystem;refertoDeploying

theZap-AlertSystem(page51)

5.Pushthelowerstakedirectionontheright joystickandspintherightstakeaugeruntilit seatsfully.

6.Repeatthisprocedurefortheleft-sidestake.

Connectingtoa Drilling-FluidSource

Whendrillingandreaming,youpumpamixture ofbentoniteclay,water,andsometimesother ingredients,collectivelycalleddrillinguidor“mud,” throughthepipeandintothebore.Thisdrillinguid, or“mud,”doesthefollowingforyourbore:

•Lubricatesthedrillhead

•Keepsthesondecool

•Loosensthesoilintowhichthedrilliscutting

•Penetratesandbindsloosesoiltokeepthemfrom

collapsingontheborepipe.

Thespecicmixtureyouneedwillvarydependingon yoursoiltypeandtheoperationyouareperforming;

refertoyourmixingsystemOperator’sManualfor details.

Conversely,forsomejobs(dependingonthesoiltype anddistance),youcanpumpscreenedwaterfroma naturalwatersource,suchasalakeorriver,through thedrillinsteadofmixeddrillinguid.

•T oconnectthemachinetoamixingsystem,refer

toSettingUptheMixingSystem(page53).

•T oconnectthemachinetoanaturalwatersource,

refertoSettingUpthePumptoUseaNatural

WaterSource(page53).

SettingUptheMixingSystem

Setupyourmixingsystemnearthedirectionaldrill location,preferablydownwindsothatfumesfromthe mixingsystemenginedonotbotheryouwhiledrilling. Followtheinstructionsprovidedinthemixingsystem Operator’sManualforsettingitupandusingit.

Completethefollowingtoconnecttheexithosefrom themixingsystemtothedrilling-uidpumponthe machine:

SettingUpthePumptoUsea NaturalWaterSource

Tosetupapumptouseanaturalwatersource, ensurethatyouusetheY-screentolterallmaterials otherthanwater.

1.Removethepump-inletcap(BoxAofFigure63).

g220801

Figure63

1.Raisethecam-lockleversonthepump-inletcap andremovethecap(Figure62).

Figure62

2.Insertthehosefromthemixingsystemover thepumpinletandsecureitwiththecam-lock levers.

2.AligntheY-screenwiththethreadsonthepump (BoxBofFigure63).

3.RotateandtightentheY-screenontothepump.

4.AttachthehosetotheY -screen,andbegin pumpingfromthenaturalwatersource.

g218943

DuringOperation

DuringOperationSafety

GeneralSafety

•Theowner/operatorcanpreventandisresponsible

foraccidentsthatmaycausepersonalinjuryor propertydamage.

•Wearappropriateclothing,includinglongpants;

eyeandhearingprotection;slip-resistant, substantialfootprotection;andhardhats.Tieback longhairanddonotwearjewelry .

•Donotoperatethemachinewhileill,tired,or

undertheinuenceofalcoholordrugs.

•Nevercarrypassengersonthemachineandkeep

bystandersandpetsawayfromthemachine duringoperation.

•Operatethemachineonlyingoodvisibilitytoavoid

holesorhiddenhazards.

•Keepyourhandsandfeetawayfrommovingparts.

•Lookbehindanddownbeforebackinguptobe

sureofaclearpath.

•Usecarewhenapproachingblindcorners,shrubs,

trees,orotherobjectsthatmayobscureyour vision.

•Donotoperateneardrop-offs,ditches,or

embankments.

•Stopthemachinewheneveryouarenotoperating

it.

•Stopthemachineandinspecttheafterstriking

anobjectorifthereisanabnormalvibrationin themachine.Makeallnecessaryrepairsbefore resumingoperation.

•Slowdownandusecautionwhenmakingturns

andcrossingroadsandsidewalkswiththe machine.Alwaysyieldtheright-of-way.

•Neverrunanengineinanareawhereexhaust

gassesareenclosed.

•Neverleavearunningmachineunattended.

•Beforeleavingtheoperatingposition,dothe

following:

–Movethemachinetolevelground.

–Shutofftheengineandremovethekey.

–Waitforallmovingpartstostop.

•Donotoperatethemachinewhenthereistherisk

oflightning.

•Donotusethemachineasatowingvehicle.

•Useaccessories,attachments,andreplacement

partsapprovedbyTheT oro®Companyonly.

SlopeSafety

Whenoperatingthemachineonaslope,theoperator mustaccountformanyvariables,suchastheamount, distribution,andheightoftheload;thestabilityof theground;uneventerrainandobstacles;andthe conditionofthebrakes.Theseandothervariables makeitimpracticaltodesignatethemaximumangle atwhichtheoperatorcansafelyusethemachinefor allslopesandsituations.

Slopesareamajorfactorrelatedtolossofcontrol androlloveraccidents,whichcanresultinsevere injuryordeath.Theoperatorisresponsibleforsafe slopeoperation.Operatingthemachineonanyslope requiresextracaution.Beforeusingthemachineona slope,theoperatormustdothefollowing:

•Reviewandunderstandtheslopeinstructionsin

themanualandonthemachine.

•Evaluatethesiteconditionsofthedaytodetermine

iftheslopeissafeformachineoperation.Use commonsenseandgoodjudgmentwhen performingthisevaluation.Changesintheterrain, suchasmoisture,canquicklyaffecttheoperation ofthemachineonaslope.

•Walkbesidethemachinewhentrammingupand

downslopes.

•Identifyhazardsatthebaseoftheslope.Do

notoperatethemachineneardropoffs,ditches, embankments,waterorotherhazards.The machinecouldsuddenlyrolloverifatrackgoes overtheedgeortheedgecollapses.Keepasafe distance(twicethewidthofthemachine)between themachineandanyhazard.

•Avoidstarting,stoppingorturningthemachineon

slopes.Avoidmakingsuddenchangesinspeedor direction;turnslowlyandgradually.

•Donotoperateamachineunderanyconditions

wheretraction,steeringorstabilityisinquestion. Beawarethatoperatingthemachineonwet terrain,acrossslopesordownhillmaycausethe machinetoslideevenifthetracksarestopped.

•Removeormarkobstaclessuchasditches,holes,

ruts,bumps,rocks,orotherhiddenhazards. Uneventerraincouldoverturnthemachine.

DieselParticulateFilter Regeneration

Thedieselparticulatelter(DPF)ispartoftheexhaust system.Thediesel-oxidationcatalystoftheDPF reducesharmfulgassesandthesootlterremoves sootfromtheengineexhaust.

TheDPFregenerationprocessusesheatfromthe engineexhausttoincineratethesootaccumulatedon thesootlter,convertingthesoottoash,andclears thechannelsofthesootltersothatlteredengine exhaustowsouttheDPF .

Theenginecomputermonitorstheaccumulationof sootbymeasuringthebackpressureintheDPF .If thebackpressureistoohigh,sootisnotincinerating inthesootlterthroughnormalengineoperation.T o keeptheDPFclearofsoot,rememberthefollowing:

•Passiveregenerationoccurscontinuouslywhile

theengineisrunning—runtheengineatfull enginespeedwhenpossibletopromoteDPF regeneration.

•Ifthebackpressureistoohigh,theengine

computersignalsyouthroughthedisplay whenadditionalprocesses(assistandreset regeneration)arerunning.

•Whenenoughsootaccumulates,thecomputer

informsyouthatitistimetoregeneratethediesel particulatelter.

•DPFregenerationisaprocessthatheatstheDPF

toconvertthesoottoash.

•Inadditiontothewarningmessages,thecomputer

reducesthepowerproducedbytheengineat differentsoot-accumulationlevels.

RefertotheSoftwareGuideforfaultmessagesand recommendedactions.

DPFAshAccumulation

•Thelighterashisdischargedthroughtheexhaust

system;theheavierashcollectsinthesootlter.

•Ashisaresidueoftheregenerationprocess.Over

time,thedieselparticulatelteraccumulatesash thatdoesnotdischargewiththeengineexhaust.

•Thecomputerfortheenginecalculatestheamount

ofashaccumulatedintheDPF.

•Whenenoughashaccumulates,theengine

computersendsinformationtothedisplayinthe formofasystemadvisoryoranenginefaultto indicatetheaccumulationofashintheDPF .

Operateandmaintainyourmachinewiththefunction oftheDPFinmind.Engineload,athighidle enginespeed,generallyproducesadequateexhaust temperatureforDPFregeneration.

Important:Minimizetheamountoftimethatyou

idletheengineoroperatetheengineatlow-engine speedtohelpreducetheaccumulationofsootin thesootlter.

CAUTION

Theexhausttemperatureishot(approximately 600°C(1,112°F)duringDPFparked regenerationorrecoveryregeneration.Hot exhaustgascanharmyouorotherpeople.

•Neveroperatetheengineinanenclosed area.

•Makesurethattherearenoammable materialsaroundtheexhaustsystem.

•Nevertouchahotexhaustsystem component.

•Neverstandnearoraroundtheexhaust pipeofthemachine.

•Theadvisoryandfaultsareindicationsthatitis

timetoservicetheDPF .

•Inadditiontothewarnings,thecomputerreduces

thepowerproducedbytheengineatdifferent ash-accumulationlevels.

RefertotheSoftwareGuideforfaultmessagesand recommendedactions.

DPFSootAccumulation

•Overtime,theDPFaccumulatessootinthesoot

lter.Thecomputerfortheenginemonitorsthe sootlevelintheDPF .

TypesofDieselParticulateFilterRegeneration

Typesofdieselparticulatelterregenerationthatareperformedwhilethemachineisoperating:

TypeofRegenerationConditionsforDPFregenerationDPFdescriptionofoperation

Passive

Assist

Reset

Occursduringnormaloperationofthemachineat high-enginespeedorhigh-engineload

Occursasaresultoflow-enginespeed,low-engine load,orafterthecomputerdetectsbackpressure intheDPF

Occursafterassistregenerationonlyifthe computerdetectsthatassistregenerationdidnot sufcientlyreducethesootlevel

Alsooccursaftertherst50enginehoursandthen every100hourstoresetbaselinesensorreadings

Typesofdieselparticulatelterregenerationthatrequireyoutoparkthemachine:

TypeofRegenerationConditionsforDPFregenerationDPFdescriptionofoperation

Parked

Recovery

Sootbuildupoccursasaresultofprolonged operationatlow-enginespeedorlow-engineload. Mayalsooccurasaresultofusingincorrectfuel oroil

Thecomputerdetectsbackpressureduetosoot buildupandrequestsaparkedregeneration

Occursasaresultofignoringparkedregeneration requestsandcontinuingoperation,addingmore sootwhentheDPFisalreadyinneedofaparked regeneration

Thedisplaydoesnotdisplayaniconindicating passiveregeneration.

Duringpassiveregeneration,theDPFprocesses high-heatexhaustgasses;oxidizingharmful emissionsandburningsoottoash.

RefertoPassiveDPFRegeneration(page57).

Duringassistregeneration,thecomputercontrols theintakethrottletoincreasetheexhaust temperature,enablingassistregenerationtooccur.

RefertoAssistDPFRegeneration(page57).

Duringresetregeneration,thecomputercontrols theintakethrottleandfuelinjectorstoincreasethe exhausttemperatureduringregeneration.

RefertoResetRegeneration(page57).

Whentheparked-regenerationicon isdisplayedonthedisplay,aregenerationis requested.

•Performtheparkedregenerationassoonas possibletoavoidneedingarecoveryregeneration.

•Aparkedregenerationrequires30minutesto complete.

•Youmusthaveatleasta1/4tankoffuelinthe tank.

•Youmustparkthemachinetoperformarecovery regeneration.

RefertoParkedRegenerationandRecovery

Regeneration(page57)andtheSoftwareGuide

foryourmachine.

Whentherecovery-regenerationiconis displayedonthedisplay,arecoveryregenerationis requested.

•Arecoveryregenerationrequiresapproximately4 hourstocomplete.

•Youmusthaveatleasta1/2tankoffuelinthe machine.

•Youmustparkthemachinetoperformarecovery regeneration.

RefertoParkedRegenerationandRecovery

Regeneration(page57)andtheSoftwareGuide

foryourmachine.

PassiveDPFRegeneration

•Passiveregenerationoccursaspartofnormal

engineoperation.

•Whileoperatingthemachine,runtheengineat

full-enginespeedwhenpossibletopromoteDPF regeneration.

DrillingtheBore

StartingtheFirstPipe

TheSoftwareGuideisusedinthisprocedure.

1.Ensurethatallbystandersareawayfromthe machineandthattheexit-sidelockoutisON.

AssistDPFRegeneration

•Thecomputertakescontroloftheintakethrottleto

increasethetemperatureoftheengineexhaust.

•Whileoperatingthemachine,runtheengineat

fullenginespeedwhenpossibletopromoteDPF regeneration.

ResetRegeneration

•Thecomputertakescontroloftheintakethrottle

andchangesthefuelinjectionoperationto increasethetemperatureoftheengineexhaust.

Important:Theassist/reset-regeneration

iconindicatesthattheexhausttemperature dischargedfromofyourmachinemaybe hotterthanduringregularoperation.

•Whileoperatingthemachine,runtheengineat

fullenginespeedwhenpossibletopromoteDPF regeneration.

ParkedRegenerationand RecoveryRegeneration

RefertotheSoftwareGuideformoreinformation.

PreparingtoPerformaParkedorRecovery Regeneration

Ensurethatthemachinehasfuelinthetankforthe typeofregenerationyouareperforming:

•ParkedRegeneration:Ensurethatyouhave

1/4tankoffuelbeforeperformingtheparked regeneration.

•RecoveryRegeneration:Ensurethatyouhave

1/2tankoffuelbeforeperformingtherecovery regeneration.

Movethemachineoutsidetoanareaawayfrom combustiblematerials.

2.Movethedrillcarriagefullydownthedrillframe andspraythespindlethreadswiththreadjoint compound,thenreturnthedrillcarriagetothe upperendoftheframe(Figure59).

Figure64

1.Drillspindle

3.Changetherowselectortorow1onthedisplay torotatethecamassemblytotherstrowinthe pipeholder;refertotheSoftwareGuide.

4.Lowerthepipeelevatorstoloadapipeintothe camassembly.

5.Rotatethecamassemblywiththepipetoward thedrillframe,andextendthepipegrippersuntil thepipeiscenteredoverthedrillstringandin frontofthedrillspindleonthecarriage.

6.Raisethepipeelevators.

7.Engagetheexitsidelockoutsystemandrotate thedrillspindleclockwiseandmovethecarriage slowlyforwardtoinsertthespindleintothe femaleendofthepipe(Figure65).

2.TJC-applicatornozzle

g023075

RefertotheSoftwareGuidefortheprocedureto performtheparkedorrecoveryregeneration.

Figure65

1.Drillspindle2.Pipe

8.Continuetomovethedrillcarriageslowlydown theframeuntilthemalethreadsonthepipeare underthethread-joint-compoundapplicatorand applythread-jointcompoundtothethreads.

1.Usingtheexit-side-lockouttransmitter,enable theexitsidelockout.

2.Handthreadtheleadbarontothepipethreads thenclearawayfromthefrontofthemachine.

3.Whentheareaisclearofpeople,pushthe exit-side-lockoutresetswitchonthefrontcontrol panel.

4.Pullthedrillpipeandleadbarbackthroughthe pipeguideandintothewrenches,aligningthe shoulderoftheupperjointoftheleadbarwith theupperwrench(Figure66).

Important:Donotclampthewrenchonthe

g218963

bodyofapipeoritmaydamagethepipe. Gripthepipesontheshoulderofthepipe joint.

9.Continuetorotatethedrivespindleclockwise, untilthemalepipethreadsarefullyseatedinto thesondehousingortheleadbar.

10.Releaseandretractthepipegripper,rotatingit allthewayouttotheparkposition.

Important:Ensurethatyoufullyretractthe

pipegripperandrotateitallthewayoutor thecarriagemaycollidewiththegripper, damagingthemachine.

Note:T orquethethreadsto2305N∙m(1,700

ft-lb).

InstallingtheDrillHead

WARNING

Ifthedrillrotatesorextendswhileyouor othersaremanuallyworkingonthedrillbitor pipeinfrontofthemachine,theworkercould getcaughtinthebitorpipecausingserious injury,amputation,ordeath.

•Enabletheexit-sidelockoutonthe exit-side-lockouttransmitterbefore approachingthedillbitorpipewhen attachedtothemachine.Thisdisablesthe drillcarriagemotionandrotaryfunctions.

•Donotwearlooseclothingorjewelrywhen workingonadrillbitorpipeattachedto themachine.Tielonghairupandoutof theway.

Figure66

1.Upperwrench (makeup/breakout wrench)

2.Lowerwrench(stationary wrench)

3.Drillpipe

4.Leadbar

5.Usingtheupperwrench,clamptheleadbarand

tightenittofullmachinetorque.

6.Usingtheexit-side-lockouttransmitter,enable

theexit-sidelockout.

7.Doublecheckthedrillheadandbittoensure

thattheuidportsarecleanandfreefrom obstructions.

8.Installthedrillheadontotheendoftheleadbar

asdirectedbythedrillheadmanufacturer,then clearawayfromthefrontofthemachine.

Important:Donotpullthedrillheadintothe

pipeguide,oryoumaydamagethemachine orthedrillhead.

g218962

BoringtheEntryShaft

Therststepistocreatetheentryshaft.Pushand borethedrillbitandtherstfewpipesintotheground atananglefrom0to16degrees(withthetracksat ontheground)untilyoureachthedesireddepth.

Important:Drillandreaminaclockwiserotation.

Ifyouuseacounterclockwiserotation,thepipe willdisconnectfromeachotherandmaybe disconnectedunderground.

1.Whentheareaisclearofpeople,disablethe exit-sidelockoutusingtheexit-side-lockout transmitter;pushtheexit-side-lockout,reset switchonthecontrolpanel.

2.Turnonthedrillinguidpumpswitchandallow theuidpressuretobuildto1379to2068kPa (200to300psi).

9.Rotatethedrillspindleclockwiseandmovethe carriageslowlyforwardtoinsertthespindleinto thefemaleendofthepipe(Figure65).

Note:Tightenthejointuntilthepipeisrotating

withthespindle.

10.Movethedrillcarriageslowlydowntheframe untilthemalethreadsonthepipeareunder thethread-joint-compoundapplicatorandapply thread-jointcompoundtothethreads.

11.Rotatethedrillspindleclockwiseandmovethe carriageslowlyforwardtoinsertthemaleend ofthepipeintothefemaleendoftheprevious pipe.Tightenthejointuntilyoureachnomore than2,304N∙m(1,700ft-lb).

12.Releaseandretractthepipegripper,rotatingit allthewayoutpastthethirdrowofpipes.

3.Rotatethedrillheaduntilthebitisatthe6 o’clockposition.

4.Movethecarriageforwarddrivingthebitstraight intothegrounduntiltheentiredillhousingis underground.

5.Continuepushingforwardandbeginrotating thedrillspindleclockwisetoinitiatethedrilling action.

6.Drillforwarduntilthecarriagereachestheendof theframe,thenretractitabout6mm(1/4inch).

AddingDrillPipes

1.Alignthepipejointinthewrenchassembly.

2.Closethelowerwrench(stationarywrench)onto therstpipe.

Note:Thedrillinguidautomaticallyshutsoff

whenyouactivatethelowerwrench.

3.Pullbackthecarriageapproximately12.7mm (0.5inch).

Note:Thisallowsthecarriagetooatandnot

damagethepipethreads.

Important:Ensurethatyoufullyretractthe

pipegripperandrotateitallthewayout; otherwisethecarriagemaycollidewiththe gripper,damagingthemachine.

13.Releasethewrenchandcontinuethedrilling operation.

SteeringtheDrillHead

Thedrillbitisshapedlikeawedge,angledfromone sideofthebittotheother.Whenyoupushthebit throughthesoilwithoutrotatingit,itmovestowardthe directionthatthewedgeispointing.Whenyourotate thepipeanddrillhead,itboresthroughthesoilina straightpath.

g02311 1

Figure67

1.Drillbit

4.Rotatethedrillheadcounterclockwiseuntilthe spindleiscompletelyremovedfromthepipe.

5.Spraythespindlewiththreadjointcompound, thenreturnthedrillcarriagetotheupperend oftheframe.

6.Rotatethecamassemblytotheclosestrowof pipesinthepipeholder.

7.Lowerapipeintothecamassemblyandgrip itinplace.

8.Rotatethecamassemblytowardthedrillframe, andextendthepipegrippersuntilthepipeis centeredoverthedrillstringandinfrontofthe spindleonthecarriage.

Whendrilling,acrewmemberfollowsthedrillhead asitprogresses.Thereceiverreceivessignalsfrom thesondeinthedrillheadidentifyingitsposition, depth,pitch,direction,transmittertemperature,and orientationinthesoil.Theremoteconsoleisascreen thatremainsnearyou(thedrilloperator)toshowyou theinformationfromthereceiverwhiledrillingsothat youcanmakesteeringdecisions.

Fordetailedinformationonusingthereceiverand remoteconsoletoguidethedrillhead,refertothe Operator’sManualthatcamewithyourreceiver.

Important:Donotsteerthedrillheadmorethan

20cm(8inches)offcenterforevery3meters(10

ft)offorwardtravel.Ifyousteermorethanthis, youwilldamagethedrillpipes.

BoringtheHorizontalShaft

Aftercreatingtheentryshaft,yougraduallysteer thedrillheadupwhilepushingforward,following theplannedborepath.Whenyoureachthedesired depth,leveloutthedrillheadandborethehorizontal shaft,addingpipesasyougo.Whileboring,payclose attentiontotheinformationrelayedbacktoyouby thecrewmemberaboutthestatusandlocationofthe drillheadtoensurethatyouarefollowingtheplanned path.

Important:Whiledrilling,watchthesonde

temperature.Allsondeshaveamaximum temperatureabovewhichtheywillbedamaged. Frictionbetweenthedrillheadandthesoil causesthetemperaturetoraise.T oreduce thetemperature,slowdown,decreaseforward pressure,andincreasethedrillinguidow.If thedrillheadisenteringasoiltypeotherthan whatitisdesignedfor,thatcanalsoraisethe temperature.Assessthesituationandpulloutthe drillheadandchangeitifnecessary.

Ifyourunintoanobstruction,dothefollowing:

1.Increasetheowofthedrillinguidforafew secondswithoutdrilling,thenattempttocontinue drillingforward.

Thismayloosentheobstructionandallowyou topushpastit.

ExitingtheGround

Asyouapproachtheendofthebore,steerthedrill headtotheexitpoint,keepingthesteeringlimitsin mindasyoudoso.Beforeexitingtheground,ensure thateveryoneisawayfromtheexitpoint.Assoonas youbreakthrough,stopthedrilling-uidow.Extend thedrillforwarduntiltheentiredrillheadisoutofthe ground.

BackreamingandPullback

Afterdrillingtheinitialbore,youattachareamerto thepipe,whichisthenconnectedtoatheproductyou areinstalling.Thereamerisdesignedtowidenthe bore,packthewalls,andlubricatethepassageofthe productintothebore.

Thefollowingreamersareavailablefromyour AuthorizedServiceDealerinvarioussizestomeet yourneedsandsoilconditions:

•Carbidestep-wingcutter—Usethisreamerin

sandyandmediumclaysoilconditionstomixthe drillinguidwiththesoil,makingamixturethat owseasilyaroundtheproductbeingpulled.

•Castconepacker—Usethisreamerinsoilsthat

packeasily,suchassoftclay,peat,andloam,to packthesidesofthebore,maintainingthebore opening.

•Flutedreamer—Usethisreamerinhardclayand

rockysoils;itcombinesthefeaturesoftheother 2reamers.

2.Iftheobstructionpersists,try1ormoreofthe followingoptions:

•Iftheobstructionisinanareawhereyou

candig,stopthedrillheadwiththeExitSide Lockoutanddigdowntotheobstructionto identifyitandremoveitifpossible.

•Pullthedrillheadback15m(50ft)ormore

andsteerthedrillheadtotheside,marking anewdrillpatharoundtheobstacle.

Important:Donotsteerthedrillhead

morethan20cm(8inches)offcenterfor every3meters(10ft)offorwardtravel.If yousteermorethanthis,youwilldamage thedrillpipes.

•Iftheobstructionisactuallyachangeinsoil

types,suchasazoneofrockysoil,pullthe drillheadallthewaybackandchangetoa drillbitappropriatefordrillingthroughthe newsoiltype.

ConnectingtheReamerand Product

WARNING

Ifthedrillrotatesorextendswhileyouor othersaremanuallyworkingonthedrillbitor pipeinfrontofthemachine,theworkercould getcaughtinthebitorpipecausingserious injury,amputation,ordeath.

•Enabletheexit-sidelockoutonthe exit-side-lockouttransmitterbefore approachingthedillbitorpipewhen attachedtothemachine.Thisdisablesthe drillcarriageandrotarygearbox.

•Donotwearlooseclothingorjewelrywhen workingonadrillbitorpipeattachedto themachine.Tielonghairupandoutof theway.

1.Usingtheexit-side-lockouttransmitter,enable theexitsidelockout.

2.Usingbreakouttools,removethedrillheadfrom theleadbar.

Important:Donotusepipewrenches.

3.Doublecheckthereamertoensurethattheuid portsarecleanandfreefromobstructions.

4.Installthereamerandswivelontotheendofthe leadbarasdirectedbythereamermanufacturer.

5.Connecttheproducttothereamerusingan appropriatepullingconnection;refertoyour AuthorizedServiceDealertoacquirethe appropriatepullertomeetyourrequirements.

RemovingDrillPipes

1.Usingtheexit-side-lockouttransmitter,enable theexitsidelockout.

2.Installadrill-pipewiperaroundthepipeandinto theretainingbracketonthefrontofthemachine.

Thisremovesmostofthedirtandmudfromthe pipeasyoupullitbackintothemachine,keeping themachineclean.ContactyourAuthorized ServiceDealertopurchasedrill-pipewipers.

g234768

Figure69

3.Disengagetheexit-sidelockoutandresetthe system.

4.Beginrotatingthedrillspindleclockwiseand slowlyretractthedrillcarriagetopullthepipe backintothemachine.

5.Whenthejointbetweenthepipesiscentered betweenthe2wrenches,thedrillcarriagestops, andagreenlightilluminatesbehindthespray valve.

6.Closethelowerwrenchontothepipejoint.

Note:Thedrillinguidautomaticallyshutsoff

whenyouclosethelowerwrench.

7.Closetheupperwrenchontothepipejoint.

8.Rotatetheupperwrenchcounterclockwiseuntil thejointisloosened.

9.Releasetheupperwrenchandretractthepipe gripperarms.

Figure68

g234769

10.Rotatethedrillspindlecounterclockwisemoving rearwardslowlyuntilthepipesareseparated.

11.Movethedrillcarriagebackuntilthemale-pipe threadsjustclearthefemaleendofthelower pipe,thenclosetheupperwrenchontothepipe shoulder,butnotonthethreads.

12.Rotatethedrillspindlecounterclockwiseuntil theupper-pipejointisloosebutnotseparated.

13.Releasetheupperwrench.

14.Rotatethecamassemblytothedrillframe, extendthepipe-gripperarmstothepipe,and gripthepipetosupportit.

15.Movethedrillcarriagebackuntilthepipeislined upwiththepipeholderloadposition,illuminating thegreenlight.

16.Rotatethedrillspindlecounterclockwisemoving rearwardslowlyuntilthespindlefullyseparates fromthepipe.

17.Sendthecarriagetotherearstoponthethrust frame.

7.Removethereamerfromtheendoftheleadbar asdirectedbythereamermanufacturer.

8.Releasethelowerwrenchandpulltheleadbar outofthepipeguide.

18.Retractthepipegripperarms.

19.Rotatethepipecamtothedesiredrow.

Note:Filltheoutsiderowsrst.

20.Releasethepipegripperandraisethepipeinto thepipeboxusingthepipeelevators.

21.Rotatethepipegripperpastthethirdrowof pipes.

Important:Ensurethatyoufullyretractthe

pipegripperandrotateitallthewayout; otherwise,thecarriagemaycollidewiththe gripper,damagingthemachine.

22.Movethedrillspindledownthethrustframeand spraythespindlewiththreadjointcompound onceitispositionedundertheapplicator.

23.Rotatethedrillspindleclockwiseandmovethe carriageslowlyforwardtoinsertthespindleinto thefemaleendofthepipesecuredinthelower wrench.

Note:Tightenthejointuntilyoureachnomore

than2,304N∙m(1,700ft-lb).

AfterOperation

AfterOperationSafety

GeneralSafety

•Cleanupanyoilorfuelspills.

•Allowtheenginetocoolbeforestoringthemachine

inanyenclosure.

•Neverstorethemachineorfuelcontainerwhere

thereisanopename,spark,orpilotlight,such asonawaterheateroronotherappliances.

24.Releasethelowerwrenchandcontinue reaming/retractionasneeded.

RemovingtheLastPipeandthe Reamer

Important:Donotpullthedrillheadintothepipe

guideoryoumaydamagethemachineorthedrill head.

1.Usingtheexit-side-lockouttransmitter,enable theexitsidelockout.

2.Afterthereamerhasclearedtheground,if youhavenotalreadydoneso,disconnectthe productbeinginstalledfromthereamer.

3.Connectthedrillinguidpumptoasourceof cleanwater.

4.Turnthepumpontoushcleanwaterthrough thepump,spindle,andreameruntilthewater runsclear.

5.Removeandstorethelastpipe;referto

RemovingDrillPipes(page61).

6.Leavetheleadbarclampedinthelowerwrench, butdonotconnectthedrillspindletothelead bar.

FinishingtheJob

AdjustingtheTJC-sprayVolume

Completethefollowingaftereachdayofuse:

•Connectthehandsprayguntothepumpandclean

themachinewithcleanwater;refertoCleaning

withtheSpray-HoseAttachment(page97).

•Flushthedrillinguidoutofthedrilling-uidpump

withwaterorantifreeze.

Note:Thedrilling-uidpumpmaybedamagedif

thedrilling-uiddriesupinthepump.

•Iftheairtemperatureisbelowfreezingorwill

bebeforethenextuse,refertoPreparingthe

Drilling-FluidSystemforColdWeather(page95).

•Addgreasetothegreasettings;refertoGreasing

theMachine(page68).

•Installtheconsolecovers;referto

Operator-ControlsCovers(page27).

UsingtheTJCApplicator

AdjustingtheApplicatorNozzle

Youcanadjusttheapplicatornozzletospray thread-jointcompound(TJC)eitherinafan-shaped sprayorasastream.

•Forfan-shapedspray—turnthesprayvalveonthe

sideofthenozzlehorizontal(Figure70).

•Forastream—turnthesprayvalveonthesideof

thenozzlevertical(Figure70).

Toadjustthevolumeofthread-jointcompoundthatis deliveredbytheapplicator,completethefollowing:

1.Loosenthejamnutontheadjustmentbolt locatedontopoftheTJC-applicatorpiston (Figure71).

Figure71

1.Adjustmentbolt

2.Jamnut

2.Adjusttheboltasfollows:

3.TJC-applicatorpiston

•T oincreasetheappliedvolumeofcompound,

threadtheboltout(up).

•T odecreasetheappliedvolumeof

compound,threadtheboltin(down).

g218970

3.Whenyouhaveattainedthedesiredapplication volume,tightenthejamnuttosecurethe adjustment.

g023077

Figure70

1.Sprayvalve—fan-shaped spray(horizontal)

2.Sprayvalve—stream (vertical)

FillingtheTJCApplicator

1.Stopthemachineandshutofftheengine.

2.Loosenthewingnutssecuringthecoverstraps tothemachine(BoxAofFigure72).

MovingaDisabledMachine

Wheneverthemachineisstoppedandtheengine isnotrunning,thehydrostaticbrakesautomatically engage.Donotattempttotowthemachineifitcannot moveunderitsownpower.Ifpossible,repairthe machineatthesite.Ifthisisnotpossible,useacrane andaspreaderbartoliftthemachineontoatrailer, usingtheliftpointsshowninFigure73.

Figure72

3.Rotatethecoverandpullthecoverstrapsoffthe retainingbolts(BoxBandCofFigure72).

4.Liftthecoverassemblyoffandoutoftheempty thread-joint-compoundbucket(BoxDofFigure

72).

5.Replacetheemptybucketwithanewfullbucket.

6.Placetheplungerintothenewbucketandlower thecoverassemblyontothebucket.

7.Slidethecoverstrapsovertheretainingbolts androtatethecovertoseatthestrapsonthe bolts.

8.Tightenthewingnuts.

g218947

Figure73

Repeatliftpointsonotherside

g218945

1.Spreaderbar2.Liftpoint

Maintenance

WARNING

Failuretoproperlymaintainthemachinecouldresultinprematurefailureofmachinesystems, causingpossibleharmtoyouorbystanders.

Keepthemachinewellmaintainedandingoodworkingorderasindicatedintheseinstructions.

Note:Determinetheleftandrightsidesofthemachinefromthenormaloperatingposition.Placeaservicetag

onthemachinewhenmaintenanceproceduresarebeingperformed. Replaceallcoversandguardsafteryouserviceorcleanthemachine.Donotoperatethemachinewithout

thecoversorguardsinplace.

Note:Downloadafreecopyoftheelectricalorhydraulicschematicbyvisitingwww.Toro.comandsearching

foryourmachinefromtheManualslinkonthehomepage.

Important:Refertoyourengineowner’smanualforadditionalmaintenanceprocedures.

RecommendedMaintenanceSchedule(s)

MaintenanceService

Interval

Aftertherst50hours

Aftertherst100hours

Aftertherst250hours

Beforeeachuseordaily

Every50hours

Every250hours

MaintenanceProcedure

•Changetheengineoilandengine-oillter.

•Changethegearbox-driveoil.

•Changetheplanetaryoil.

•Greasethemachine.(Greaseimmediatelyaftereverywashing).

•Checktheengine-oillevel.

•Drainthewaterseparator.

•Checktherotarygearboxdriveoil.

•Checkthetracktension.

•Checkthecoolantlevelinthereservoirfortheradiator.

•Checkthehydraulicuidlevel.

•Checkthedrilling-uid-pumpoillevel.

•Cleanthemachinewiththespray-hoseattachment.

•Removetheair-cleanercoverandcleanoutthedebris.Donotremovethelter.

•Checkthebatterycondition

•Checktheplanetary-driveoillevel(Also,checkifexternalleakageisobserved).

•Checkthecoolantlevelintheradiator.

•Checktheair-cleanerlterfordamagewhichcouldcauseanairleak.Replaceif damaged.

•Checkthewholeair-intakesystemforleaks,damage,orloosehoseclamps.

•Checktheconditionoftheengine-drivebelt.

Every400hours

•Changetheengineoilandengine-oillter.

•Checkandreplace(ifnecessary)fuelhosesandengine-coolanthoses.

•Replacethefuel/waterseparatorelement.

•Replacethefuel-lterelement.

•Checktheconditionofthecoolantsystemcomponents.Cleandirtanddebrisfrom themandrepairorreplacethecomponentsasnecessary.

•Changethedrilling-uidpumpoil.

•Calibratethejoysticksandthetravelpendant.

MaintenanceService

Every800hours

Interval

MaintenanceProcedure

•Adjusttheengine-valveclearance(ifnecessary).

•Drainandcleanthefueltank.

•Changetheplanetaryoil(oryearly ,whichevercomesrst).

•Checktherotarygearboxdriveoil(oryearly,whichevercomesrst).

•Changethegearbox-driveoil(oryearly,whichevercomesrst).

•Checktheconcentrationofthecoolantbeforethewinterseason.

•Cleanthecoolingsystem.(Cleanthecoolingsystemifthecoolantbecomesdirtyor rustcolored.)

•Checkthetensionontheenginedrivebelt.

•Changethehydraulic-uidreturnlter.

•Changethehydraulic-pressurelter.

•Changethehydraulicuid.

Every1,500hours

Every2,000hours

Every3,000hours

Yearlyorbeforestorage

Every2years

•CleantheengineEGRcooler.

•Inspecttheenginecrankcase-breathersystem.

•Laporadjusttheengineintakeandexhaustvalves(ifnecessary).

•Inspectandclean(ifnecessary)theengine-emission-controlcomponentsand turbocharger.

•Touchupchippedpaint.

•Replacemovinghoses.

WARNING

Improperlyservicingorrepairingthemachinemaycauseinjuryordeath.

Ifyoudonotunderstandtheserviceproceduresforthismachine,contactyourAuthorized ServiceDealerorseetheservicemanualforthismachine.

WARNING

Operatingthemachinewithoutcoversandguardsinplacemaycausepersonalinjuryordeath.

Replaceallcoversandguardsafteryouserviceorcleanthemachine.Donotoperatethe machinewithoutthecoversorguardsinplace.

Pre-MaintenanceProcedures

Pre-MaintenanceSafety

•Beforeadjusting,cleaning,repairing,orleaving

themachine,dothefollowing:

–Movethemachineonalevelsurface. –Shutofftheengineandremovethekey. –Setthebattery-disconnectswitchtotheOFF

position.

–Waitforallmovingpartstostop.

AccessingInternalComponents

OpeningtheFrontandRearHoods

Use1keytounlockthelatchandpushtheleveropen.

Usethesmallerkeytounlatchthehood.

–Allowmachinecomponentstocoolbefore

performingmaintenance.

•Ifpossible,donotperformmaintenancewhilethe

engineisrunning.Keepawayfrommovingparts.

•Useadequatesupporttosupportthemachineor

componentswhenrequired.

•Carefullyreleasepressurefromcomponentswith

storedenergy.

Figure74

g218949

UsingtheCylinderLock

Lubrication

WARNING

Thethrustframemaylowerwhenitisinthe raisedposition,causingseriousinjuryor death.

Installthecylinderlockbeforeperforming maintenancethatrequiresthethrustframe toberaised.

InstallingtheCylinderLock

1.Starttheengine.

2.Lowerthethrustframetothefully-lowered position.

3.Shutofftheengine.

4.Positionthecylinderlockoverthecylinderrod (Figure75).

5.Securethecylinderlockwiththecotterpinand clevispin(Figure75).

6.TurntheenginetotheONposition,andraisethe thrustframeuntilitrestsonthecylinderlock.

GreasingtheMachine

ServiceInterval:Beforeeachuseordaily(Grease

immediatelyaftereverywashing).

Greasetype:General-purposegrease.

Totalnumberofgreasettings:51

1.Cleanthegreasettingswitharag.

2.Connectagreaseguntoeachtting.

3.Pumpgreaseintothettingsuntilgreasebegins tooozeoutofthebearings(approximately3 pumps).

4.Wipeupanyexcessgrease.

Figure75

g223044

Figure76

OperatorPlatform—1tting

g230470

g220079

Figure77

Carriage—10ttings

Figure78

CamAssembly(OperatorSide)—2ttings

Figure79

LeftSide,FrontCamAssembly—4ttings

g220078

g222835

Figure80

LeftSide,RearCamAssembly—4ttings

g222836

Figure81

Tracks—12ttings(6oneachside)

g222837

Figure83

StakedownMotors—2ttings

g220081

Figure82

StabilizerFeet—8ttings(4oneachfoot)

g220082

Figure84

StakedownCylinders—4ttings(2ttingsoneachcylinder)

g224193

Figure85

LiftCylinder(Drill/CarriageSide;lowergreasettingis

behindthetrackroller)—3ttings

EngineMaintenance

EngineSafety

•Shutofftheenginebeforecheckingtheoilor

addingoiltothecrankcase.

•Donotchangethegovernorspeedoroverspeed

theengine.

g223045

ServicingtheAirCleaner

Checktheair-cleanerbodyfordamagethatcould causeanairleakandreplaceitifitisdamaged.Check theentireintakesystemforleaks,damage,orloose hoseclamps.Also,inspecttherubberintake-hose connectionsattheaircleanerandturbochargerto ensurethattheconnectionsarecomplete.

Servicetheair-cleanerlteronlywhenthe“CheckAir Filter”messageisdisplayedonthedisplay;referto theSoftwareGuideforthemachine.Changingtheair lterbeforeitisnecessaryonlyincreasesthechance ofdirtenteringtheenginewhenyouremovethelter.

Figure86

ThrustFramePivotPin(UndersideoftheMachine)—1

tting

Ensurethatthecoverisseatedcorrectlyandseals withtheair-cleanerbody.

ServicingtheAir-CleanerCover

ServiceInterval:Every50hours—Removethe

air-cleanercoverandcleanoutthe debris.Donotremovethelter.

Checktheair-cleanerbodyfordamagethatcould causeanairleak.Replaceadamagedaircleaner body.

g223046

Cleantheair-cleanercover(Figure87).

Figure87

ServicingtheAir-CleanerFilter

g008909

Figure88

1.Air-cleanercover2.Air-cleanerlatch

2.Removethecoverfromtheair-cleanerbody.

3.Beforeremovingthelter,uselow-pressure air(275kPaor40psi,cleananddry)tohelp removelargeaccumulationsofdebrispacked betweentheoutsideoftheprimarylterandthe canister.

Note:Avoidusinghigh-pressureairthatcould

forcedirtthroughthelterintotheintake.This

g031340

cleaningprocesspreventsdebrisfrommigrating intotheintakewhentheprimarylterisremoved.

4.Removetheprimarylter(Figure89).

Note:Donotcleantheusedelementduetothe

possibilityofdamagetotheltermedia.

ServiceInterval:Every250hours—Checkthe

air-cleanerlterfordamagewhich couldcauseanairleak.Replaceif damaged.

Every250hours—Checkthewholeair-intake systemforleaks,damage,orloosehose clamps.

Theair-intakesystemonthismachineiscontinuously monitoredbyanair-restrictionsensorthatdisplays whenanadvisorywhentoreplacetheairlter.Donot replacetheelementsuntilthisoccurs.

Important:Replacethesecondarylterelement

onlyevery3primarylterservices.Donotremove thesecondaryelementwhencleaningorreplacing theprimaryelement.Theinnerelementprevents dustfromenteringtheenginewhenyouservice theprimaryelement.

Important:Donotoperatetheenginewithoutthe

air-cleanerelements,asthiswouldallowforeign materialtoentertheengineanddamageit.

1.Releasethelatchessecuringtheair-cleaner covertotheair-cleanerbody(Figure88).

Note:Replacethesecondarylterevery3

primarylterservices(Figure90).

g008910

Figure89

1.Primarylter

ServicingtheEngineOil

CrankcaseOilCapacity

11.2L(11.8USqt)withthelter

OilSpecication

Figure90

1.Secondarylter

5.Inspectthenewlterforshippingdamage, checkingthesealingendofthelterandthe body.

Important:Donotuseadamagedelement.

6.Insertthenewlterbyapplyingpressuretothe outerrimoftheelementtoseatitinthecanister.

Important:Donotapplypressuretothe

exiblecenterofthelter,asthismay damagethelter.

7.Cleanthedirt-ejectionportlocatedinthe removablecover.

8.Removetherubberoutletvalvefromthecover, cleanthecavity,andreplacetheoutletvalve.

9.Installthecoverorientingtherubberoutletvalve inadownwardposition—approximatelybetween the5o’clockand7o’clockpositionwhenviewed fromtheend.

10.Securethecoverlatches.

g034926

Usehigh-quality,low-ashengineoilthatmeetsor exceedsthefollowingspecications:

•APIservicecategoryCJ-4orhigher

•ACEAservicecategoryE6

•JASOservicecategoryDH-2

Important:UsingengineoilotherthanAPICJ-4

orhigher,ACEAE6,orJASODH-2maycausethe dieselparticulateltertoplugorcauseengine damage.

Usethefollowingengineoilviscositygrade:

•Preferredoil:SAE15W-40(above0°F)

•Alternateoil:SAE10W-30or5W-30(all

temperatures)

ToroPremiumEngineOilisavailablefromyour AuthorizedServiceDealerineither15W-40or 10W-30viscositygrades.Seethepartscatalogfor partnumbers.

CheckingtheEngine-OilLevel

ServiceInterval:Beforeeachuseordaily—Check

theengine-oillevel.

Theengineisshippedwithoilinthecrankcase; however,theoillevelmustbecheckedbeforeand aftertheengineisrststarted.

Important:Checktheengineoildaily.Ifthe

engine-oillevelisabovetheFullmarkonthe dipstick,theengineoilmaybedilutedwithfuel;

IftheengineoillevelisabovetheFullmark, changetheengineoil.

Thebesttimetochecktheengineoiliswhenthe engineiscoolbeforeithasbeenstartedfortheday. Ifithasalreadybeenrun,allowtheoiltodrainback downtothesumpforatleast10minutesbefore checking.IftheoillevelisatorbelowtheAddmark onthedipstick,addoiltobringtheoilleveltotheFull mark.Donotoverlltheenginewithoil.

Important:Keeptheengineoillevelbetweenthe

upperandlowerlimitsonthedipstick;theengine mayfailifyourunitwithtoomuchortoolittleoil.

Checktheengine-oillevelasshowninFigure91.

Figure91

g220795

g220852

g031256

g220851

Figure92

ChangingtheEngineOiland Engine-OilFilter

ServiceInterval:Aftertherst50hours—Change

theengineoilandengine-oillter.

Every400hours—Changetheengineoiland engine-oillter.

Note:Changetheengineoilandltermorefrequently

whentheoperatingconditionsareextremelydusty orsandy.

1.Starttheengineandletitrun5minutestoallow theoiltowarmup.

2.Movethemachinetoalevelsurface,shutoff theengine,andremovethekey.

3.ChangetheengineoilasshowninFigure93.

4.Changetheengine-oillter(Figure94).

Note:Ensurethattheoil-ltergaskettouches

theengine,andthenanextra3/4turnis completed.

Figure93

AdjustingtheEngine-Valve Clearance

ServiceInterval:Every800hours

Refertoyourengineowner’smanualforthe adjustmentprocedure.

CleaningtheEngineEGR Cooler

ServiceInterval:Every1,500hours

ForinformationoncleaningtheengineEGRcooler, refertoyourengineowner’smanual.

g220797

1.Engine-oillter2.Fuellter

InspectingtheEngine Crankcase-Breather System

ServiceInterval:Every1,500hours

Forinformationoninspectingtheengine crankcase-breathersystem,refertoyourengine owner’smanual.

CheckingandReplacing FuelHosesand Engine-CoolantHoses

ServiceInterval:Every400hours

Forinformationoncheckingandreplacingfuelhoses andengine-coolanthoses,refertoyourengine owner’smanual.

Figure94

LappingorAdjustingthe EngineIntakeandExhaust Valves

ServiceInterval:Every2,000hours

Forinformationonlappingoradjustingtheengine

g031261

intakeandexhaustvalves,refertoyourengine owner’smanual.

InspectingandCleaning

FuelSystem

Engine-Emission-Control Componentsand Turbocharger

ServiceInterval:Every3,000hours

Forinformationoninspectingandcleaningthe engine-emission-controlcomponents,refertoyour engineowner’smanual.

Maintenance

ServicingtheFuelSystem

DrainingtheFuelTank

ServiceInterval:Every800hours—Drainandclean

thefueltank.

Drainandcleanthetankalsoifthefuelsystem becomescontaminatedorifyouarestoringthe machineforanextendedperiodoftime.Useclean fueltoushoutthetank.

ServicingtheWater Separator

ServiceInterval:Beforeeachuseordaily—Drainthe

waterseparator.

Every400hours—Replacethefuel/water separatorelement.

DrainingtheWaterSeparator

1.Placeadrainpanunderthefuellter.

2.Loosenthedrainvalveonthebottomofthelter (Figure95).

Figure95

3.Tightenthevalveafterdraining.

g220798

ReplacingtheWater-Separator Element

1.Placeacleancontainerunderthewater separator.

2.Drainsomefuelbylooseningtheventplugand openingthedrainvalve(Figure95).

3.Cleantheareawherethelterelementmounts tothehead.

4.Removethelterelement.

5.Applyacoatingofcleanfuelorengineoiltothe newO-ringandelementseal.

6.Installthenewltercanisterbyhanduntilthe gasketcontactsthelterhead,thentightenit anadditional1/2turn.

Note:Donotusetools.

7.Closethedrainplug.

8.Withtheventplugstillloosened,turnthekeyto theRunposition(donotstarttheengine)sothat theelectricfuelpumpcanllthenewlter.

9.Whenfuelowsfromtheventplug,closethe ventplug,starttheengine,andcheckforleaks.

2.Removethelterandcleanthe lter-head-mountingsurface(Figure96).

3.Lubricatetheltergasketwithclean,engineoil; refertotheengineowner'smanual(included withthemachine)foradditionalinformation.

4.Installthedryltercanister,byhand,untilthe gasketcontactsthelterhead,thenrotateitan additional1/2turn.

5.TurnthekeytotheRUNpositionsothatthe electricfuelpumpcanllthefuel-ltercanister.

6.Starttheengineandcheckforfuelleaksaround thelterhead.

Note:Correctasnecessarywiththeengineoff.

ReplacingtheFuelFilter Element

ServiceInterval:Every400hours—Replacethe

fuel-lterelement.

1.Cleantheareaaroundthefuel-lterhead (Figure96).

Figure96

1.Engine-oillter2.Fuellter

g220797

ElectricalSystem Maintenance

WARNING

Abatterycontainssulfuricacid,whichcan causeseriousburns;andtheycanproduce explosivegases.

BatterySafety

•Disconnectthebatterybeforerepairingthe

machine.Disconnectthenegativeterminalrst andthepositivelast.Connectthepositiveterminal rstandthenegativelast.

•Chargethebatteryinanopen,well-ventilated

area,awayfromsparksandames.Unplugthe chargerbeforeconnectingordisconnectingthe battery.Wearprotectiveclothinganduseinsulated tools.

ServicingtheBattery

ServiceInterval:Every50hours—Checkthebattery

condition

WARNING

CALIFORNIA

Proposition65Warning

Batteryposts,terminals,andrelated

accessoriescontainleadandlead

compounds,chemicalsknownto

theStateofCaliforniatocause

cancerandreproductiveharm.Wash

handsafterhandling.

•Avoidcontactwithskin,eyes,orclothing; ushaffectedareaswithwater.

•Iftakeninternally,drinklargequantities ofwaterormilk.Donotinducevomiting. Seekmedicalattentionimmediately.

•Keepsparks,ames,andlitcigarettesand cigarsawayfromthebattery.

•Ventilatethebatterywhenyouarecharging itorusingitinanenclosedarea.

•Weareyeprotectionwhenworkingneara battery.

•Washyourhandsafterhandlingabattery.

•Keepthebatteryoutofthereachof children.

WARNING

Ifyoutrytochargeorjumpstartafrozen battery,itcouldbeexplosive,causing personalinjurytoyouorothersinthearea.

Topreventthebatteryelectrolytefrom freezing,keepthebatteryfullycharged.

Important:Beforeweldingonthemachine,

disconnectthenegativecablefromthebatteryto preventdamagetotheelectricalsystem.Also, disconnecttheengineandmachinecontrollers beforeweldingonthemachine.

Note:Checkthebatteryconditionweeklyorafter

every50hoursofoperation.Keeptheterminalsand theentirebatterycasecleanbecauseadirtybattery dischargesslowly.T ocleanthebattery,washthe entirecasewithasolutionofbakingsodaandwater. Rinsewithclearwater.Coatthebatterypostsand cableconnectorswithGrafo112X(skin-over)grease (ToroPartNo.505-47)orpetroleumjellytoprevent corrosion.

WARNING

Exposuretobatteryacidorabattery explosioncancauseseriouspersonalinjury.

Beforeyouserviceabattery,wearface protection,protectivegloves,andprotective clothing.

WARNING

•Sparksoraamecancausehydrogengas inabatterytoexplode.

•Whenyoudisconnectthebatterycables, disconnectthenegative(-)cablerst.

•Whenyouconnectthebatterycables, connectthenegative(-)cablelast.

•Donotshort-circuitthebatterypostswith ametalobject.

•Donotweld,grind,orsmokenearabattery .

Note:Theelectricalsysteminthismachineis12V.

ChargingtheBattery

WARNING

Chargingthebatteryproducesgassesthat canexplode.

Battery-ChargerT able

ChargersettingChargingtime

10A8to10hours

20A

4to6hours(donotexceed 6hours)

Donotsmokenearthebatteryandkeep sparksandamesawayfrombattery.

Important:Keepthebatteryfullycharged.This

isespeciallyimportanttopreventbatterydamage whenthetemperatureisbelow32°F(0°C).

1.Movethemachinetoalevelsurface,shutoff theengine,andremovethekey.

2.Openthefronthood.

3.Cleantheexteriorofthebatterycaseandthe batteryposts.

Note:Connecttheleadsofthebatterycharger

tobatterypostsbeforeconnectingthecharger totheelectricalsource.

4.Lookatthebatteryandidentifythepositiveand negativebatteryposts.

5.Connectthepositiveleadofthebatterycharger tothepositivebatterypost(Figure97).

8.Whenthebatteryisfullycharged,unplug thechargerfromtheelectricalsource,then disconnectthechargerleadsfromthebattery posts(Figure97).

Jump-StartingtheMachine

WARNING

Jump-startingthebatterycanproducegasses thatcanexplode.

Donotsmokenearthebatteryandkeep sparksandamesawayfrombattery.

Note:Thisprocedurerequires2peopletoperform.

Ensurethatthepersonmakingtheconnectionswears theproperfaceprotection,protectivegloves,and clothing.

1.Movethemachinetoalevelsurface,shutoff theengine,andremovethekey.

2.Openthefronthood.

Figure97

1.Positivebatterypost

2.Negativebatterypost

6.Connectthenegativeleadofthebatterycharger tothenegativebatterypost(Figure97).

7.Connectthebatterychargertotheelectrical source.

3.Red(+)chargerlead

4.Black(-)chargerlead

Important:Donotoverchargethebattery.

Note:Chargethebatteryashowninbattery

chargingtable.

3.EnsurethatallcontrolsareintheNEUTRAL position.

4.Sitintheoperatorseatandhavetheother personmaketheconnections.

Note:Ensurethatthejumperbatteryisa12-V

battery.

Important:Ifyouareusinganothermachine

forpower,ensurethatthe2machinesare

g003792

nottouchingeachother.

5.Preparetostarttheengine;refertoStartingand

ShuttingOfftheEngine(page47).

6.Removethecoverfromthejumppost(Figure

98).

DriveSystem Maintenance

CheckingthePlanetary DriveOilLevelPlanetary Drive

ServiceInterval:Every50hours—Checkthe

planetary-driveoillevel(Also,check ifexternalleakageisobserved).

Figure98

1.Jumper-cablepost (negative)

7.Connectthepositive(+)jumpercabletothe

jumppost(Figure98).

8.Connectthenegative(-)jumpercabletoa

groundpoint,suchasanunpaintedboltor chassismember(Figure98).

9.Starttheengine;refertoStartingandShutting

OfftheEngine(page47).

2.Jumper-cablepost (positive)

Important:Iftheenginestartsandthen

stops,donotoperatethestartermotoruntil thestartermotorstopsturning.Donot operatethestartermotorformorethan30 secondsatatime.Wait30secondsbefore operatingthestartermotortocoolthemotor andtobuildupthechargeinthebattery.

10.Whentheenginestarts,havetheotherperson disconnectthenegative(-)jumpercablefrom theframeandthendisconnectthepositive(+) jumpercable(Figure98).

g234645

Oilspecication:SAE85W-140APIclassication levelGL4

Planetarydriveoilcapacity:approximately1.4L (1.5USqt)

ToroPremiumGearOilisavailablefromanAuthorized ServiceDealer.SeethePartsCatalogforpart numbers.

1.Movethemachinetoalevelsurface,shutoff theengine,andremovethekey.

2.Cleantheareaaroundtheoil-levelplugwitha cleaningsolvent(Figure99).

Figure99

1.Oil-levelplug2.Oil-drainplug(6o’clock

position)

3.Rotatetheplanetarydriveuntiltheoilleveland theoil-drainplugsareverticaltotheground(at the6o’clockposition)asshowninFigure99.

4.Removetheoil-levelplug(Figure99).

Note:Theoilleveliscorrectwhenitisuptothe

bottomoftheoil-levelplughole.

5.Iftheoilisbelowthebottomofthehole,addthe speciedoiluntiltheoilislevelwiththebottom ofthehole.

6.Installandtightentheoil-levelplug.

g021828

7.Repeatsteps1through6tocheckthe planetary-driveoillevelontheothersideofthe machine.

ChangingthePlanetary DriveOil

ServiceInterval:Aftertherst250hours—Change

theplanetaryoil.

Every800hours—Changetheplanetaryoil(or yearly,whichevercomesrst).

Note:Changetheoilwhenitiswarm,ifpossible.

1.Movethemachinetoalevelsurface.

2.Cleantheareaaroundtheoil-levelplug(Figure

99).

CheckingtheRotary GearboxDriveOil

ServiceInterval:Beforeeachuseordaily—Check

therotarygearboxdriveoil.

Every800hours—Checktherotarygearbox driveoil(oryearly,whichevercomesrst).

Oilspecication:SAE85W-140APIclassication levelGL4

Rotary-gearboxdriveoilcapacity:approximately

2.7L(5.75USpt)

1.Movethemachinetoalevelsurface,shutoff theengine,andremovethekey.

2.Checktheoillevelonthesight-glassonthe gearboxdrive(Figure100).

3.Rotatetheplanetarydriveuntiltheoil-drainplug isdirectlybelowtheoil-levelplug(Figure99).

4.Shutofftheengineandremovethekey.

5.Placeadrainpanundertheoil-drainplug.

6.Removetheoil-levelplugandtheoil-drainplug.

7.Installtheoil-drainplug.

8.Fillthetrack-driveplanetarywithoiluntiltheoil isevenwiththebottomoftheoil-level-plughole.

9.Installtheoil-levelplug.

10.Repeatsteps1through9tochangethe planetary-driveoilontheothersideofthe machine.

Note:Theoillevelshouldcoverhalfofthe

sight-glass.

Figure100

1.Breathercap

3.Removethebreathercapandaddtheoilintothe gearboxdriveuntiltheoillevelonthesight-glass isatleasthalffull(Figure100).

2.Sight-glass

g220070

ChangingtheRotary GearboxDriveOil

ServiceInterval:Aftertherst100hours—Change

thegearbox-driveoil.

Every800hours—Changethegearbox-driveoil (oryearly,whichevercomesrst).

Note:Changetheoilwhenitiswarm,ifpossible.

1.Movethemachinetoalevelsurfaceandmove thecarriageallthewaytotherearstop.

2.Shutofftheengineandremovethekey.

3.Removethedrainpluganddraintheoil(Figure

101).

g235824

Figure102

6.Fillthegearboxwithoiluntiltheoillevelinthe sightglassismorethanhalffull(Figure100).

7.Installthebreathercap(Figure102).

Figure101

4.Installthedrainplug.

5.Removethebreathercap(Figure102).

g235823

ServicingtheTracks

ServiceInterval:Beforeeachuseordaily—Check

thetracktension.

WARNING

Ifyouremovethetrack-tensiongreasevalve foundinthehydraulic-tracktensioneror loosenittoomuch,greasecanbereleased andmaycauseseriousinjuryordeath.

LooseningtheTrackTension

Ifthetrackseemstight,loosenthetracktensionas follows:

1.Movethemachinetoalevelsurfaceandraise thethrustframeandstabilizerssothatthetracks areraised.

2.Shutofftheengineandremovethekey.

3.Removedirtanddebrisfoundaroundthe track-tensiongreasevalve(Figure103).

Greaseinthehydraulictrackishighly pressurized;ensurethatthetrack-tension greasevalveisnotloosenedmorethan1 revolutionatatime.

TighteningtheTrackTension

Ifthetrackseemsloose,tightenthetracktensionas follows:

1.Movethemachinetoalevelsurfaceandraise thethrustframeandstabilizerssothatthetracks areraised.

2.Shutofftheengineandremovethekey.

3.Removedirtanddebrisfoundaroundthe track-tensiongreasevalve(Figure103).

Important:Ensurethattheareasurrounding

thetrack-tensiongreasevalveiscleanbefore beginningtoadjustthetracktension.

4.Removetheretainingboltsandcoverthathouse thetrack-tensiongreasevalve.

5.Applygreasetothettinguntilthetension reaches22,063kPa(3,200psi)asshownin

Figure103.

Important:Ensurethattheentirearea

surroundingthetrack-tensiongreasevalve iscleanbeforebeginningtoadjustthetrack tension.

4.Removetheretainingboltsandcoverthathouse thetrack-tensiongreasevalve.

5.Turnthetrack-tensiongreasevalve counterclockwisenomorethan1revolution (Figure103).

Note:A1-revolutionturnreleasesgreaseand

loosensthetrack.

6.Whenthetensionreaches3,200psi,turnthe track-tensiongreasevalveclockwisetotighten it.

7.Removeexcessgreasefromaroundthevalve.

8.Installthecoverandretainingbolts.

9.Repeatsteps3through8toloosenthetrack tensionontheotherside.

Figure103

Track-tensiongreasevalveshown

6.Removeexcessgreasefromaroundthevalve.

7.Installthecoverandretainingbolts.

8.Repeatsteps3through7totightenthetrack tensionontheotherside.

g220084

CoolingSystem

CheckingtheCoolantLevel

Maintenance

Coolantspecication:50/50solutionof ethylene-glycolantifreezeandwaterorequivalent

EngineandRadiatorcoolantcapacity:16.77L (17.7USqt)

WARNING

Ifyouremovetheradiatorcapfromahot engine,hotcoolantcouldspray,causing scalding.

•Wearfaceprotectionwhenopeningthe radiatorcap.

•Allowthecoolingsystemtocooldownto below50°C(120°F)beforeremovingthe radiatorcap.

•Followtheinstructionsforcheckingand maintainingtheenginecoolingsystem.

intheReservoir

ServiceInterval:Beforeeachuseordaily

Important:Donotremovetheradiatorllercap

duringthisprocedure.

1.Movethemachinetoalevelsurface,shutoff theengine,andremovethekey.

2.Allowtheenginetocool.

3.Openthefronthood.

4.Checkthecoolantlevelinthereservoir(Figure

104).

WARNING

Coolantistoxic.

•Keepcoolantawayfromchildrenandpets.

•Ifyouarenotusingthesamecoolant again,disposeofitaccordingtolocal environmentalregulations.

CoolingSystemSafety

•Swallowingenginecoolantcancausepoisoning;

keepitoutofreachofchildrenandpets.

•Dischargeofhot,pressurizedcoolantortouching

ahotradiatorandsurroundingpartscancause severeburns.

–Alwaysallowtheenginetocoolatleast15

minutesbeforeremovingtheradiatorcap.

–Usearagwhenopeningtheradiatorcap,and

openthecapslowlytoallowsteamtoescape.

g220074

Figure104

1.Radiatorcap2.Reservoir

5.Addthespeciedcoolantuntilthecoolantlevel is1/2thereservoircapacity.

Note:Ensurethatthecoolantsolutionis

thoroughlymixedbeforellingthereservoir.

CheckingtheCoolantLevel intheRadiator

5.Ifthecoolantlevelislow,addcoolantuntilthe levelisuptothebottomofthellerneck(Figure

105).

ServiceInterval:Every50hours

WARNING

Iftheenginehasbeenrunning,theradiator willbepressurizedandthecoolantinsidewill behot.Ifyouremovethecap,coolantmay sprayout,causingsevereburns.

•Donotremovetheradiatorcaptocheck coolantlevels.

•Donotremovetheradiatorcapwhenthe engineishot.Allowtheenginetocoolfor atleast15minutesoruntiltheradiatorcap iscoolenoughtotouchwithoutburning yourhand.

Note:Thecoolingsystemislledwitha50/50

solutionofwaterandethylene-glycolantifreeze.

1.Movethemachinetoalevelsurface,shutoff theengine,andremovethekey.

2.Allowtheenginetocool.

3.Openthefrontandrearhood.

4.Removetheradiatorcapfromthellerneckof theradiatorandcheckthecoolantlevel(Figure

104andFigure105).

Important:Donotoverlltheradiator.

Note:Iftheradiatorcoolantlevelislowandthe

coolantreservoirlevelisattheFullmark,check forairleaksinthehosebetweentheradiator andthecoolantreservoir.

6.Installtheradiatorllercap,ensuringthatitis tightlysealed(Figure105).

7.Iftheairtemperatureisbelow0°C(32°F),mix theethyleneglycolandwatercompletelyby runningtheengineatoperatingtemperaturefor 5minutes.

CheckingtheCondition oftheCooling-System Components

ServiceInterval:Every400hours/Yearly(whichever

comesrst)

Checktheconditionofthecoolingsystemforleaks, damage,dirt,andloosehosesandclamps.Clean, repair,tighten,andreplacethecomponentsas necessary.

Note:Thecoolantshouldbeuptotheller

neck.

Figure105

Checkingthe Concentrationofthe Coolant

ServiceInterval:Every800hours/Yearly

(whichevercomesrst)—Checkthe concentrationofthecoolantbefore thewinterseason.

Testtheconcentrationofethyleneglycol-based antifreezeinthecoolant.Ensurethatthecoolant hasa50%ethyleneglycoland50%watermixtureor equivalent.

Note:A50%ethyleneglycoland50%distilledwater

mixturewillprotecttheengineto-37°C(-34°F) throughouttheyear.

Usingaconcentrationtester,checktheconcentration ofthecoolantmixturetoensurethatitis50%ethylene glycoland50%distilledwaterorequivalent;referto

g220074

themanufacturer’sinstructionsfortesting.

1.Radiatorcap2.Reservoir

CleaningtheCooling System

ServiceInterval:Every800hours/Yearly(whichever

comesrst)(Cleanthecooling systemifthecoolantbecomesdirty orrustcolored.)

DrainingtheCoolantfromthe System

Important:Donotpourcoolantontotheground

orintoanunapprovedcontainerthatcanleak.

1.Movethemachinetoalevelsurface,shutoff theengine,andremovethekey.

2.Allowtheenginetocool.

3.Openthefronthood.

4.Removetheradiatorcap(Figure105).

5.Placeadrainpanunderthedrainplug(Figure

106).

FlushingtheCoolingSystem

Engineandradiatorcoolantcapacity:16.8L(17.7

USqt)

1.Movethemachinetoalevelsurface,shutoff theengine,andremovethekey.

2.Conditionthecoolingsystemasfollows:

A.Ensurethatthecoolantisdrainedfromthe

radiatorandthatthedrainplugisclosed; refertoDrainingtheCoolantfromthe

System(page87).

B.Addacoolingsystemcleaningsolutionto

theradiatorthroughthellerneck(Figure

107).

Note:Usecleaningsolutionof21g(12

ozdry)ofsodiumcarbonateforevery17 L(18USqt)ofwater;otherwise,usea commerciallyavailableequivalent.Follow thedirectionsthatcomewiththecleaning solution.

Note:Thecoolantcapacityofboththeengine

andtheradiatoris16.8L(17.7USqt).

Figure106

1.RadiatorCap

2.Radiatorhoseanddrain

g220077

Figure107

1.Fillerneck(radiator)3.Coolantsystemcleaning

2.Funnel

C.Closethedrainplug(Figure106).

solution

Important:Donotinstalltheradiator

g220073

plug

cap.

D.Operatetheenginefor5minutesoruntilthe

coolanttemperatureindicates82°C(180° F),andthenshutofftheengine.

6.Opentheradiatordrainplugandallowthe coolantsystemtodraincompletely.

Note:Disposeoftheusedcoolantproperly

accordingtolocalcodes.

7.Cleanthethreadsonthedrainplugandapply3 layersofPTFEsealingtape.

8.Closethedrainplug(Figure106).

CAUTION

Thecleaningsolutionishotandcan causeburns.

Stayawayfromthedischargeendof thecoolantdrain.

E.Openthedrainplugfortheradiator,and

drainthecleaningsolutionintoadrainpan.

F.Cleanthethreadsonthedrainplugand

apply3layersofPTFEsealingtape.

G.Closethedrainplug.

3.Flushthecoolingsystemasfollows:

A.Opentheller-neckcap.

B.Filltheradiatorwithcleanwater(Figure

108).

FillingtheSystemwithCoolant

Important:Youmustllthecoolingsystem

properlytopreventairpocketsinthecooling passages.Failingtoventthecoolingsystem properlycanseverelydamagethecoolingsystem andengine.

Important:Useamixtureof50%ethylene

glycoland50%watermixtureorequivalentin themachine.Thelowestambientoperating temperatureforthismixtureisabove-37°C(-34° F).Iftheambienttemperatureislower,adjustthe mixture.Useamixtureofethyleneglycoland waterorequivalentinthemachineallyear.

1.Movethemachinetoalevelsurface,shutoff theengine,andremovethekey.

2.Removetheradiatorcap(Figure105).

3.Filltheradiatorwithcoolantuntiltheuidlevelis uptothebottomofthellerneck(Figure109).

Figure108

1.Cleanwater

2.Funnel

3.Fillerneck

C.Closetheller-neckcap.

D.Operatetheenginefor5minutesoruntil

thecoolanttemperatureindicates82°C (180°F),andthenshutofftheengine.

CAUTION

Thewaterishotandcancauseburns.

Stayawayfromthedischargeendof thecoolantdrainplug.

E.Openthedrainpluganddrainthewaterinto

adrainpan.

F.Cleanthethreadsonthedrainplugand

apply3layersofPTFEsealingtape.

G.Ifthewaterdrainedfromtheradiatoris

dirty,performsteps3-Athrough3-Euntil thewaterdrainedfromtheradiatorisclean.

H.Closethedrainplug(Figure106).

g220076

Note:Thecoolantcapacityofboththeengine

andtheradiatoris16.8L(17.7USqt).

g220077

Figure109

1.Fillerneck

2.Funnel

3.Coolant(50/50ethylene glycolandwateror equivalent)

4.Installtheradiatorcap(Figure105).

5.Fillthecoolantreservoirwithcoolantuntilitis full.

6.Installthecoolantreservoircap.

7.Starttheengineandrunitathalfthrottlefor5 minutes.

8.shutofftheengineandremovethekey.

9.Wait30minutes,thenchecktheuidlevelinthe coolantreservoir.Ifitislow,addcoolant.

BeltMaintenance

CheckingtheBeltTension

ServiceInterval:Every800hours

ServicingtheEngine-Drive Belt

WARNING

Contactingarotatingbeltcancauseserious injuryordeath.

Shutofftheengineandremovethekeybefore workingnearbelts.

CheckingtheConditionoftheBelt

ServiceInterval:Every250hours

1.Movethemachinetoalevelsurface,shutoff theengine,andremovethekey.

2.Openthefronthood.

3.Inspectthebeltforcuts,cracks,loosecords, grease,oil,twisting,orsignsofabnormalwear (Figure110).

Note:Replacethebeltifitisexcessivelyworn

ordamaged.

1.Movethemachinetoalevelsurface,shutoff theengine,andremovethekey.

2.Openthefronthood.

3.Alignastraightedgeoverthedrivebeltand acrossthepulleys(Figure110).

Figure110

4.Pushthebeltdownatthemidwaypointbetween thefanpulleyandthealternatorpulleyasshown inFigure110.

Note:Therangeofbeltdeectionbetweenthe

straightedgeandthebeltshouldbe7to9mm (0.28to0.35inches),underaloadof10kg(22 lb).

5.Ifthetensionofthebeltisaboveorbelowthe speciedrange,adjustthedrivebelttension; refertoAdjustingtheT ensionoftheBelt(page

90).

g220794

AdjustingtheTensionoftheBelt

1.Movethemachinetoalevelsurface,shutoff theengine,andremovethekey.

2.Openthefronthood.

HydraulicSystem Maintenance

3.Loosenthenutandboltatthepivotpointforthe alternator(Figure111).

Figure111

1.Adjustmentbolt

2.Nut(alternatorpivotpoint)4.Bolt(alternatorpivotpoint)

4.Loosentheadjustmentboltonthealternator (Figure111).

5.Movethealternatorawayfromtheengineto increasethebelttension;movethealternator towardtheenginetodecreasethebelttension (Figure111).

6.Tightenthealternatoradjustmentbolt(Figure

111).

7.Checkthetensionofthebelt;refertoChecking

theBeltT ension(page89).

8.Ifthebelttensioniscorrect,tightenthenutand boltatthepivotpointforthealternator(Figure

111);otherwiserepeatsteps4through7.

3.Alternator

HydraulicSystemSafety

•Seekimmediatemedicalattentionifuidisinjected

intoskin.Injecteduidmustbesurgicallyremoved withinafewhoursbyadoctor.

•Ensurethatallhydraulic-uidhosesandlinesare

ingoodconditionandallhydraulicconnections andttingsaretightbeforeapplyingpressureto thehydraulicsystem.

•Keepyourbodyandhandsawayfrompinhole

leaksornozzlesthatejecthigh-pressurehydraulic uid.

•Usecardboardorpapertondhydraulicleaks.

•Safelyrelieveallpressureinthehydraulicsystem

beforeperforminganyworkonthehydraulic

g021648

system.

ServicingtheHydraulic Fluid

Thehydraulicreservoirislledatthefactorywith approximately102L(27USgallons)ofhigh-quality hydraulicuid.Checkthelevelofthehydraulic

uidbeforetheengineisrststartedanddaily thereafter.Therecommendedreplacementuid

follows:

ToroPremiumAllSeasonHydraulicFluid

(Availablein5gallonpailsor55gallondrums.Contact yourAuthorizedServiceDealerforpartnumbers.)

Alternateuids:IftheT orouidisnotavailable,other uidsmaybeusedprovidedtheymeetallthefollowing materialpropertiesandindustryspecications.Wedo notrecommendtheuseofsyntheticuid.Consultwith yourlubricantdealertoidentifyasatisfactoryproduct.

Note:T orowillnotassumeresponsibilityfordamage

causedbyimpropersubstitutions,souseonly productsfromreputablemanufacturerswhowillstand behindtheirrecommendation.

HighViscosityIndex/LowPourPoint Anti-wearHydraulicFluid,ISOVG46

MaterialProperties:

Viscosity,ASTMD445

ViscosityIndexASTM D2270

42.2cStat40°C(104°F)

7.8cStat100°C(212°F)

158

HighViscosityIndex/LowPourPoint

Anti-wearHydraulicFluid,ISOVG46(cont'd.)

PourPoint,ASTMD97-6°C(-42°F)

IndustrySpecications:VickersI-286-S(QualityLevel),

VickersM-2950-S(Quality

Level),DenisonHF-0

Note:Manyhydraulicuidsarealmostcolorless,

makingitdifculttospotleaks.Areddyeadditive forthehydraulicuidisavailablein20mL(2/3oz) bottles.Onebottleissufcientfor15-22L(4-6 gallons)ofhydraulicuid.Orderthehydraulicoilfrom yourAuthorizedServiceDealer.

Note:Ifambientoperatingtemperaturesexceed43°

C(110°F),contactT oroforuidrecommendations.

CheckingtheHydraulicFluid

ServiceInterval:Beforeeachuseordaily

Checkthehydraulicuidasfollows:

1.Movethemachinetoalevelsurface,shutoff theengine,andremovethekey.

2.Wait10minutestoallowtheenginetocooland thehydraulicoiltostabilize.

3.Ifthelevelislow,openthehydraulic-tankcap, addasmallamountofoilandwait2minutesfor theoilleveltostabilize.

Note:Theoillevelisbetween1/2to2/3full

whentheoilisatambienttemperatureorifthe enginehasnotyetbeenstartedfortheday.

4.Continuetoaddtheappropriateuidinsmall incrementsuntilitreachesthetopoftheller neck.

5.Installthecapontothellerneck.

g220799

Figure112

ChangingtheHydraulic-Fluid

ChangingtheHydraulic-Charge

ReturnFilter

ServiceInterval:Every800hours/Every6months

(whichevercomesrst)

1.Movethemachinetoalevelsurface,shutoff theengine,andremovethekey.

2.Discardtheoldhydraulic-uidreturnlter.

Filter

ServiceInterval:Every800hours/Every6months

(whichevercomesrst)

1.Movethemachinetoalevelsurface,shutoff theengine,andremovethekey.

2.Openthefronthood.

3.Placeadrainpanunderthelter.

4.Usingalterwrench,removethe hydraulic-chargelter(Figure114).

Figure113

3.Installanewhydraulic-uidreturnlter.

g229101

g229100

Figure114

5.Discardtheoldlter.

6.Applyathinlayerofhydraulicoiltotheo-ring ofthelter.

7.Installandtightenthenewlterwithalter wrench.

8.Starttheengine,letitrunidleforapproximately 1minute,thencheckforleaksaroundthe hydraulic-chargelter.

ChangingtheHydraulicFluid

ServiceInterval:Every800hours/Yearly(whichever

comesrst)

Important:Iftheuidbecomescontaminated,

contactyourAuthorizedServiceDealer,because thesystemmustbeushed.Contaminateduid looksmilkyorblackwhencomparedtocleanoil.

Important:Useofanyotherltermayvoidthe

warrantyonsomecomponents.

1.Movethemachinetoalevelsurface,shutoff theengine,andremovethekey.

2.Openthefronthood.

3.Raisethemachineusingproperequipment.

WARNING

Raisingtherearofthemachinerelying solelyonmechanicalorhydraulicjacks couldbedangerous.Themechanical orhydraulicjacksmaynotbeenough supportormaymalfunctionallowingthe machinetofall,whichcouldcauseinjury ordeath.

•Donotrelysolelyonmechanicalor hydraulicjacksforsupport.

•Useadequatejackstandsor equivalentsupport.

4.Placealargedrainingcontainerunderthe hydraulicuidtank.

5.Removethedrainplugfromthebottomofthe tank(Figure115).

g229374

Figure115

6.Cleanthethreadsonthedrainplugandapply3 layersofPTFEsealingtape.

7.Drainthehydraulicuidintothecontainer.

Important:Thecapacityofthe

hydraulic-uidtankis102L(27US gallons),soensurethatyouhaveacontainer ofatleast114L(30USgallons).

8.Installthedrainplugwhenthehydraulicuid stopsdraining.

9.Cleantheareaaroundtheltermountingareas.

10.Placeadrainpanunderthelterandremove thelter(Figure112).

11.Lubricatetheltergasketofeachnewlterand llthemwithhydraulicuid.

12.Screwtheltersonuntilthegasketscontact themountingplates;thentightenthelteran additional1/2turn.

13.Fillthereservoirwithhydraulicuid.

Important:Useonlythehydraulicuids

specied.Otheruidscouldcausesystem damage.

14.Installthereservoircap.

15.Starttheengineanduseallofthehydraulic controlstodistributehydraulicuidthroughout

thesystem.Checkforleaks;thenshutoffthe engine.

Drilling-uidPump

16.Checktheuidlevelandaddenoughtoraise

theleveltotheFullmarkonthedipstick.Donot

overll.

CheckingtheHydraulicLinesand Hoses

ServiceInterval:Every2years—Replacemoving

hoses.

Inspectthehydrauliclinesandhosesdailyfor leaks,kinkedlines,loosemountingsupports,wear, loosettings,weatherdeterioration,andchemical deterioration.Makeallnecessaryrepairsbefore operating.

WARNING

Hydraulicuidescapingunderpressurecan penetrateskinandcauseinjury.

•Makesurethatallhydraulicuidhoses andlinesareingoodconditionandall hydraulicconnectionsandttingsaretight beforeapplyingpressuretothehydraulic system.

Maintenance

Servicingthe Drilling-Fluid-PumpOil

Thedrilling-uidpumpisshippedwithoilinthe crankcase;however,checktheoillevelbeforeand afteryourststarttheengine.

Thecrankcasecapacityis1.9L(2USqt).

Useonlyhigh-qualityengineoilthatmeetsthe followingspecications:

•APIClassicationLevelRequired:CH-4,CI-4

orhigher

•Oil:SAE30-weight,non-detergentoilabove0°

C(32°F)

ToroPremiumEngineOilisavailablefromyour dealer.Seethepartscatalogforpartnumbers.Also, refertotheengineownersmanual,includedwiththe machine,forfurtherrecommendations.

CheckingtheDrilling-Fluid-Pump OilLevel

•Keepyourbodyandhandsawayfrom pinholeleaksornozzlesthatejecthigh pressurehydraulicuid.

•Usecardboardorpapertondhydraulic leaks.

•Safelyrelieveallpressureinthehydraulic systembeforeperforminganyworkonthe hydraulicsystem.

•Seekimmediatemedicalattentionifuid isinjectedintoskin.

HydraulicSystemTestPorts

Thetestportsareusedtotestthepressureinthe hydrauliccircuits.ContactyourAuthorizedService Dealerforassistance.

ServiceInterval:Beforeeachuseordaily—Check

thedrilling-uid-pumpoillevel.

1.Movethemachinetoalevelsurface,shutoff theengine,andremovethekey.

2.Opentherearhood.

3.Removetheoildipstick(Figure116).

g220256

Figure116

4.Ensurethattheoilisattheoil-lllineasshown inFigure116.

Note:Iftheoilisbelowtheoil-llline,refer

tostep8ofChangingtheDrilling-FluidPump

Oil(page95)andaddthenecessaryamount

ofoil.

PreparingtheDrilling-Fluid SystemforColdWeather

ChangingtheDrilling-FluidPump Oil

ServiceInterval:Every400hours—Changethe

drilling-uidpumpoil.

1.Movethemachinetoalevelsurface,shutoff theengine,andremovethekey.

2.Opentherearhood.

3.Allowtheenginetocool.

4.Removethedrainplugandplaceadrainpan underthedrain-plughole(Figure117).

Preparethemachineasfollowsafterdrillingifthe temperaturewillbebelow0°C(32°F).

1.Movethemachinetoalevelsurface,shutoff theengine,andremovethekey.

2.Preparethemachinetocirculatetheantifreeze asfollows:

A.Opentherearhood.

B.Placeadrainpanunderthedrillspindlefor

theleakedantifreeze(Figure118).

Figure117

5.Cleanthethreadsonthedrainplugandapply3 layersofPTFEsealingtape.

6.Allowalloftheoiltodrainintotheoilpan(Figure

117).

7.Installthedrainplug.

8.Removetheoil-llercap(Figure117)andadd approximately1.9L(2USqt)ofoil,oruntil theoilreachestheoil-lllineonthedipstickas showninFigure116.

g220257

g220259

Figure118

C.Ensurethatthecapisinstalledonthe

drilling-uidpumpinlet(Figure119).

Figure119

D.Removethecapfromtheantifreezetankfor

thedrilling-uidpump(Figure120).

A.Opentheantifreezevalveonthefrontside

ofthedrilling-uidpumpasshowninFigure

120.

B.StartthemachineandturnOnthe

drilling-uidpump.

C.Addantifreezetothetankasneeded

(Figure120).

D.Whentheantifreezecomesoutofthedrill

spindle(Figure118),turnthepumpoff.

4.Turnthemachineoff.

5.Installthecapontotheantifreezetank(Figure

120).

6.Closetheantifreezevalve(Figure120).

g220260

Figure120

1.Antifreezetank3.Antifreezevalve(shownin

theONposition)

2.Drilling-uidvalve(shown

intheONposition)

E.Ensurethatthetankisfullofantifreeze

(Figure120).

3.Circulatetheantifreezeasfollows:

g220258

ControlsMaintenance

Cleaning

CalibratingtheJoysticks andtheTravelPendant

ServiceInterval:Every400hours

RefertothejoysticksectionoftheSoftwareGuide forthisprocedure.

Cleaningwiththe Spray-HoseAttachment

ServiceInterval:Beforeeachuseordaily

Themachinecomeswithaspray-hoseattachment thatyoucanusetocleanthemachineandpipes.

Important:Donotsprayanyelectronic

componentofthemachineandensurethatthe hoodisdownbeforecleaningthemachinewith thespray-hoseattachment.

Important:Iftheoutsidetemperatureisbelow

freezing,refertoPreparingtheDrilling-Fluid

SystemforColdWeather(page95)beforecleaning

themachine.

Tousethespray-hoseattachment,performthe followingprocedure:

1.Movethemachinetoalevelsurface,shutoff theengine,andremovethekey.

2.Ensurethatthespray-hoseattachmentswitchis intheOFFposition(Figure121).

Figure121

1.Travelpendantbracket3.Engine,keyswitch

2.Fluidpumpswitch

3.Opentherearhood.

4.Turnthedrilling-uidvalveclockwisetotheOFF position(Figure122).

4.OK-to-startlight

g229102

Figure122

7.Turnthedrilling-uidpumptotheONposition throughthedisplayscreen;refertotheMain DrillFunctionsDisplayedinthePressureScreen intheSoftwareGuide.

8.Usingthespray-hoseattachment,holddownthe leverandspraydownthemachineandpipes.

CleaningPlasticandResin Parts

Avoidusinggasoline,kerosene,paintthinner,etc. whencleaningplasticwindows,theconsole,the instrumentcluster,themonitor,gauges,etc.Useonly water,mildsoap,andasoftclothwhenyouclean theseparts.

Usinggasoline,kerosene,paintthinner,etc.toclean

g234644

aplasticorresinpartwillcauseittodiscolor,crack, ordeform.

1.Antifreezetank3.Antifreezevalve(shownin

2.Drilling-uidvalve(shown intheONposition)

theOFFposition)

5.Connectthespray-hoseattachmenttothetting

(Figure123).

Figure123

6.SetupupthepumptocleanwaterConnectingto

aDrilling-FluidSource(page52).

Turnthespray-hoseattachmentswitchtothe ONposition(Figure122).

g220261

Storage

1.Shutofftheengineandremovethekey.

2.Removedirtandgrimefromtheentiremachine.

Important:Youcanwashthemachinewith

milddetergentandwater.Avoidexcessive useofwater,especiallynearthecontrol panel,engine,hydraulicpumps,andmotors.

3.Servicetheaircleaner;refertoServicingtheAir

Cleaner(page72).

4.Greasethemachine;refertoGreasingthe

Machine(page68).

5.Chargethebattery;refertoChargingthe

Battery(page80).

6.Checkandadjustthetracktension;referto

ServicingtheTracks(page84).

7.Checkthecoolantbeforewinterstorage;referto

CoolingSystemMaintenance(page85).

8.Preparethedrilling-uidpumpforcoldweather;

refertoPreparingtheDrilling-FluidSystemfor

ColdWeather(page95).

9.Checkandtightenallbolts,nuts,andscrews.

Repairorreplaceanypartthatisdamaged.

10.Paintallscratchedorbaremetalsurfaces.Paint isavailablefromyourAuthorizedServiceDealer.

11.Storethemachineinaclean,drygarageor storagearea.Removethekeyfromtheswitch andkeepitinamemorableplace.

12.Coverthemachinetoprotectitandkeepitclean.

Troubleshooting

Problem

Themachineisnotrespondingtothe controlsproperly.

Thestarterdoesnotcrank.

Theenginecranks,butdoesnotstart.

PossibleCauseCorrectiveAction

1.Thejoysticksneedtobecalibrated.

2.Thecamassemblyneedstobe calibrated.

3.Oneofthesensorsisnotresponding.3.Checkthemachinecaninformation

1.TheBATTERY-DISCONNECTswitchisin theOFFposition.

2.Theelectricalconnectionsare corrodedorloose.

3.Afuseisblownorloose.3.Correctorreplacethefuse.

4.Thebatteryisdischarged.

5.Therelayorswitchisdamaged.

6.Astarterorstartersolenoidis damaged.

7.Theinternalenginecomponentshave seized.

1.Anincorrectstartingprocedurewas used.

2.Thefueltankisempty.2.Fillthetankwithfreshfuel.

3.Thefuelshut-offvalveisclosed.3.Openthefuelshut-offvalve.

4.Dirt,water,stalefuel,orincorrectfuel isinthefuelsystem.

5.Thefuellineisclogged.5.Cleanorreplacethefuelline.

6.Thereisairinthefuel.

7.Theglowplugsareinoperative.

8.Thecrankingspeedisslow .

9.Theaircleanerltersaredirty .9.Servicetheairlters.

10.Thefuellterisclogged.10.Replacethefuellter.

11.Thefuelgradeisimproperforcold weatheruse.

12.Thereislowcompression.

13.Theinjectionnozzlesorpumpare malfunctioning.

14.TheETRsolenoidisbroken.

1.Calibratethejoysticks.

2.Calibratethecamassembly;referto theSoftwareGuide.

screen;refertotheSoftwareGuide.

1.TurntheBATTERY-DISCONNECTswitch totheONposition.

2.Checktheelectricalconnectionsfor goodcontact.

4.Chargethebatteryorreplaceit.

5.ContactyourAuthorizedService Dealer.

6.ContactyourAuthorizedService Dealer.

7.ContactyourAuthorizedService Dealer.

1.RefertoStartingandStoppingthe Engine.

4.Drainandushthefuelsystem,then addfreshfuel.

6.Bleedthenozzlesandcheckforair leaksatthefuelhoseconnectionsand ttingsbetweenthefueltankandthe engine.

7.Checkthefuse,glowplugs,andwiring.

8.Checkthebattery ,oilviscosity,and startingmotor(contactyourAuthorized ServiceDealer).

11.Drainthefuelsystemandreplace thefuellter.Addfreshfuelofthe propergradeforambienttemperature conditions.Youmayneedtowarmthe entiremachine.

12.ContactyourAuthorizedService Dealer.

13.ContactyourAuthorizedService Dealer.

14.ContactyourAuthorizedService Dealer.

100

Toro 23803 Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

GeneralSafety

DrillingDangerZone

ProductOverview

GeneralSafety

FuelSafety

GatheringSiteInformation

CheckingthePipeLoadGuard SafetyInterlockFunctions

FuelTankCapacity

LoweringtheStakes

PreparingtheMachinetoLower theStakes

GeneralSafety

SlopeSafety

DieselParticulateFilter Regeneration

DPFAshAccumulation

DPFSootAccumulation

TypesofDieselParticulateFilterRegeneration

PassiveDPFRegeneration

AssistDPFRegeneration

ResetRegeneration

ParkedRegenerationand RecoveryRegeneration

GeneralSafety

AdjustingtheApplicatorNozzle

GreasingtheMachine

EngineSafety

CrankcaseOilCapacity

CheckingtheEngine-OilLevel

ChangingtheEngineOiland Engine-OilFilter

AdjustingtheEngine-Valve Clearance

CleaningtheEngineEGR Cooler

InspectingtheEngine Crankcase-Breather System

CheckingandReplacing FuelHosesand Engine-CoolantHoses

LappingorAdjustingthe EngineIntakeandExhaust Valves

ServicingtheFuelSystem

BatterySafety

CoolingSystemSafety

HydraulicSystemSafety

CalibratingtheJoysticks andtheTravelPendant

Cleaningwiththe Spray-HoseAttachment

Storage

Troubleshooting