Toro 2024 Directional Drill Utility Equipment Operator's Manual

Form No. 3402-234 Rev A
2024 Directional Drill
Model No.
Model No.
Model No.
Model No.
Register at www.Toro.com.
Original Instructions (EN)
23800—Serial No. 313000001 and Up
23800A—Serial No. 314000001 and Up
23800C—Serial No. 314000001 and Up
23800W—Serial No. 314000001 and Up
*3402-234* A
You may contact Toro directly at www.Toro.com for product
and accessory information, help finding a dealer, or to register
your product.
This product complies with all relevant European directives;
for details, please see the separate product specific Declaration
of Conformity (DOC) sheet.
Whenever you need service, genuine Toro parts, or additional
information, contact an Authorized Service Dealer or Toro
Customer Service and have the model and serial numbers of
your product ready. Figure 1 identifies the location of the
model and serial numbers on the product. Write the numbers
in the space provided.
WARNING
CALIFORNIA
Proposition 65 Warning
This product contains a chemical or chemicals
known to the State of California to cause cancer,
birth defects, or reproductive harm.
Diesel engine exhaust and some of its
constituents are known to the State of
California to cause cancer, birth defects,
and other reproductive harm.
Because in some areas there are local, state, or federal
regulations requiring that a spark arrester be used on the
engine of this machine, a spark arrester is available as
an option. If you require a spark arrester, contact your
Authorized Toro Service Dealer.
Genuine Toro spark arresters are approved by the USDA
Forestry Service.
Figure 1
Important: It is a violation of California Public
Resource Code Section 4442 to use or operate the engine
on any forest-covered, brush-covered, or grass-covered
land without a spark arrester muffler maintained in
working order, or the engine constricted, equipped, and
maintained for the prevention of fire. Other states or
federal areas may have similar laws.
1. Model and serial number location
Model No.
Serial No.
The enclosed Engine Owner's Manual is supplied for
information regarding the US Environmental Protection
Agency (EPA) and the California Emission Control
Regulation of emission systems, maintenance, and
warranty. Replacements may be ordered through the
engine manufacturer.
This manual identifies potential hazards and has safety
messages identified by the safety alert symbol (Figure 2),
which signals a hazard that may cause serious injury or death
if you do not follow the recommended precautions.
For radio frequency compliance information, refer to
your Compliance Statement Addendum that pertains
to your country.
Figure 2
1. Safety alert symbol
Introduction
This manual uses 2 words to highlight information.
Important calls attention to special mechanical information
and Note emphasizes general information worthy of special
attention.
This machine is a directional drill intended for underground
drilling and pullback operation for utility lines including:
electrical, gas, communication, water, etc. It is designed to
operate a wide variety of attachments each of which perform
a specialized function.
Read this information carefully to learn how to operate and
maintain your product properly and to avoid injury and
product damage. You are responsible for operating the
product properly and safely.
© 2016—The Toro® Company
8111 Lyndale Avenue South
Bloomington, MN 55420
2
Contact us at www.Toro.com.
Printed in the USA.
All Rights Reserved
Contents
Priming the Fuel System ..........................................84
Replacing the Fuel Filters.........................................85
Checking Fuel Lines and Connections .......................86
Draining and Cleaning the Fuel Tank.........................86
Electrical System Maintenance ....................................86
Servicing the Battery...............................................86
Charging the Battery ...............................................87
Jump-starting the Machine.......................................88
Drive System Maintenance .........................................89
Checking the Oil Level for the Planetary
Drive ................................................................89
Changing the Oil for the Planetary Drive....................89
Checking the Oil for the Gearbox Drive.....................89
Changing the Oil for the Gearbox Drive.....................90
Servicing the Tracks................................................91
Cooling System Maintenance ......................................92
Checking the Coolant Level in the Reservoir ...............92
Checking the Coolant Level in the Radiator ................92
Checking the Condition of Cooling-system
Components ......................................................93
Checking the Concentration of the Coolant ................93
Cleaning the Cooling System....................................93
Belt Maintenance ......................................................95
Servicing the Engine-drive Belt ................................95
Hydraulic System Maintenance ....................................97
Servicing the Hydraulic Fluid ...................................97
Drilling-fluid Pump Maintenance ............................... 100
Servicing the Drilling-fluid-pump Oil ...................... 100
Preparing the Drilling-fluid System for Cold
Weather........................................................... 101
Cleaning ................................................................. 102
Cleaning with the Spray-hose Attachment ................ 102
Cleaning Plastic and Resin Parts.............................. 103
Storage ...................................................................... 103
Troubleshooting ......................................................... 104
Index ........................................................................ 107
Safety ........................................................................... 4
Training ................................................................. 4
Preparation............................................................. 4
General Operation .................................................. 4
Driving Safety ......................................................... 5
Drilling Safety ......................................................... 6
Maintenance and Storage.......................................... 8
Noise and Vibration Levels....................................... 8
Safety and Instructional Decals ................................. 9
Product Overview .........................................................18
Controls ...............................................................21
Operator Platform ..............................................21
Control Panel .....................................................31
Left Joystick—Mode I .........................................32
Left Joystick—Mode II........................................33
Right Joystick—Mode I .......................................34
Right Joystick—Mode II ......................................35
Rear Control Panel..............................................36
Drill Frame and Stabilizer Controls........................37
Drive Pendant ....................................................37
Drill Pendant......................................................38
Stake-Down Levers.............................................38
Specifications ........................................................39
Attachments/Accessories........................................39
Operation ....................................................................40
Understanding Horizontal Directional Drilling
........................................................................40
Gathering Site Information......................................41
Planning the Bore Path............................................43
Understanding and Using the Exit-side-lockout
System (Standard Range) .....................................48
Understanding and Using the Exit-side-lockout
System (Long Range) ..........................................50
Preparing the Job Site and the Machine ......................52
Drilling the Bore ....................................................63
Backreaming and Pullback .......................................66
Finishing the Job ....................................................68
Using the TJC Applicator ........................................68
Moving a Disabled Machine .....................................70
Maintenance .................................................................71
Recommended Maintenance Schedule(s) ......................71
Premaintenance Procedures ........................................72
Opening the Front Hood.........................................72
Opening the Rear Hood ..........................................73
Using the Cylinder Lock ..........................................74
Lubrication ...............................................................75
Greasing the Machine .............................................75
Engine Maintenance ..................................................77
Cleaning the Crankcase-vent Tube ............................77
Servicing the Air-cleaning System .............................78
Servicing the Engine Oil and Filter............................80
Adjusting the Valve Clearance ..................................82
Servicing the Spark Arrestor (If Equipped).................83
Fuel System Maintenance ...........................................83
Draining Water from the Fuel Filter...........................83
Draining Water from the Fuel Tank ...........................84
3
Preparation
Safety
• Evaluate the terrain to determine what accessories and
Improper use or maintenance by the operator or owner
can result in injury. To reduce the potential for injury,
comply with these safety instructions, and pay attention to
the safety alert symbol , which means Caution, Warning, or
Danger—“personal safety instruction.” Failure to comply
with the instructions may result in personal injury or
death.
attachments are needed to properly and safely perform
the job. Only use accessories and attachments approved
by the manufacturer.
• Wear appropriate clothing; including a hard hat, safety
glasses, long pants, safety shoes, and hearing protection.
Important: Long hair, loose clothing or jewelry may
get tangled in moving parts.
Important: This machine was manufactured according
to the appropriate regulatory standards in effect at the
time of manufacture. Modifying this machine in any
way may cause it to be out of compliance with those
standards and with the instructions in this Operator’s
Manual. Modifications to this machine should only be
made by either the manufacturer or an Authorized Toro
Dealer.
• Inspect the area where the equipment is to be used and
ensure that all objects are removed from the machine
before use.
• Use extra care when handling fuels. They are flammable
and vapors are explosive.
– Use only an approved container.
This product is capable of amputating hands and feet. Follow
all safety instructions to avoid serious injury or death.
– Do not remove the fuel cap or add fuel with the
engine running. Allow the engine to cool before
refueling. Do not smoke near the machine when the
engine is running.
The owner/user can prevent and is responsible for accidents
or injuries occurring to people, or damage to property.
– Do not refuel or drain the machine indoors.
Important: Before operating in an area with
high-voltage lines or cables, contact a “One-Call
System Directory” service. In the USA, call 811 or
your local utility company. If you do not know your
local utility company’s phone number, call the national
number (USA and Canada only) at 1-888-258-0808. Also,
contact any utility companies that are not participants
of the “One-Call System Directory” service. Please
refer to Drilling Near Utility Lines (page 6) for more
information.
• Check that the operator's presence controls, safety
switches, and shields are attached and functioning
properly. Do not operate the machine unless they are
functioning properly.
General Operation
• Do not run the engine in an enclosed area.
• Do not operate without the guards securely in place. Be
sure all interlocks are attached, adjusted, and functioning
properly.
Training
• Do not change the engine governor setting or overspeed
• Read the Operator's Manual and other training material.
the engine.
Note: If the operator(s) or mechanic(s) cannot read
English, it is the owner's responsibility to explain this
material to them.
• Keep away from moving machine parts and pipes.
• Do not operate the machine when under the influence
of alcohol or drugs.
• Become familiar with the safe operation of the equipment,
• Do not leave the machine running unattended. Stop the
operator controls, and safety signs.
engine and remove the key before leaving.
• All operators and mechanics should be trained. The
• Locate the pinch-point areas marked on the machine and
owner is responsible for training the users.
attachments and keep hands and feet away from these
areas.
• Do not let children or untrained people operate or service
the equipment. Local regulations may restrict the age of
the operator.
• Lightning can cause severe injury or death. If lightning
is seen or thunder is heard in the area, do not operate
the machine; seek shelter.
4
Driving Safety
• Use care when loading or unloading the machine onto a
You drive the machine to and from the work site with the use
of a tethered remote. When driving the machine, observe the
following safety precautions:
• Watch for traffic when crossing roadways.
trailer.
• Check for overhead clearances (i.e. branches, doorways,
electrical wires) before driving under any objects and do
not contact them.
• Operate the drive pendant alongside the machine outside
of the danger zone (Figure 3).
• When driving on a slope, the operator should be up-slope
• Keep all bystanders away while moving the machine.
from the machine.
• Do not carry passengers on the machine.
The following illustration displays the safe distance that all
individuals must maintain while moving the machine.
• Watch for the turning-radius sweep of the drill frame, as
the center of the turning radius is the end of the track.
• Moving the machine with the tethered remote can
be erratic; move slowly when using the remote for
movement.
2
3
4
X
1
1
1
G021 118
3
4
Figure 3
Driving Danger Zone
1. 1.8 m (6 ft) safety distance
3. Turning-radius center
2. Operator
4. 2.4 m (8 ft) safety distance
5
4
Drilling Safety
Drilling Danger Zone
• Always lower the safety bar before drilling (Figure 4).
The danger zone is the area within and around the machine
where a person is exposed to the risk of injury. This proximity
includes where a person can be reached by operational
movement of the machine, its working devices, auxiliary
equipment, or swinging/falling equipment.
• Ensure that no one approaches a pipe while it is spinning.
The pipe can snag on clothing and cause amputation
or death. Always engage the Exit-side Lockout before
anyone approaches the front of the machine, bit, reamer,
or pipe.
Note: The danger zone defines the amount of space
needed for safe drilling operation, including movement of
the carriage.
The following illustration displays the safe distance that must
be kept by all individuals while drilling.
2
3
1
1
G021 117
Figure 4
Drilling Danger Zone
1. 3 m (10 ft) safety distance
3. 1.8 m (6 ft) safety distance
2. Safety bar
Drilling Near Utility Lines
When working near buried utility lines, safety precautions
must be taken.
Important: Before operating in an area with
high-voltage lines or cables, contact a “One-Call
System Directory” service. In the USA, call 811 or
your local utility company. If you do not know your
local utility company’s phone number, call the national
number (USA and Canada only) at 1-888-258-0808. Also,
contact any utility companies that are not participants
of the “One-Call System Directory” service. Please
refer to Drilling Near Utility Lines (page 6) for more
information.
6
Utility Line Color
Refer to the following table for the proper utility line and the corresponding utility line color (USA and Canada).
Utility Line
Utility Line Color
Electric
Red
Telecommunication, alarm or signal, cables, or conduit
Orange
Natural gas, oil, steam, petroleum, or other gaseous or flammable
material
Sewer and drain
Yellow
Drinking water
Blue
Reclaimed water, irrigation, and slurry lines
Purple
Temporary survey markings
Pink
Proposed excavation limits
White
Green
Gas Line Safety
Electrical Line Safety
WARNING
WARNING
If you damage a gas line, an immediate explosion
and fire hazard could occur. Leaking gas is both
flammable and explosive and may cause serious
injury or death.
• Do not smoke while operating the machine.
• Shut off the machine and remove the key.
• Remove all individuals from the work area.
• Immediately contact the proper emergency and
utility authorities to secure the area.
If you leave the seat of the machine or touch
any part of the machine when it is charged with
electricity, serious injury or death could result.
Do not leave the seat of the machine if the machine
is charged with electricity.
In the event of an electric strike that charges the machine, the
Zap-Alert Electric Strike alarm system will sound for as long
as the machine is charged with power.
Note: Immediately contact the proper emergency and utility
authorities to secure the area in the case that the machine is
charged and you cannot leave the seat of the machine.
Water Line Safety
If you damage a water line, a potential flood hazard
could occur.
• Shut off the machine and remove the key.
• Remove all individuals from the work area.
• Immediately contact the proper emergency and
utility authorities to secure the area.
Note: It is possible to strike a utility line without the machine
becoming charged.
• The alarm will sound if the drill contacts an electrical
power source.
• It is likely (but not always the case) that the power-source
interrupter or breaker will trip, but to ensure your safety,
consider that the machine may be conducting electricity.
Communication Line Safety
• Do not attempt to leave the machine.
Important: Refer to Electrical Line Safety (page 7) if a
communication line is damaged.
Note: You will be safe as long as you do not leave the
seat of the machine.
CAUTION
• Touching any part of the machine may ground you.
If you damage the fiber-optic cable and look into
the exposed highly-intense light, you may harm
your eyes.
• Shut off the machine and remove the key.
• Remove all individuals from the work area.
• Immediately contact the proper emergency and
utility authorities to secure the area.
• Do not allow another individual to touch or approach
the machine when charged.
• The alarm may sound if a communication line is broken,
but until you are certain, you must consider the alarm to
be an electric strike.
7
Maintenance and Storage
– Do not refuel the machine indoors.
• Do not touch parts which may be hot from operation.
– Do not store the machine or fuel container inside
where there is an open flame, such as near a water
heater or furnace.
Allow them to cool before attempting to maintain, adjust,
or service.
– Do not fill a container while it is inside a vehicle,
trunk, pick-up bed, or any surface other than the
ground.
• Lower the thrust frame, stop the engine, and remove
the key. Wait for all movement to stop before adjusting,
cleaning, or repairing.
– Keep container nozzle in contact with the tank during
filling.
• Clean debris from attachments, drives, mufflers, and
engine to help prevent fires. Clean up oil or fuel spillage.
• Use only genuine Toro replacement parts to ensure that
• Let the engine cool before storing and do not store near
original standards are maintained.
flame.
•
•
•
•
• Keep your body and hands away from pin hole leaks
Do not store fuel near flames or drain indoors.
or nozzles that eject high pressure hydraulic fluid. Use
cardboard or paper to find hydraulic leaks; do not use
your hands. Hydraulic fluid escaping under pressure can
penetrate skin and cause injury requiring surgery within a
few hours by a qualified surgeon or gangrene may result.
Park the machine on level ground.
Do not allow untrained personnel to service the machine.
Carefully release pressure from components with stored
energy.
• Keep hands and feet away from moving parts. If possible,
Noise and Vibration Levels
do not make adjustments with the engine running.
• Disconnect the battery before making any repairs.
WARNING
Disconnect the negative terminal first and the positive
last. Reconnect positive first and negative last.
The operator must wear hearing protection when
operating the machine. Failure to wear hearing
protection may cause hearing impairment.
• Charge batteries in an open, well ventilated area, away
from spark and flames. Unplug the charger before
connecting or disconnecting it from the battery. Wear
protective clothing and use insulated tools.
Sound Pressure Level
• Battery acid is poisonous and can cause burns. Avoid
This unit has a sound pressure level at the operator’s ear of 92
dBA, which includes an Uncertainty Value (K) of 1 dBA.
contact with skin, eyes, and clothing. Protect your face,
eyes, and clothing when working with a battery.
Sound pressure level was determined according to the
procedures outlined in EN 791.
• Battery gases can explode. Keep cigarettes, sparks and
flames away from the battery.
• Keep all parts in good-working condition and all hardware
Sound Power
tightened. Replace all worn or damaged decals.
This unit has a guaranteed sound power level of 113 dBA,
which includes an Uncertainty Value (K) of 3.75 dBA.
• If any maintenance or repair requires the frame to be
in the raised position, secure the frame in the raised
position with the hydraulic cylinder lock; refer to Using
the Cylinder Lock (page 74).
•
•
•
•
The sound power level was determined according to the
procedures outlined in ISO 4871.
Keep nuts and bolts tight.
Keep equipment in good condition.
Vibration Level
Do not tamper with safety devices.
Measured vibration level for right hand = 0.3 m/s2
Keep the machine free of grass, leaves, or other debris
build-up. Clean up oil or fuel spillage. Allow the machine
to cool before storing.
Measured vibration level for left hand = 0.8 m/s2
Measured vibration level for whole body = 0.17 m/s2
• Use extra care when handling fuels. They are flammable
Uncertainty Value (K) = 0.08 m/s2
and vapors are explosive.
Measured values were determined according to the procedures
outlined in EN ISO 20643.
– Use only an approved container.
– Do not remove the fuel cap or add fuel when the
engine is running. Allow the engine to cool before
refueling. Do not smoke.
8
Safety and Instructional Decals
Safety decals and instructions are easily visible to the operator and are located near any area of potential
danger. Replace any decal that is damaged or lost.
Battery Symbols
Some or all of these symbols are on your battery
1. Explosion hazard
6. Keep bystanders a safe
distance from the battery.
2. No fire, open flame, or
smoking.
7. Wear eye protection;
explosive gases can
cause blindness and other
injuries
3. Caustic liquid/chemical
burn hazard
4. Wear eye protection
8. Battery acid can cause
blindness or severe burns.
9. Flush eyes immediately
with water and get medical
help fast.
5. Read the Operator's
Manual.
10. Contains lead; do not
discard.
125-6118
1. Crushing hazard, machine movement—read the Operator’s
Manual.
117-2718
125-6120
9
1. Raise drill carriage
4. Lower left stabilizer
2. Lower drill carriage
5. Raise right stabilizer
3. Raise left stabilizer
6. Lower right stabilizer
125-6137
125-6108
1. Thrown object hazard—read the Operator’s Manual.
125-6694
125-6121
1. Engine—heating light
5. Fluid pump on
2. Engine—stop
6. Fluid pump off
3. Engine—run
7. Drill-pendant receptacle
4. Engine—start
8. Drive-pendant receptacle
1. Tie-down point
10
125-6119
125-8473
1. Explosion hazard—wear
eye protection.
3. Fire hazard—keep open
flames away.
2. Caustic liquid/chemical
burn hazard—rinse
affected area and seek
medical assistance.
4. Poison hazard—do not
tamper with the battery.
1. Entanglement hazard—keep away from moving objects.
125-6126
1. Entanglement hazard—keep away from moving parts.
125-6114
1. Stored energy hazard—do not use tools; read the
Operator’s Manual.
11
125-6110
1. Crushing hazard—do not stand under any part of the
machine.
125-6128
125-6131
1. High pressure fluid hazard, injection into the body—read
the Operator’s Manual before performing maintenance.
1. Warning—stay at least 3 m (10 ft) away from the machine.
125-6115
1. Crushing hazard—deploy cylinder locks before performing
maintenance.
125-6130
1. Warning—read the Operator’s Manual; stay at least 3 m (10 ft) away from the front and rear of the machine and 1.8 m (6 ft)
away from the sides of the machine.
12
125-6123
1. Load pipes from back row first.
125-6109
1. Electrical shock hazard—when the Zap-Alert system is
activated by a power strike, do not leave the operator’s
position or touch the ground and the machine at the same
time; the machine will be energized with electrical power.
125-6124
1. Center the pipe joint between the upper and lower
wrenches.
125-6111
1. Stake up
6. Stake up
2. Stake down
7. Stake spin
counterclockwise
8. Stake down
3. Stake spin
counterclockwise
4. Stake spin clockwise
5. Left stake
9. Stake spin clockwise
10. Right stake
125-6122
1. Pipe row
13
125-6140
1. Rotate the chair.
125-6107
1. Crushing hazard of hand and foot—keep hands and feet
away.
125-6152
1. Move seat forwards and backwards.
125-6116
1. Falling hazard—do not move the machine when someone
is in the operator’s position.
14
125-6112
1. Exit-side lockout—reset light
14. Work lights—Off
2. Exit-side lockout—drill-enabled light
15. Press and hold to increase engine speed.
3. Receiver-battery-status light
16. Engine speed
4. Engine—start
17. Press and hold to decrease engine speed.
5. Press down to stop the engine; pull up to start the engine.
18. Mode I—left trigger released, extends pipe gripper toward
drill frame; left trigger pressed, opens lower wrench. Mode
II—spin drill spindle clockwise.
6. Reset Zap-Alert system
19. Mode I—left trigger released, extends pipe gripper toward
pipe holder; left trigger pressed, closes lower wrench. Mode
II—spin drill spindle counterclockwise.
7. Zap-Alert system triggered
20. Mode I—left trigger released, lowers pipe elevator; left trigger
pressed, opens upper wrench. Mode II—left trigger released,
extends pipe gripper toward drill frame; left trigger pressed,
opens upper wrench.
8. Unlock exit-side lockout
21. Mode I—left trigger released, raises pipe elevator; left trigger
pressed, closes upper wrench. Mode II—left trigger released,
extends pipe gripper toward pipe holder; left trigger pressed,
closes upper wrench.
9. Reset exit-side lockout
22. With trigger released, rock forward to rotate pipe loader
toward pipe cam, rock backward to rotate pipe loader toward
drill frame.
23. With trigger released, upper button closes pipe gripper, lower
button opens pipe gripper.
10. Engage drive movement and setup functions
11. Engage drill carriage movement and other drill functions
24. With trigger pressed, rock forward to rotate the upper wrench
counterclockwise to loosen a joint; rock rearward to rotate the
upper wrench clockwise to tighten a joint.
12. Work lights—On
25. With trigger pressed, press front or rear button to resume
the previously set auto-drill speed; press and hold the front
button to increase the auto-drill speed; press and hold the
rear button to decrease the auto-drill speed.
13. Work lights
15
125-1645
1. Pull back drill carriage
6. Wrench controls on
2. Reverse left track
7. Drill spindle clockwise spin
3. Forward left track
8. Forward right track
4. Forward drill carriage
9. Reverse right track
5. Drill fluid pump on
10. Drill spindle
counterclockwise spin
125-6125
1. Warning—read the
Operator’s Manual.
2. Explosion hazard;
electrical shock
hazard—do not dig before
calling local services.
3. Press to apply tread-joint
compound.
4. Press and hold for
maximum drilling fluid
pressure; release to stop
the flow.
5. Press to turn the
drilling-fluid pump on
or off.
6. Press and hold to move
the drill carriage at high
speed up or down the drill
frame.
7. Mode I—spin drill spindle
clockwise. Mode II—left
trigger pressed, open the
lower wrench; left trigger
released, raise the pipe
elevator.
8. Mode I—spin drill spindle
counterclockwise. Mode
II—left trigger pressed,
close the lower wrench;
left trigger released, lower
the pipe elevator.
125-1641
9. Thrust the drill carriage
forward.
1. Forward left
6. Forward right
2. Increase rpm
7. High
3. Engine speed
8. Track speed
4. Decrease rpm
5. Reverse left
9. Low
10. Reverse right
10. Pull the drill carriage
rearward.
125-1621
1. Press the operator presence switch to enable machine
movement.
16
125-1622
1. Pull up to start the engine.
2. Push down to stop the
engine.
125-6127
1. Cutting/dismemberment hazard, fan—keep away from
moving parts.
125-6129
1. Hot surface—keep away from hot surfaces.
114-9600
1. Read the Operator's Manual.
17
Product Overview
Figure 5
1. Drill carriage
6. Front hood
2. Zap-alert strobe
7. Right stabilizer
3. Operator seat
8. Rear hood
4. Control panel
9. Thrust frame
5. Track
18
Figure 6
1. Stake-down cage
5. Rear-control panel
2. Pipe holder
6. Left stabilizer
3. Safety bar
7. Stake-down plate
4. Drilling-fluid-pump inlet
19
Figure 7
4. Upper wrench
1. Thrust frame
2. Drill carriage
5. Lower wrench
3. Drill spindle
6. Pipe wiper
20
Controls
Operator-Controls Covers
Refer to the following sections for the appropriate machine
controls:
The covers protect the operator controls from adverse
weather conditions, such as rain, wind, sunlight, etc. Remove
them before using the machine and replace them before
leaving the machine for the day. Each cover is secured with 2
screws as shown in Figure 9.
• Operator Platform
• Monitor
• Control Panel
• Left Joystick—Mode I
• Left Joystick—Mode II
• Right Joystick—Mode I
• Right Joystick—Mode II
• Exit-Side-Lockout System (Standard Range)
• Exit-Side-Lockout System (Long Range)
• Rear Control Panel
• Drill Frame and Stabilizer Controls
• Drive Pendant
• Drill Pendant
• Stake-Down Levers
• Battery-Disconnect Switch
Figure 9
1. Screws
Operator Platform
The operator platform, located on the right, front corner of
the machine, contains most of the controls you use to operate
the drilling functions of the machine.
2. Covers
Operator-Platform Latch
The operator platform swings out away from the machine,
making room for you to sit. It has 4 positions: travel (swung
all the way into the machine), full-out, and 2 intermediate
positions. Return the platform to the TRAVEL position before
moving the machine.
To release the platform and swing it out or in, press down on
the rear platform latch (Figure 10).
Figure 8
1. Operator display
3. Right joystick
2. Left control panel and
joystick
Figure 10
1. Rear platform latch
21
Control-select Screen
To release the platform and swing it out or in, press up on the
front platform latch (Figure 11).
When you power up the machine, this is the screen that
appears after the start-up screen.
The 2 control layouts that the operator can choose from
consist of the following:
• Mode I—Places the drilling functions on right joystick,
while the left joystick operates the pipe loader and the
wrench functions (Figure 13)
Press button number 4 to select this function (Figure 13).
• Mode II—This function splits the drilling, wrench, and
pipe loading between the left and right joysticks (Figure
13)
Press button number 8 to select this function (Figure 13).
Figure 11
1. Front platform latch
Monitor
Start-up Screen
When you power up the machine, this is the first screen that
appears (Figure 12).
The start-up screen appears whenever you press the ESC
button (found in the bottom-left corner of the screen) from
the first 3 pages of the display.
Note: No keys are active from this screen.
Figure 13
Control-select Screen
1
5
2
6
3
MODEL
DD2024
4
ESC
1. Mode I
2. Mode II
Note: If a selection is not made within 5 seconds, the screen
will default to the previous setting and will go to the Main
Operating Screen (page 23).
7
8
OK
g025815
Figure 12
Start-up Screen
22
Machine-information Screen
Main Operating Screen
This screen contains the following information:
To access this screen, press button 4 or the down arrow on
the Machine-information Screen (page 23).
• The machine model and serial number (Figure 14).
The main operating screen displays the engine-rpm gauge,
the fuel-quantity gauge, and the engine-temperature gauge
(Figure 15).
• The number of engine hours for the machine (Figure 14).
• The number of drilling fluid-gallons used and the number
of re-settable drilling-fluid gallons used (Figure 14).
The low-fuel indicator lights up on the main operating screen
when the machine is running low on fuel (Figure 15).
Note: Press button 3 to reset the number of drilling-fluid
gallons since the last reset (Figure 14).
Press button number 4 to select the horsepower control
(Figure 15).
2
1
3
5
1
6
2
18
12
24
7
3
6
30
n/min
x 100
8
4
Figure 14
Machine-information Screen
1. Model and machine serial
number
2. Number of engine hours
OK
ESC
G021246
4. Reset drilling-fluid gallons
used
5. Next screen
5
4
Figure 15
Main Operating Screen
3. Total number of
drilling-fluid gallons used
and resettable drilling-fluid
gallons used
1. Fuel gauge
4. Low-fuel indicator
2. Engine-speed (rpm) gauge 5. Horsepower control
3. Coolant-temperature
gauge
23
Main Drill Functions Displayed in Pressure Screen
Main Drill Functions Displayed in Torque Screen
To access this screen, press the down arrow on the Main
Operating Screen (page 23).
To access this screen, press the down arrow on the Main Drill
Functions Displayed in Pressure Screen (page 24).
This screen provides measurements on rotary pressure in psi,
drilling-fluid pressure in psi, carriage pressure in psi, and
drilling-fluid flow rate in gpm (Figure 16).
This screen provides measurements on rotary torque in
ft-lbs, drilling-fluid pressure in psi, carriage force in lbs, and
drilling-fluid flow rate in gpm (Figure 17).
There are also 4 indicators (listed from top to bottom in the
middle of the screen), which indicate the following:
There are also 4 indicators (listed from top to bottom in the
middle of the screen), which indicate the following:
• Drilling and/or engine-error code warning (Figure 16)
• Drilling and/or engine-error code warning (Figure 17)
• Low-fuel warning (Figure 16)
• Low-fuel warning (Figure 17)
• Drilling fluid is in the On position (Figure 16)
• Drilling fluid is in the On position (Figure 17)
• Auto drilling is in the On position (Figure 16)
• Auto drilling is in the On position (Figure 17)
Figure 16
Main Drill Functions Displayed in Pressure Screen
Figure 17
Main Drill Functions Displayed in Torque Screen
1. Rotary pressure (psi)
5. Drilling-fluid flow rate
(gpm)
1. Rotary torque (ft-lbs)
5. Drilling-fluid flow rate
(gpm)
2. Drilling-fault indicator
6. Auto-drilling indicator
2. Drilling-fault indicator
6. Auto-drilling indicator
3. Low-fuel indicator
7. Drilling-fluid indicator
3. Low-fuel indicator
7. Drilling-fluid indicator
4. Drilling-fluid pressure (psi)
8. Carriage-pressure gauge
(psi)
4. Drilling-fluid pressure (psi)
8. Carriage-force gauge (lb)
24
Drill-rotation-speed Screen
Horsepower-control Screen
To access this screen, simultaneously press the OK button
and the left and right arrow buttons on the Main Operating
Screen (page 23).
The horsepower control allows the user to change the
engine-speed (rpm) setting that the engine can droop to
before the horsepower-control system can activate.
This screen allows the user to increase or decrease the
rotation speed of the drill.
The horsepower control allows the operator to function the
unit at low rpm levels, so that the engine can stall under heavy
loads.
To change the rotation speed of the drill, perform the
following:
Note: For example, at the 50% engine-speed (rpm) setting,
the engine can stall under heavy loads.
1. Press the Left arrow to decrease the speed, or press the
Right arrow to increase the speed (Figure 18).
After selecting the horsepower control (Figure 15), select one
of the following options:
2. Press the OK button to set the drill-rotation speed
(Figure 18).
• Press button number 1 to activate 90% engine speed
(rpm) as shown in Figure 19.
1
• Press button number 2 to activate 75% engine speed
(rpm) as shown in Figure 19.
• Press button number 3 to activate 50% engine speed
(rpm) as shown in Figure 19.
5
1
• Press button number 4 to return to the main-operating
2
screen (Figure 19).
6
18
12
24
7
3
6
30
n/min
x 100
4
8
OK
ESC
g025794
4
3
2
Figure 18
Drill-rotation-speed Screen
1. Drill-rotation speed meter
3. OK button (sets the
drill-rotation speed)
2. Right arrow (increase
speed)
4. Left arrow (decrease
speed)
Figure 19
Horsepower-control Screen
25
1. Return to previous screen
3. 75% engine speed (rpm)
2. 50% engine speed (rpm)
4. 90% engine speed (rpm)
Clear-service-reminder Screen
To access this screen, press button number 4 as shown in
Figure 20.
1
1
2
2
3
3
4
Enter PIN
BACK
ESC
A
5
B
6
C
7
ENTER
8
OK
g025094
Figure 22
Maintenance-cleared Screen
Figure 20
Access-PIN Screen
1. Button number 4 (diagnose and update system)
To clear a service reminder, enter the 8-digit PIN (16527316)
into this screen (Figure 21):
Figure 21
Enter-PIN Screen
1. Buttons for corresponding
PIN numbers
2. PIN entry appears here
3. Enter PIN
4. Return to the previous
screen
After entering the 8-digit PIN, the following screen will
appear stating that the maintenance reminder has been
cleared (Figure 22).
26
Lubrication and Maintenance Screens
These screens provide the user with maintenance schedules
at 10-hour, 50-hour, 250-hour, 500-hour, and 1,000-hour
increments.
Note: Press the OK button to exit this screen.
Press the following button to attain the subsequent
maintenance schedule:
• Button 1—10-hour and 50-hour maintenance schedule
(Figure 24)
• Button 2—250-hour maintenance schedule (Figure 25)
• Button 3—500-hour maintenance schedule (Figure 26)
• Button 4—1,000-hour maintenance schedule (Figure 27)
Figure 25
250-Hour Maintenance Screen
Figure 23
Main Maintenance Screen
Figure 26
500-Hour Maintenance Screen
Figure 24
10-Hour and 50-Hour Maintenance Screen
Figure 27
1000-Hour Maintenance Screen
27
Error Codes Screen
The following figure is an example of how an error code
appears.
This screen displays the number of drill errors that have
occurred.
Notice that the text before the occurrence count entails what
the actual error is.
If more than 1 drill error is shown on the screen, press button
6 to see the next drilling error (Figure 28).
Note: If there are no drilling errors, press the OK button to
exit this screen (Figure 28).
Figure 30
1. Number of errors and
number of reset errors
2. Next error
3. Reset error
Figure 28
1. Total number of drilling
errors
2. Next drilling error
Carriage-pressure Screen
When this screen appears, the carriage-pressure selection is
in the On position (green) or Off position (red), as shown
in Figure 31.
Stored/Reset Error Codes Screen
Figure 31
Figure 29
1. Number of errors and
number of reset errors
2. Reset error
3. Next error
1. Carriage-pressure gauge
4. Decrease carriage
pressure
2. Carriage pressure in the
Off (red) position
5. Air-hammer control
3. Increase carriage pressure 6. Switch joystick functions
28
Rotary and Carriage-service Screen
Auxiliary-activations Screen
From the Main Operating Screen (page 23), press button
numbers 1 and 5 simultaneously to access this screen.
Press the down arrow on the Rotary and Carriage-service
Screen (page 29) to access this screen.
The rotary and carriage service screen (Figure 32) provides
the following information:
The auxiliary-activations screen (Figure 33) provides the
following information:
Figure 32
Figure 33
• Rotary and carriage joystick output
• On and Off indicators for clamps, wrench breakout, TJC
applicator, setup, pipe rotation, pipe arms, pipe grip, and
pipe elevator
• Makeup percentage and output
• Breakout percentage and output
• Multifunction percentage and output
• Thrust percentage and output
• Pullback percentage and output
• On and Off indicators for two-speed, seats switch, cam
rotation, carriage back, and arms out
29
Drilling-fluid-information Screen
Track-drive-information Screen
Press the down arrow on the Auxiliary-activations
Screen (page 29) to access this screen.
Press the down arrow on the Drilling-fluid-information
Screen (page 30) to access this screen.
The drilling-fluid-information screen (Figure 34) provides the
following information:
The track-drive-information screen (Figure 35) provides the
following information:
Figure 34
Figure 35
• On and Off indicators for drilling fluid, flow increase,
• Output for left forward, left reverse, right forward, and
flow increase, and mud max
right reverse movements of the track drive
• On and Off indicators for seat switch and setup
• Front-Neutral-Reverse (FNR) and steer joystick output
• Drilling fluid percentage and output
• On and Off indicators for setup and seat switch
30
Control Panel
Engine-Start Button
Press this button (Figure 36) to start the engine. The key
switch on the rear, control panel must be in the ON position.
Engine-Stop Button
1
2
3
6
Press this button (Figure 36) to immediately stop the engine
and all drilling operations. You must pull this button out
before you can start the engine again.
7
Ground-Strike-Reset Switch
8
Press this switch (Figure 36) to reset the Zap-Alert system
after a ground strike has occurred and been fixed; refer to
Deploying the Zap-Alert System (page 62).
4
Drive/Drill Switch
9
Press the top of this switch (Figure 36) to enable the drive and
setup controls or the bottom to enable drill and pipe-loader
functions.
5
10
Lights Switch
g021834
Press the top of this switch (Figure 36) to turn the machine
lights on or the bottom to turn them off.
Figure 36
1. Engine-stop button
6. Ground-strike-reset switch
2. Exit-side lockout—reset
light
7. Exit-side-lockout—reset
switch
Engine-Speed Switch
3. Exit-side
lockout—drill-enabled
light
8. Drive/drill switch
• Press and hold the top of this switch to increase the
4. Receiver-battery-status
light
9. Lights switch
5. Engine-start button
engine speed.
• Press and hold the bottom of this switch to decrease the
engine speed.
10. Engine-speed switch
• Release the switch to maintain the current engine speed.
Exit-Side Lockout—Reset Light
This light (Figure 36) illuminates yellow when the exit-side
lockout function is turned off on exit-side-lockout transmitter,
indicating that you may reset the system.
Exit-Side Lockout—Drill-enabled Light
This light (Figure 36) illuminates green when the
exit-side-lockout feature has been turned off and reset and
the machine is ready to drill.
Exit-Side Lockout—Reset Switch
Press this switch (Figure 36) to enable drilling operation when
the reset light illuminates.
Transmitter-Battery—Status Light
This light (Figure 36) illuminates red when the battery on
the exit-side-lockout transmitter is too low to transmit. Stop
drilling operations and fix the problem with the transmitter
before continuing.
31
Left Joystick—Mode I
Front Button
Note: The joystick controls vary depending on the control
mode you select when powering up the machine. There
are 2 control modes: Mode I and Mode II; refer to the
Control-Select Screen in the Software Guide for information
on setting the control mode.
• Left trigger pressed—press this button to resume the
1
previously set auto-drill speed. Press and hold this button
to increase the auto-drill speed.
• Left trigger released—press this button to close the pipe
gripper.
2
Rear Button
• Left trigger pressed—press this button to set the auto
4
3
drill speed. Press and hold this button to decrease the
auto-drill speed.
5
6
7
• Left trigger released—press this button to open the pipe
gripper.
8
Lower Button
9
In the event of a sensor failure, use this button to override the
pipe cam presets and manually move the cam. Only operate
in this mode if absolutely necessary; you could damage the
pipe cam or pipes if you do not align them correctly. If the
sensor fails, contact your Authorized Toro Dealer for repair.
g021833
Figure 37
Joystick—Forward
1. Joystick—move left
6. Front button
• Left trigger pressed—closes the lower wrench.
2. Joystick—move forward
7. Rear button
3. Joystick—move rearward
8. Lower button
• Left trigger released—retracts the pipe gripper toward
4. Joystick—move right
9. Trigger
the pipe holder.
5. Toggle switch
Joystick—Rearward
• Left trigger pressed—opens the lower wrench.
• Left trigger released—extends the pipe gripper toward
Trigger
the drill frame.
The trigger changes the other joystick controls from pipe
loader controls to wrench operation controls.
Joystick—Left
• Press the trigger to enable the wrench controls.
• Left trigger pressed—opens the upper wrench.
• Release the trigger to enable the pipe loader controls.
• Left trigger released—lowers the pipe elevator.
Toggle Switch
Joystick—Right
• Left trigger pressed—rock the switch forward to
• Left trigger pressed—closes the upper wrench.
rotate the upper wrench clockwise to loosen a joint;
rock the switch rearward to rotate the upper wrench
counterclockwise to tighten a joint.
• Left trigger released—raises the pipe elevator.
• Left trigger released—rock the switch forward to rotate
the pipe cam out towards the pipe loader; rock the switch
rearward to rotate the pipe cam towards the drill frame.
32
Left Joystick—Mode II
Front Button
Note: The joystick controls vary depending on the control
mode you select when powering up the machine. There
are 2 control modes: Mode I and Mode II; refer to the
Control-Select Screen in the Software Guide for information
on setting the control mode.
• Left trigger pressed—press this button to resume the
1
previously set auto-drill speed. Press and hold this button
to increase the auto-drill speed.
• Left trigger released—press this button to close the pipe
gripper.
2
Rear Button
• Left trigger pressed—press this button to set the auto
4
3
drill speed. Press and hold this button to decrease the
auto-drill speed.
5
6
7
• Left trigger released—press this button to open the pipe
gripper.
8
Lower Button
9
In the event of a sensor failure, use this button to override the
pipe cam presets and manually move the cam. Only operate
in this mode if absolutely necessary; you could damage the
pipe cam or pipes if you do not align them correctly. If the
sensor fails, contact your Authorized Toro Dealer for repair.
g021833
Figure 38
1. Joystick—move left
6. Front button
2. Joystick—move forward
7. Rear button
3. Joystick—move rearward
8. Lower button
4. Joystick—move right
9. Trigger
Joystick—Forward
Push the joystick forward to spin the drill spindle
counterclockwise.
Joystick—Rearward
5. Toggle switch
Pull the joystick rearward to spin the drill spindle clockwise.
Joystick—Left
Trigger
• Left trigger pressed—opens the upper wrench.
The trigger changes the other joystick controls from pipe
loader controls to wrench operation controls.
• Left trigger released—extends the pipe gripper toward
the drill frame.
• Press the trigger to enable the wrench controls.
• Release the trigger to enable the pipe loader controls.
Joystick—Right
• Left trigger pressed—closes the upper wrench.
Toggle Switch
• Left trigger released—retracts the pipe gripper toward
• Left trigger pressed—rock the switch forward to
the pipe holder.
rotate the upper wrench clockwise to loosen a joint;
rock the switch rearward to rotate the upper wrench
counterclockwise to tighten a joint.
• Left trigger released—rock the switch forward to rotate
the pipe cam out towards the pipe loader; rock the switch
rearward to rotate the pipe cam towards the drill frame.
33
Right Joystick—Mode I
Lower Button
Note: The joystick controls vary depending on the control
mode you select when powering up the machine. There
are 2 control modes: Mode I and Mode II; refer to the
Control-Select Screen in the Software Guide for information
on setting the control mode.
Press this button to turn the drilling-fluid pump on or off.
1
Trigger
Press and hold the trigger to move the drill carriage at high
speed up or down the drill frame.
2
Joystick—Forward
Push the joystick forward to thrust the drill carriage forward.
4
3
5
6
7
Joystick—Rearward
Pull the joystick rearward to pull the drill carriage rearward.
8
Joystick—Left
9
Push the joystick left to spin the drill spindle clockwise.
Joystick—Right
Push the joystick right to spin the drill spindle
counterclockwise.
g021833
Figure 39
1. Joystick—move left
6. Front button
2. Joystick—move forward
7. Rear button
3. Joystick—move rearward
8. Lower button
4. Joystick—move right
9. Trigger
5. Toggle switch
Toggle Switch
Rock the switch forward to increase the rate of flow of the
drilling fluid; rock the switch rearward to decrease the rate
of flow of the drilling fluid.
Note: Before using this feature you must first turn on
the drilling-fluid pump using the lower button on the right
joystick.
Front Button
Press this button to apply tread-joint compound.
Rear Button
Press and hold this button for maximum drilling fluid
pressure; use this to quickly fill the pipe with drilling fluid
after adding or removing a pipe. Release the button to stop
the flow or return to the previously set flow rate.
34
Right Joystick—Mode II
Lower Button
Note: The joystick controls vary depending on the control
mode you select when powering up the machine. There are 2
control modes: Mode I and Mode II; refer to Control-Select
Screen in the Software Guide for information on setting the
control mode.
Press this button to turn the drilling-fluid pump on or off.
1
Trigger
Press and hold the trigger to move the drill carriage at high
speed up or down the drill frame.
2
Joystick—Forward
4
3
Push the joystick forward to thrust the drill carriage forward.
5
6
7
Joystick—Rearward
Pull the joystick rearward to pull the drill carriage rearward.
8
Joystick—Left
9
• Left trigger pressed—opens the lower wrench.
• Left trigger released—raises the pipe elevator.
Joystick—Right
g021833
• Left trigger pressed—closes the lower wrench.
Figure 40
1. Joystick—move left
6. Front button
2. Joystick—move forward
7. Rear button
3. Joystick—move rearward
8. Lower button
4. Joystick—move right
9. Trigger
• Left trigger released—lowers the pipe elevator.
5. Toggle switch
Toggle Switch
Rock the switch forward to increase the rate of flow of the
drilling fluid; rock the switch rearward to decrease the rate
of flow of the drilling fluid.
Note: Before using this feature you must first turn on
the drilling-fluid pump using the lower button on the right
joystick.
Front Button
Press this button to apply tread-joint compound.
Rear Button
Press and hold this button for maximum drilling fluid
pressure; use this to quickly fill the pipe with drilling fluid
after adding or removing a pipe. Release the button to stop
the flow or return to the previously set flow rate.
35
Exit-Side-Lockout System (Standard
Range)
Engine, Key Switch
The key switch has 3 positions as follows (Figure 42):
The exit-side-lockout system provides the individuals working
around the machine with a means to disable the drill pipe
from rotating and thrusting.
1
2
For more information and instructions, refer to the Operator’s
Manual for the Exit-side-lockout system.
Exit-Side-Lockout System (Long
Range)
3
The exit-side-lockout system provides the individuals working
around the machine with a means to disable the drill pipe
from rotating and thrusting.
For more information and instructions, refer to the Operator’s
Manual for the Exit-side-lockout system.
G0221 15
Rear Control Panel
Figure 42
1. Engine-off position
2
1
3. Engine-start position
2. Engine-run position
3
• Engine-off position—turn the key to this position to
stop the engine. The engine cannot be started from the
operator platform when the key is in this position.
• Engine-run position—turn the key to this position after
starting the engine. Turning the key to this position
also enables the engine start button from the operator
platform.
• Engine-start position—turn the key to this position to
start the engine. Release the key to the RUN position once
the engine has started.
4
5
g021837
Fluid-Pump Switch
Figure 41
1. Engine-heating light
4. Drill-pendant receptacle
2. Engine, key switch
5. Drive-pendant receptacle
Use this switch to turn on the fluid pump to use the spray gun
when cleaning the machine.
3. Fluid-pump switch
Drill-Pendant Receptacle
Plug the drill pendant into this receptacle to attach it to the
machine (Figure 41).
Engine-Heating Light
When the engine is cold, the heater warms the intake air to
enable easier starting. This light illuminates while the heater is
on. Wait until this light turns off before starting the engine.
Drive-Pendant Receptacle
Plug the drive pendant into this receptacle to attach it to the
machine (Figure 41).
36
Drive Pendant
Drill Frame and Stabilizer Controls
Refer to Figure 41 for location.
1
2
3
1
3
2
4
5
g021843
Figure 43
1. Drill-frame tilt lever
3. Right-stabilizer lever
2. Left-stabilizer lever
g021855
Figure 44
Stabilizer Levers
Use the stabilizer levers to raise and lower the stabilizers.
Note: The DRIVE/DRILL switch on the operator panel must
be switched to the DRIVE position for this function to work.
1. Engine-speed switch
4. Drive-speed switch
2. Drive-direction joystick
5. Operator-presence switch
3. Engine-stop button
Drill-Frame Tilt Lever
Engine-Stop Button
Use the drill-frame tilt lever to tilt the drill frame to place
the stake-down plate on the ground or to return the frame
to the travel position.
Press this button to immediately stop the engine and all
movement/drilling operations. You must pull this button out
before you can start the engine again.
Note: The DRIVE/DRILL switch on the operator panel must
be switched to the DRIVE position for this function to work.
Engine-Speed Switch
• Press and hold the top of this switch to increase the
engine speed.
• Press and hold the bottom of this switch to decrease the
engine speed.
• Release the switch to maintain the current engine speed.
Drive-Direction Joystick
Use the joystick to control the direction of the machine. The
machine will travel in the direction you move the joystick.
37
Drive-Speed Switch
Left Switch
The switch sets the speed at which the machine will travel.
Move the switch up for high speed or down for low speed.
• When connected to the drill-pendant receptacle, move
Operator-Presence Switch
• When connected to the drive-pendant receptacle, move
this switch up to move the drill carriage forward or down
to move the drill carriage rearward.
this switch up to move the left track forward or down to
move the left track rearward.
Press and hold this button to enable the other controls on the
drive pendant. The machine will stop moving if you release
this button.
Center Switch
Move this switch to the left to enable the pipe loader and
wrench operation; move the switch to the center to turn off
the drilling fluid.
Drill Pendant
The drill pendant (also referred to as the life-jacket
pendant) is designed to allow you rudimentary control
over only the drilling features when connected to the front
receptacle, should the operator platform controls become
non-responsive. You can also plug this pendant into the rear
drill-pendant receptacle in the event that the drive pendant
malfunctions to obtain basic movement functions at slow
speed.
Right Switch
• When connected to the front drill-pendant receptacle,
move this switch up to rotate the drill spindle clockwise
or down to rotate the drill spindle counterclockwise.
• When connected to the rear drill-pendant receptacle,
move this switch up to move the right track forward or
down to move the right track rearward.
Only the drive functions can be operated from the rear
drill-pendant receptacle.
Stake-Down Levers
Refer to Figure 41 for location.
1 2
1
2
3
4
g021835
Figure 46
1. Left-stake-raise/lower
lever
2. Left-stake-spin lever
3
3. Right-stake-raise/lower
lever
4. Right-stake-spin lever
Stake-Raise/Lower Levers
Push down on these levers to lower the stakes into the ground.
Pull up on these levers to raise the stakes out of the ground.
g021839
Figure 45
1. Left switch
Note: The DRIVE/DRILL switch on the operator panel must
be switched to the DRIVE position for this function to work.
3. Right switch
2. Center switch
Stake-Spin Levers
Push down on these levers to spin the stakes clockwise. Pull
up on these levers to spin the stakes counterclockwise.
Note: The DRIVE/DRILL switch on the operator panel must
be switched to the DRIVE position for this function to work.
38
Battery-Disconnect Switch
Specifications
Open the front hood to access the BATTERY -DISCONNECT
switch; refer to Opening the Front Hood (page 72).
Note: Specifications and design are subject to change
without notice.
The BATTERY -DISCONNECT switch is located to the right of
the engine; it is used to electrically disconnect the battery
from the machine.
Machine
Turn the BATTERY -DISCONNECT switch to the ON or OFF
position to perform the following:
Width
131 cm (51.5 inches)
Length
Height
Weight
525 cm (207 inches)
188 cm (74 inches)
4,765 kg (10,500 lbs)
• To energize the machine electrically, rotate the
BATTERY -DISCONNECT switch clockwise to the ON
position (Figure 47).
Attachments/Accessories
• To de-energize the machine electrically, rotate the
BATTERY -DISCONNECT switch
OFF position (Figure 47).
A selection of Toro approved attachments and accessories is
available for use with the machine to enhance and expand
its capabilities. Contact your Authorized Service Dealer or
Distributor or go to www.Toro.com for a list of all approved
attachments and accessories.
counterclockwise to the
Important: Use only Toro approved attachments.
Other attachments may create an unsafe operating
environment or damage the traction unit.
Figure 47
1. Battery-disconnect switch
(On position)
2. Battery-disconnect switch
(Off position)
39
Operation
Refer to Preparing the Job Site and the Machine (page
52) for instructions on preparing the job site and the
machine.
Note: Determine the left and right sides of the machine
from the normal operating position.
4. Drill the bore.
You drill the bore in three stages:
Understanding Horizontal
Directional Drilling
A. Entry
In the entry phase of the bore, you push the drill
bit and head into the ground at an angle of up to
16 degrees. After pushing in one or more pipes,
you begin drilling down and forward until you
reach the desired depth or depth-gauge hole (if
used).
Horizontal directional drilling is a process used for drilling a
horizontal bore through the soil and under obstructions such
as roads, buildings, bodies of water, etc. Once you drill the
bore, you pull back the utility lines or pipes through the bore
and connect them as needed. Because it does not require
very much disturbance of the surface, installation of utilities
using directional drilling preserves the environment and saves
both time and money over traditional installation methods
such as trenching.
B.
Horizontal Reach
After reaching the desired depth, you push the
bit forward, steering the bit to a horizontal depth.
The drill bit emits a radio signal from the sonde
housing, which allows a crew member on the
surface to track the location and depth of the head
using the sonde receiver as you drill and steer it
along a planned route.
When installing cabling or pipe using a directional drill, you
complete the following steps:
1. Gather site information.
C.
Before operating in an area with high-voltage lines or
cables, contact a “One-Call System Directory” service.
In the USA, call 811 or your local utility company. If
you do not know your local utility company’s phone
number, call the national number (USA and Canada
only) at 1-888-258-0808. Also, contact any utility
companies that are not participants of the “One-Call
System Directory” service. Please refer to Drilling
Near Utility Lines (page 6) for more information.
Exit
Once you have attained the planned horizontal
reach, you steer the head up at an angle similar
to your entry angle bringing the bit into the exit
hole or trench.
Refer to Drilling the Bore (page 63).
5. Backream the bore and pull back the cabling or
pipe.
Before fully planning the bore, you must gather
information about the job site such as the location of
other utilities, obstacles at the site, and what regulations
and permits you will need to complete the job; refer to
Gathering Site Information (page 41).
After entering the exit hole, the end crew detaches the
drill bit and sonde housing from the drill pipe. In its
place, they attach a reaming bit and the end of the cable
or pipe to be pulled through the bore. The reaming
bit is designed to enlarge the bore as you pull it back.
As before, you pump drilling fluid through the pipe
to the reaming bit as you pull the cable or pipe back
through the bore to lubricate the reamer and allow
the cable or pipe to slide easily through the bore. You
continue pulling the pipe back until the reamer reaches
the depth-gauge hole or exits at the entry point. There
you remove the reamer and product from the drill pipe,
pulling the pipe the rest of the way back to the machine.
2. Plan the bore.
Before you can drill, you must first plan the bore path
based on the information you gathered. Refer to
Planning the Bore Path (page 43).
3. Prepare the job site and the machine.
Before drilling, you prepare the job site with an entry
point, depth-gauge hole (optional), and an exit hole.
You also need to drive the unit to the site, set it up for
drilling, and connect it to a drilling-fluid mixer.
Refer to Backreaming and Pullback (page 66) for
instructions on backreaming and pulling cable or pipe.
6. Finish the bore and leave the job site.
Note: When drilling, you connect the machine to a
drilling-fluid mixer that mixes water with bentonite
clay and other ingredients. The machine pumps this
mixture, referred to as drilling fluid or “Mud”, through
the drill pipe and out the drill bit. The drilling fluid
lubricates the bit, helps to hold the bore open while
drilling, and mixes with the spoils, flushing them out
of the bore through the entry point.
After completing the operation, you need to disconnect
and clean the machine and load it on the trailer; refer to
Cleaning with the Spray-hose Attachment (page 102).
40
Gathering Site Information
DANGER
Contacting underground hazards with the
machine while drilling or reaming can cause
explosion, electrocution, breathing problems,
severe trauma, and death to you or bystanders.
Planning the Initial Route
Before you can begin boring, you need to plan the route you
will bore and prepare as follows:
– Ensure that all personnel at the job site wear
personal protective equipment including
a hard hat, eye protection, and hearing
protection.
• Create a basic plan for the bore, mapping out the
proposed route.
– Note any obstacles which may affect the bore such as
large trees, bodies of water, buildings, etc.
– Keep bystanders and spectators away from
the job site, including the complete bore
path.
– Plan the route of the bore to avoid as many obstacles
as possible.
– Determine the depth of any bodies of water to be
crossed to ensure that you can get deep enough under
them.
– Locate and expose all electric and gas lines
that you will be crossing by careful hand
digging.
• Determine the depth you need to install the material at
and the minimum bend radius both of the drill pipe and
of the material being installed. This will seriously affect
how long the bore needs to be and at what angle you can
begin and end; refer to Planning the Bore Path (page 43).
– Ensure that you use the Zap-Alert system
whenever operating the machine.
Common hazards include the following:
• Have the area of the bore marked for utility lines (in the
– Gas lines
US call 811). Ensure that all lines are marked on your
blueprints/bore plan as well.
DANGER
• Contact the local authorities to arrange for any permits
Drilling into a gas line can cause an explosion
or fire, burning, injuring, or killing you or
others in the vicinity of the break.
and traffic control that you will need to conduct the job.
Inspecting the Proposed Job Site
◊ Do not smoke or have any source of flame
near gas lines or at either end of a bore
that will be crossing a gas line.
Physically inspect the site as follows:
• Note the terrain, slopes, valleys, hills, and any features
not planned for previously.
◊ Keep bystanders and spectators away
from the job site, including the complete
bore path.
Determine the degree of slope at both the proposed entry
point and exit point.
• Determine what the soil types are in the area and, if
◊ Locate and expose all gas lines that you
will be crossing by careful hand digging.
possible, what they are at the depth you will be boring.
You may need to dig test holes at intervals along the bore
path to fully determine this.
◊ Have the gas company turn off the gas
to any lines you will be crossing before
drilling.
• Walk the area of the bore looking for any possible
unmarked obstructions. Look for manholes, pedestals,
old foundations, etc.
◊ Use the receiver to track the exact position
of the drill head when approaching gas
lines.
• Identify all hazards of which you will be passing within
3 m (10 ft).
41
– Electrical power lines
– Crystalline silica and other dust
If you will be drilling through or cutting concrete,
sand, or other substances that create dusts or fumes,
you need to ensure that you and all workers wear
breathing protection to protect your lungs from the
dust.
DANGER
Drilling into an electric power line will cause
the machine to become electrified and may
electrocute you or any bystanders.
◊ Keep bystanders and spectators away
from the job site, including the complete
bore path.
WARNING
Machining or handling stone, masonry,
concrete, metal, and other materials can
generate dust, mists, and fumes containing
chemicals, such as silica, known to cause
serious or fatal injury or illness, such as
respiratory disease, silicosis, cancer, birth
defects, or other reproductive harm.
◊ Locate and expose all electric lines that
you will be crossing by careful hand
digging.
◊ Have the electric company turn off the
power to any lines you will be crossing
before drilling.
◊ Control dust, mist, and fumes at the
source where possible. Water should be
used for dust suppression when feasible.
◊ Use the receiver to track the exact
position of the drill head when
approaching electric lines.
◊ Use good work practices and follow the
recommendations of the manufacturer or
suppliers, OSHA, and other occupational
and trade associations.
◊ Before drilling, setup and use the
Zap-Alert system which is designed to
notify in the case of an electric strike and
electrically isolate the machine operator
from the machine. If the Zap-Alert alarm
triggers, stop what you are doing and do
not leave the operator’s position. Refer
to Deploying the Zap-Alert System (page
62) for detailed instructions on using the
Zap-Alert system.
◊ When the hazards from inhalation cannot
be eliminated, the operator and any
bystanders should wear a respirator
approved by OSHA for the material being
handled.
WARNING
Silicosis Warning: Grinding, cutting, or
drilling stone, masonry, concrete, metal,
and other materials with silica in their
composition may give off dust or mist
containing crystalline silica. Silica is a
basic component of sand, quartz, brick,
clay, granite, and numerous other minerals
and rocks. Repeated and/or substantial
inhalation of airborne crystalline silica can
cause fatal respiratory diseases, including
silicosis. In addition, some other authorities
have listed respirable crystalline silica as a
substance known to cause cancer. When
cutting such materials, follow respiratory
precautions.
42
Planning the Bore Path
Before setting up the job site, you need to plan the bore path,
including the following:
1
4
3
2
5
g021764
Figure 48
1. Bore entry
4. Obstacle
2. Beginning-of-bore-at-depth point
5. End-of-bore-at-depth point and bore exit
3. Bore depth
• Bore entry
needed for steering the drill to the surface, typically 9 to 15
m (30 to 50 ft) from the end-of-the-bore-at-depth point.
The is the location where you setup the machine and the
drill bit enters the ground. Depending on conditions, this
will typically be set back 9 to 15 m (30 to 50 ft) from the
beginning-of-the-bore-at-depth point.
Determining the Bore Entry Point
One of the more challenging aspects of planning the bore
path is to determine the entry point of the bore. You need to
take the following traits into account when determining the
location of the entry point:
• Beginning-of-bore-at-depth point
This is the point where you want the utility line or pipe to
end after installation is complete. It is typically the point at
which the bore levels out and begins to bore horizontally.
This may be the same as the entry point, or you may dig a
separate depth-gauge hole at this point (Figure 48).
• Bore depth
This the depth at which you want to install the utility
line or pipe. This machine is designed primarily for
installations between 1 and 3 m (3.5 to 10 ft).
• Bore depth
This the depth at which you want to install the utility
line or pipe. This machine is designed primarily for
installations between 1 and 3 m (3.5 to 10 ft).
• Pipe and material flexibility
The 3 m (10 ft) pipes used on this machine can flex to an
8% pitch over the length of the pipe; this equates to a
bend of no more than 20 cm (8 inches) off of a straight
path (Figure 49).
• Obstacles in the path
It is important to know where the known obstacles are
that you will need to steer around or under before starting
so that you can plan where to begin steering prior to
reaching the obstacle.
Important: If you steer the pipe to bend sharper
than 20 cm (8 inches) per pipe, you may damage the
pipes and their connections. You must also make
steering changes gradually over the entire length of
each pipe. If you steer the whole 20 cm (8 inches)
in only 25 to 50 cm (1 to 2 ft) of travel, you will
permanently damage the pipes.
• End-of-bore-at-depth point
This is the point where you want the utility line or pipe
to begin after installation is complete. Often this will also
be the bore exit.
• Bore exit
This is the location where the drill head will exit the
ground and the point at which you will pull the utility lines
or pipe into the bore. If this point will be at the surface
instead of at installation depth, you will need to determine
the distance from the end-of-bore-at-depth location
43
1
g021765
Figure 49
1. 20 cm (8 inches)
This flexibility is often rated in materials as a minimum
bend radius, which is the radius of the circle formed if the
material or pipes, connected together, were bent to form
a giant circle. The minimum radius of a circle made with
the pipe used with this machine is 36.6 m (102 ft).
1
2
• Entry pitch
g021767
The entry pitch is the angle at which the machine
enters the ground. With the tracks on level ground, the
stabilizers down, and the stake-down plate on the ground,
the drill frame angle is about 15 degrees or a 27% pitch.
This pitch will change depending on the slope of the
ground and other factors of the job site. You can also
reduce this pitch a bit by building up the ground under
the stake-down plate before positioning the machine.
You can determine the actual pitch of the drill frame by
placing the drill bit and sonde housing on the frame and
then use the receiver to display the pitch.
Figure 51
1. 18% pitch
2. 3 m (10 ft)
The steeper your entry pitch is, the deeper your bore will
have to be due to the limitations of the pipe flexibility.
Typically you need to insert the drill and at least 1/3 of a
pipe into the ground before you can start steering toward
the beginning of the bore point. Figure 50, Figure 51,
and the following table illustrate the relationship between
entry pitch and depth.
1
2
3
g021766
Figure 50
1. 26% pitch
3
3. 76 cm (30 inches)
2. 3 m (10 ft)
44
3. 53 cm (21 inches)
Note: The depths given in the following table are for 3 m (10 ft) of combined drill head and pipe. As you steer up, the
pitch of the steered section will change and can be monitored with the receiver. Use the following table to identify how
many lengths of pipe will be necessary to insert and steer to the beginning point and help you choose an entry point.
Pitch
Depth Change per 10 feet
1%
2 cm (1 inch)
2%
5 cm (2 inches)
3%
10 cm (4 inches)
4%
13 cm (5 inches)
5%
15 cm (6 inches)
6%
18 cm (7 inches)
7%
20 cm (8 inches)
8%
25 cm (10 inches)
9%
28 cm (11 inches)
10%
30 cm (12 inches)
11%
33 cm (13 inches)
12%
36 cm (14 inches)
13%
39 cm (15 inches)
14%
43 cm (17 inches)
15%
46 cm (18 inches)
16%
48 cm (19 inches)
17%
51 cm (20 inches)
18%
53 cm (21 inches)
19%
56 cm (22 inches)
20%
61 cm (24 inches)
21%
64 cm (25 inches)
22%
66 cm (26 inches)
23%
69 cm (27 inches)
24%
71 cm (28 inches)
25%
74 cm (29 inches)
All measurements are approximate and will vary depending on soil
Pitch
26%
27%
28%
29%
30%
31%
32%
33%
34%
35%
36%
37%
38%
39%
40%
41%
42%
43%
44%
45%
46%
47%
48%
49%
50%
conditions.
Depth Change per 10 feet
76 cm (30 inches)
79 cm (31 inches)
81 cm (32 inches)
84 cm (33 inches)
86 cm (34 inches)
91 cm (36 inches)
94 cm (37 inches)
97 cm (38 inches)
99 cm (39 inches)
102 cm (40 inches)
104 cm (41 inches)
107 cm (42 inches)
109 cm (43 inches)
112 cm (44 inches)
114 cm (45 inches)
117 cm (46 inches)
117 cm (46 inches)
119 cm (47 inches)
122 cm (48 inches)
124 cm (49 inches)
127 cm (50 inches)
130 cm (51 inches)
133 cm (52 inches)
135 cm (53 inches)
137 cm (54 inches)
Note: These values and more can be found in the Driller’s Handbook & Daily Log by Digital Control Incorporated.
45
Given the above information, you can calculate the number of
rods required to reach your beginning point at the appropriate
depth. Toro recommends that you start the entry point a
distance back from your beginning-at-depth point by the
same distance as the length of pipes you will need to reach
that point. This will ensure that you have enough extra space
so you will not need to over-steer and damage the pipes.
The following example illustrates the process given an
installation using the maximum entry pitch of the machine
(26%) on level ground:
• You insert the first 3 m (10 ft) of drill bit/pipe into the
ground with no steering. The end of the drill bit will be
76 cm (30 inches) deep (Figure 49).
7
1
2
3
4
5
6
g021768
Figure 52
1. 26% pitch
4. 185 cm (73 inches)
2. 76 cm (30 inches)
5. 203 cm (80 inches)
3. 142 cm (56 inches)
6. 208 cm (82 inches)
• You begin steering up for the next 3 m (10 ft), pushing the
pipes in at the maximum pitch change of 8%. This results
in a change of pitch from 26% at the beginning of the 3 m
(10 ft) to 18% at the end of the 3 m (10 ft) for an average
pitch of 22%. Given that, the drill head lowers another 66
cm (26 inches) and is now 142 cm (56 inches) deep.
• Continuing steering up for the next 3 m (10 ft) at an 8%
pitch change, your pitch will change from 18% to 10%
for an average pitch of 14%. Given that, the drill head
lowers another 43 cm (17 inches) and is now 185 cm (73
inches) deep.
• Continuing steering up for the next 3 m (10 ft) at an 8%
pitch change, your pitch will change from 10% to 2% for
an average pitch of 6%. Given that, the drill head lowers
another 18 cm (7 inches) and is now 203 cm (80 inches)
deep.
• Leveling the drill head from 2% to 0% takes less than 1.5
m (5 ft) more for a final depth of 208 cm (82 inches).
Reaching this final point took four and a half, 3 m (10 ft)
pipes. So for this example your entry point should be
14.7 m (45 ft) back from the beginning-at-depth point of
your installation.
46
7. 14.7 m (45 ft)
• You insert the first 3 m (10 ft) of drill bit/pipe into the
The following example illustrates the process given an
installation using the machine at an 18% pitch on level
ground:
ground with no steering. The end of the drill bit will be
53 cm (21 inches) deep (Figure 53).
6
1
2
3
4
5
g021769
Figure 53
1. 18% pitch
3. 96 cm (38 inches
5. 119 cm (47 inches)
2. 53 cm (21 inches)
4. 114 cm (45 inches)
6. 10.6 m (35 ft)
Mapping the Bore
• You begin steering up for the next 3 m (10 ft), pushing the
pipes in at the maximum pitch change of 8%. This results
in a change of pitch from 18% at the beginning of the 3 m
(10 ft) to 10% at the end of the 3 m (10 ft) for an average
pitch of 14%. Given that, the drill head lowers another 43
cm (17 inches) and is now 96 cm (38 inches) deep.
With the information you gathered previously, map out the
route of the bore, identifying the following so that you can
mark the site later:
• Entry point
• Continuing steering up for the next 3 m (10 ft) at an 8%
• Location of the machine and supporting equipment
pitch change, your pitch will change from 10% to 2% for
an average pitch of 6%. Given that, the drill head lowers
another 18 cm (7 inches) and is now 114 cm (45 inches)
deep.
• Beginning of bore at depth
• Any obstacles that you need to steer around and the
locations where you need to start steering to get around
or under them
• Leveling the drill head from 2% to 0% takes less than 1.5
m (5 ft) more for a final depth of 119 cm (47 inches).
Reaching this final point took three and a half, 3 m (10
ft) pipes. So for this example your entry point should be
10.6 m (35 ft) back from the beginning-at-depth point of
your installation.
• Any utility lines you will need to cross
• Slope and soil changes along the path that will affect the
bore
• End of the bore at depth
• Exit location if different than the end of the bore
Important: You can use the information contained in
this section to determine both the space needed to steer
up to the exit point if needed and also to steer around
obstacles.
47
Understanding and Using
the Exit-side-lockout System
(Standard Range)
Understanding and Using the Handheld
Transmitter (Standard Range)
The individual holding the transmitter can push the Lock
Drill (Off) button to stop the drill rotation and thrust. This
is primarily used to stop/lockout the drill operations in the
following situations:
• When installing or removing a drill head or reamer
Indicator Light State
Meaning
Green light is blinking rapidly
The transmitter is transmitting
to the base unit
Green light is illuminated
without blinking
A button on the transmitter is
currently pressed
Yellow light is blinking slowly
The batteries are low; change
the batteries. If you do not
change the batteries soon, the
handheld will power down.
Red light is blinking
The transmitter is actively
receiving messages from the
base unit.
Replacing the Handheld Transmitter
Batteries (Standard Range)
• Whenever someone needs to approach the drill pipe or
head anywhere in front of the machine
1. Loosen the 4 screws securing the battery cover (Figure
55).
• Placing a wiper on the drill pipe
• When the location receiver operator identifies a problem
requiring immediate shutdown of drilling
When it is safe to resume drilling, the individual holding the
transmitter can press the Unlock Drill (On) button. This
button sends a signal to the receiver that allows the machine
operator to reset the system and restore the thrust and rotary
functions.
The following table lists the various states of the indicator
lights on the handheld transmitter (Figure 54) and their
meanings:
3
4
Figure 55
5
ON
1. Handheld transmitter
2. Battery cover
OFF
3. Screws
2. Remove the cover (Figure 56).
2
1
G022151
Figure 56
Figure 54
1. Red indicator light
4. On button
2. Yellow indicator light
5. Off button
1. Handheld transmitter
2. Battery cover
3. Remove the existing batteries.
3. Green indicator light
4. Install 3 new, AAA batteries in the orientation shown
in Figure 57.
Important: Ensure that you install the batteries
in the correct polarity orientation or you could
damage the transmitter.
48
8. Release the On button.
The Red light turns off and the Green light flashes for
a few seconds.
Disassociating all Handheld
Transmitters from the Base Unit
(Standard Range)
Important: Completing this procedure will disassociate
all transmitters from the base unit, which will need to be
associated again before they will function.
1. Ensure that the machine is turned off.
2. Ensure that the handheld transmitter is not active (i.e.,
no lights are on).
Figure 57
1. Handheld transmitter
2. AAA batteries
3. Stand near the rear control panel of the machine.
4. Simultaneously press and hold the On and Off buttons.
5. Replace the cover and secure it with the screw removed
previously.
The Green light illuminates.
Tighten the screws enough to ensure that the sealing
gasket is compressed, but do not over tighten them.
5. Continue holding the buttons until the Yellow light
begins flashing, then release the buttons.
The Red light begins flashing allowing you 2 seconds
to press the next button.
Associating the Handheld Transmitter
with the Base Unit (Standard Range)
6. Press and hold the Off button
If the handheld transmitter ever stops communicating with
the base unit, or if you replace it with a new transmitter, you
need to associate the transmitter to the base unit as follows:
The Red light turns off and the Green and Yellow
lights illuminate.
Important: If you do not press this button within
2 seconds, you will have to start this procedure
over again.
1. Ensure that the machine is turned off.
2. Ensure that the handheld transmitter is not active (i.e.,
no lights are on).
7. Continue holding the Off button and turn on the
machine to power the base unit.
3. Stand near the rear control panel of the machine.
4. Simultaneously press and hold the On and Off buttons.
The base unit and handheld establish a communication
link while you hold the button. Once the process is
complete, the Yellow light turns off, the Red light
begins flashing, and the Green light illuminates. All
lights remain as mentioned until you release the button.
The Green light illuminates.
5. Continue holding the buttons until the Yellow light
begins flashing, then release the buttons.
The Red light begins flashing allowing you 2 seconds
to press the next button.
8. Release the Off button.
The Red light turns off and the Green light flashes for
a few seconds.
6. Press and hold the On button
The Red light turns off and the Green and Yellow
lights illuminate.
Important: If you do not press this button within
2 seconds, you will have to start this procedure
over again.
7. Continue holding the On button and turn on the
machine to power the base unit.
The base unit and handheld establish a communication
link while you hold the button. Once the process is
complete, the Yellow light turns off, the Red light
begins flashing, and the Green light illuminates. All
lights remain as mentioned until you release the button.
49
Understanding and Using
the Exit-side-lockout System
(Long Range)
Indicator Light
Understanding the Base-unit
Transmitter Indicator Lights (Long
Range)
The following table lists the various states of the indicator
lights on the base-unit transmitter (Figure 58) and their
meanings:
Figure 58
1. Polarity-reversal indicator
2.
3.
4.
5.
6.
+V1
+V2
+V3
RTX
RRX
7. Over temperature/voltage
8.
9.
10.
11.
12.
HTH
Under current
Out
Not used
In
50
Meaning
Unmarked indicator light
Input power polarity reverse
when lit
+V1 to +V3
OK and active when solid
RTX
Blinking when transmitting
RRX
Active when receiving
Over temp/voltage
Lights up when the
temperature or voltage is
exceeded
HTH
OK when blinking
Under current
Lights up when the current is
too low
Out
Output is active when lit
Not used
Unused
In
Input is active when lit
Understanding and Using the Handheld
Transmitter Indicator Lights (Long
Range)
Meaning
Indicator Light State
The individual holding the transmitter can push the Lock
Drill (Off) button to stop the drill rotation and thrust. This
is primarily used to stop/lockout the drill operations in the
following situations:
• When installing or removing a drill head or reamer
• Whenever someone needs to approach the drill pipe or
head anywhere in front of the machine
• Placing a wiper on the drill pipe
• When the locator operator identifies a problem requiring
immediate shutdown of drilling
The green transmit (TX) light
is blinking rapidly and is dim.
The handheld is transmitting
to the base unit.
The green transmit (TX) light
is blinking rapidly and is bright.
The buttons on the handheld
are now active.
The yellow receive (RX) light
is blinking rapidly and is bright.
The handheld is receiving.
The red error (ER) light is
solidly lit.
An error is occurring.
The yellow low battery (BA)
light is slowly blinking.
The batteries for the handheld
are running low.
The yellow auxiliary 1 and 2
(A1 and A2) lights are lit.
The machine and handheld
are unused.
Replacing the Handheld Transmitter
Batteries (Long Range)
When it is safe to resume drilling, the individual holding the
transmitter can press the Unlock Drill (On) button. This
button sends a signal to the receiver that allows the machine
operator to reset the system and restore the thrust and rotary
functions.
1. Loosen the 4 screws securing the battery cover (Figure
55).
The following table lists the various states of the indicator
lights on the handheld transmitter (Figure 59) and their
meanings:
Figure 60
1. Handheld transmitter
2. Battery cover
3. Screws
2. Remove the cover (Figure 61).
Figure 59
Figure 61
1. Transmit (TX)—green
indicator light
5. Auxiliary 1 (A1)—yellow
indicator light
2. Receive (RX)—yellow
indicator light
6. Auxiliary 2 (A2)—yellow
indicator light
3. Error (ER)—red indicator
light
7. On button
3. Remove the existing batteries.
4. Low battery (BA)—yellow
indicator light
8. Off button
4. Install 3 new, AAA batteries in the orientation shown
in Figure 57.
1. Handheld transmitter
51
2. Battery cover
Preparing the Job Site and the
Machine
Important: Ensure that you install the batteries
in the correct polarity orientation or you could
damage the transmitter.
Before drilling, prepare the job site and machine as follows:
• Mark and prepare the bore path Marking and Preparing
the Bore Path (page 52).
• Test the Zap-Alert system; refer to Testing the Zap-Alert
System (page 53).
• Load the drill pipes into the pipe holder if needed; refer
to Loading Drill Pipes into the Pipe Holder (page 55).
• Add fuel to the machine; refer to Adding Fuel (page 55).
• Check the oil level in the engine; refer to Checking the
Engine-oil Level (page 81)
• Check the engine coolant level; refer to Checking the
Cooling System (page 57).
Figure 62
1. Handheld transmitter
• Check the hydraulic oil level; refer to Checking the
2. AAA batteries
Hydraulic Fluid (page 97).
• Check the oil level in the drilling-fluid pump; refer to
5. Replace the cover and secure it with the screw removed
previously.
Checking the Drilling-fluid-pump Oil Level (page 100).
• Load/unload the machine; refer to Loading and
Tighten the screws enough to ensure that the sealing
gasket is compressed, but do not over tighten them.
Unloading the Machine (page 58).
• Drive the machine to the entry point; refer to
Understanding Horizontal Directional Drilling (page 40).
Associating the Handheld Transmitter
with the Base Unit (Long Range)
• Connect the machine to a drilling-fluid source; refer to
Connecting to a Drilling-fluid Source (page 61).
• Set up the drill bit(s) and tracking electronics; refer to
If the handheld transmitter ever stops communicating with
the base unit, or if you replace it with a new transmitter, you
need to associate the transmitter to the base unit as follows:
Setting Up the Drill Head and Tracking System (page 58).
• Set up the machine for drilling; refer to Setting up the
Machine for Drilling (page 60).
1. Ensure that the machine is turned off.
• Deploy the Zap-Alert system; refer to Deploying the
2. Ensure that the handheld transmitter is not active (i.e.,
no lights are on).
Zap-Alert System (page 62)
3. While holding the handheld transmitter, stand near the
base unit with an unobstructed, clear line-of-sight.
Marking and Preparing the Bore Path
4. Simultaneously press and hold the On and Off buttons
(Figure 59).
1. Walk the bore path, marking it on the ground with
marking paint so that the receiver operator will be able
to follow the plan.
Note: All of the LED lights activate.
2. Hand dig to expose any buried utility lines marked
previously that the bore path will be crossing. This
will allow the receiver operator to know exactly where
they are.
5. Continuously hold both On and Off buttons until
the green transmit (TX) indicator light begins to flash
(Figure 59).
6. Turn the machine on while continuing to hold On and
Off buttons (Figure 59).
3. If you are exiting the bore at ground level and not in an
existing trench, dig an angled hole into which the bit
will enter at the end of the bore.
Note: The TX, RX, ER, and BA indicator lights
should flash.
4. If desired, dig a hole to the beginning-of-the-bore point
where you can disconnect the pipe or lines after pulling
them back.
7. Release the On and Off buttons (Figure 59).
Note: The TX and RX indicator lights should flash.
52
Testing the Zap-Alert System
The Zap-Alert system is an electric strike sensing device on
the machine that triggers a strobe light and audible alarm in
the event that the drill bit, reamer, or stake breaks into an
energized power line. In the event of an electric strike, the
machine will become energized, setting off the alarm.
DANGER
If the Zap-Alert system activates while drilling, the
machine, except for the operator’s platform, will
become energized. If you step off the operator
platform or if someone touches the machine or wet
ground near the machine or in the bore, you or
they could be electrocuted causing serious injury
or death.
• Test the Zap-Alert system before drilling.
• Deploy the grounding stake before drilling.
Ensure that the stake is fully inserted into moist
soil.
Figure 63
• If the Zap-Alert is triggered:
1. Test button
2. Zap-alert tester
5. Reset button
6. Alligator clips
3. Zap-alert system
7. Machine grounding point
4. Zap-alert system
grounding stud
– Stay in the seat and do not touch the ground
or any other part of the machine until the
power has been turned off. Do not pour
liquids or urinate from the operator platform
onto the ground.
4. Connect the other alligator clip to a metal component
of the machine frame.
5. Press the Test button on the Zap-Alert tester (Figure
63).
– Stop drilling, stop the drilling-fluid flow, and
retract the drill out of the ground.
The Zap-Alert alarm should sound, and the strobe on
top of the front hood should flash.
– Keep everyone away from the machine.
– Keep standing or running water and drilling
fluid contained close to the machine. Keep
water and drilling fluid sources away from
the broken line.
6. Press the Zap-Alert reset button to stop the alarm
(Figure 63).
– Contact the utility company to have power
shut off to the broken line. Do not reset the
Zap-Alert system until the power has been
turned off.
Test the Zap-Alert system before using the drill each day, as
follows:
1. Open the front hood; refer to Opening the Front
Hood (page 72).
2. Lay the grounding stake flat on the ground away from
the machine. Do not drive the stake into the ground.
Important: Do not allow the stake to touch any
part of the machine.
3. Connect an alligator clip from the Zap-Alert tester to
the grounding stud on the Zap-Alert system (Figure
63).
53
7. Disconnect the alligator clips from the grounding stud
and the machine.
8. Store the grounding stake in the holder on the operator
platform as shown in Figure 64.
1
g021838
Figure 64
1. Grounding stake
If either the audible alarm or the strobe light failed to
trigger when you pressed the test button, have them
repaired before drilling with the machine.
Mounting a Fire Extinguisher
Mount your fire extinguisher below the operator seat (Figure
65).
Note: A fire extinguisher is not provided with the machine.
The recommended fire extinguisher is a dry chemical fire
extinguisher approved for class B and C fires.
Figure 65
1. Mounting location
54
Loading Drill Pipes into the Pipe Holder
Before using the machine, fill the pipe holder with up to 40
drill pipes.
Figure 66
1. Pipe
2. Male end
3. Clevis pins
Adding Fuel
1. Remove the clevis pins from the pipe holder (Figure
66).
Service Interval: Before each use or daily—Check the fuel
level.
2. Insert the pipes from the top with the male threaded
pipe ends toward the front of the machine (Figure 66).
Use only clean, fresh diesel fuel or biodiesel fuels with low
(<500 ppm) or ultra low (<15 ppm) sulfur content. The
minimum cetane rating should be 40. Purchase fuel in
quantities that can be used within 180 days to ensure fuel
freshness.
3. Install the clevis pins before drilling.
Note: Before drilling, check the condition of the pipes and
replace any that are bent or damaged.
Fuel tank capacity: 114 L (30 US gallons)
Use summer grade diesel fuel (No. 2-D) at temperatures
above -7° C (20° F) and winter grade (No. 1-D or No.
1-D/2-D blend) below that temperature. Use of winter grade
fuel at lower temperatures provides lower flash point and
cold flow characteristics which will ease starting and reduce
fuel filter plugging.
55
Use of summer grade fuel above -7° C (20° F) will contribute
toward longer fuel pump life and increased power compared
to winter grade fuel.
• If this is not possible, then refuel such equipment on
Important: Do not use kerosene or gasoline instead of
diesel fuel. Failure to observe this caution will damage
the engine.
• If a fuel dispenser nozzle must be used, keep the nozzle in
a truck or trailer from a portable container, rather than
from a fuel dispenser nozzle.
contact with the rim of the fuel tank or container opening
at all times until fueling is complete.
DANGER
WARNING
Fuel is harmful or fatal if swallowed. Long-term
exposure to vapors can cause serious injury and
illness.
In certain conditions, fuel is extremely flammable
and highly explosive. A fire or explosion from fuel
can burn you and others and can damage property.
• Avoid prolonged breathing of vapors.
• Fill the fuel tank outdoors, in an open area, when
the engine is cold. Wipe up any fuel that spills.
• Keep face away from nozzle and gas tank or
conditioner opening.
• Do not fill the fuel tank inside an enclosed trailer.
• Do not smoke when handling fuel, and stay
away from an open flame or where fuel fumes
may be ignited by a spark.
• Keep fuel away from eyes and skin.
Biodiesel Ready
• Store fuel in an approved container and keep it
out of the reach of children. Do not buy more
than a 30-day supply of fuel.
This machine can also use a biodiesel blended fuel of up
to B20 (20% biodiesel, 80% petrodiesel). The petrodiesel
portion should be low or ultra low sulfur. Observe the
following precautions:
• Do not operate without entire exhaust system in
place and in proper working condition.
• The biodiesel portion of the fuel must meet specification
ASTM D6751 or EN14214.
1. Park the machine on a level surface.
• The blended fuel composition should meet ASTM D975
2. Open the rear hood; refer to Opening the Rear
Hood (page 73).
or EN590.
• Painted surfaces may be damaged by biodiesel blends.
3. Using a clean rag, clean the area around fuel tank cap.
• Use B5 (biodiesel content of 5%) or lesser blends in cold
4. Remove the cap from the fuel tank (Figure 67).
weather.
• Monitor seals, hoses, gaskets in contact with fuel as they
may be degraded over time.
• Fuel filter plugging may be expected for a time after
converting to biodiesel blended.
• Contact your dealer if you wish for more information
on biodiesel.
In certain conditions during fueling, static electricity can be
released causing a spark which can ignite the fuel vapors. A
fire or explosion from fuel can burn you and others and can
damage property.
• Place fuel containers on the ground away from your
Figure 67
vehicle before filling.
1. Fuel-tank cap
• Do not fill fuel containers inside a vehicle or on a truck
or trailer bed because interior carpets or plastic truck bed
liners may insulate the container and slow the loss of any
static charge.
5. Fill the tank until the level is to the bottom of the filler
neck with diesel fuel.
• When practical, remove equipment from the truck or
6.
trailer and refuel the equipment with its tracks on the
ground.
Install fuel tank cap tightly.
Note: If possible, fill the fuel tank after each use. This
will minimize possible buildup of condensation inside
the fuel tank.
56
Adjusting the Carriage Pressure
Checking the Engine-oil Level
To hydraulically adjust the carriage pressure, do the following:
Before you start the engine and use the machine, check the oil
level in the engine crankcase; refer to Checking the Engine-oil
Level (page 81) in Engine Maintenance.
1. Press button 7 on the screen to turn the carriage
pressure to the On position (green), as shown in Figure
68.
Checking the Cooling System
Before you start the engine and use the machine, check the
cooling system; refer to Cooling System Maintenance (page
92).
Checking the Hydraulic-fluid Level
Before you start the engine and use the machine, check
the hydraulic fluid level; refer to Checking the Hydraulic
Fluid (page 97) in Hydraulic System Maintenance.
Starting/Stopping the Engine
To start the engine, complete the following:
1. Open the front hood; refer to Opening the Front
Hood (page 72).
2. Turn the battery disconnect switch to the On position;
refer to Battery-Disconnect Switch (page 39).
3. Close and latch the hood.
4. Open the door on the rear control panel.
5. Turn the ignition key to the Run position.
Figure 68
1. Carriage-pressure gauge
3. Increase carriage pressure
2. Carriage pressure in the
On (green) position
4. Decrease carriage
pressure
2. Increase or decrease the carriage pressure as
follows:(Figure 69).
If the Wait-to-Start light illuminates, wait until it turns
off before proceeding.
6. Turn the ignition key to the Start position until the
engine starts, then release it.
• Press button 5 on the screen to decrease the
carriage pressure (Figure 69).
• Press button 6 on the screen to increase the
carriage pressure (Figure 69).
To stop the engine, turn the ignition key to the Off position.
In an emergency, you can also stop the engine and all
processes by pressing the Engine-stop button on either the
drive pendant or the control panel.
Note: The carriage-pressure gauge (Figure 69) will
fluctuate up or down based on how much you increase
or decrease the carriage pressure.
2
1
Driving the Machine
1. Walk around the machine to ensure that no one is near
it. Ensure that all bystanders are clear of the area where
you will be moving the machine.
2. Connect the drive pendant to the right receptacle on
the bottom of the rear control panel.
3. With the pendant in hand, walk at least 6 feet to the
side of the machine. Be sure to keep this safe distance
whenever moving the machine.
4. Press and hold the operator presence button on the
drive pendant.
5. Use the speed switch on the pendant to increase or
decrease the engine speed as desired.
6. Set the desired travel speed, using the speed switch.
7. Use the joy stick to move the machine as desired.
3
+
1
Machine Information
2
Lubrication and
Maintenance Chart
6
3
Read Error Codes
7
4
Diagnose and
Update System
ESC
Air Hammer
Control: OFF
Switch
Joystick
Functions
5
4
8
OK
G021581
Figure 69
1. Carriage-pressure gauge
3. Increase carriage pressure
2. Carriage pressure in the
On (green) position
4. Decrease carriage
pressure
Note: For more information on the drive pendant, refer
to Drive Pendant (page 37).
57
Loading and Unloading the Machine
4. Using the drive pendant, set the engine speed to slow
and the drive speed to slow.
WARNING
5. Using the drive pendant, carefully drive the machine
forward or rearward up the ramp and into position on
the trailer.
Moving a machine of this size on a trailer over
public roads carries risks to those around the
machine if it should come loose, be involved in an
accident, hit a low hanging structure, etc.
6. Lower the stake-down plate to the deck of the trailer.
7. Turn off the engine.
• Follow the tie-down procedures described in
this section when moving the machine.
8. Use appropriately rated chains and binders to secure
the rings on the left and right track frames and the
stake-down plate to the trailer (Figure 71).
• Follow all local traffic regulations governing the
hauling of large equipment. This manual cannot
adequately cover all laws and safety regulations;
it is your responsibility to know and follow the
laws and regulations that pertain to you.
WARNING
The machine can slip and fall from a trailer or ramp,
crushing anyone caught beneath it and causing
serious injury or death.
• Keep all bystanders away from the machine and
trailer.
• Ensure that the trailer and ramp are not slippery
and are free of ice, grease, oil, etc.
Figure 71
• Move the machine onto the ramp at slow speed
with the engine at slow speed.
1. Tie-down points (only right side shown)
• Ensure that you have the machine centered on
the ramp and trailer.
9. Measure the distance from the ground to the highest
point on the machine for reference to ensure that you
do not collide with low hanging obstacles.
1. Ensure the ramp and the trailer or truck bed can
support the weight of the machine.
10. Remove the block from the trailer tires, and stow them
with the machine for use when unloading it.
2. Ensure that the upper and rear pipe-holder pins are
installed Figure 70.
11. After driving a few miles, pull over and check to ensure
that all chains are still tight and that the machine has
not moved.
To unload the machine, reverse the above procedure.
Setting Up the Drill Head and Tracking
System
The drill head consists of two parts, the drill bit and the sonde
housing (Figure 72).
Figure 70
1. Upper pins
2. Lower pins
Figure 72
1. Sonde housing
3. Place a block at the front and rear of the trailer and/or
truck tires.
58
2. Drill bit
Drill bits vary in size and type to meet the various soil
conditions you may need to drill through. Some of the
possibilities are as follows:
• Straight blade—Used in a wide range of medium density
soils.
• Bent blade—Used in medium to soft soils. This bit has
an added 20° bend to increase steering performance in
soft soils.
Figure 74
• Triangle point blade—Use in hard and rocky soils. This
bit has carbide edges to reduce wear.
1. Sonde housing
3. Drill bit
2. Sonde beacon
All of the above bits come in varying widths. A wider blade
increases your ability to steer in soft soils. A narrower blade
moves through hard soils better. Contact your Authorized
Toro Dealer for a complete list of available blades.
4. Install the housing cover and secure it with the screws
(Figure 73).
The sondes and receivers are essential to track the position
of the drill head throughout the drilling operation. The
sonde housing on the drill head opens up to accept the sonde
beacon which works with the receiver to track the location,
pitch, direction, head orientation, and more of the drill head.
Refer to the Tracking System Operator’s Manual for instructions
on using the system.
To install the sonde beacon into the sonde housing on the
drill head, complete the following:
1. Replace the batteries in the sonde beacon as described
in the Tracking System Operator’s Manual.
2. Loosen the screws securing the housing cover to the
housing and remove the cover (Figure 73).
Figure 73
3. Insert the sonde beacon with the forward end toward
the drill bit into the sonde housing (Figure 74).
59
Setting up the Machine for Drilling
Note: The operator platform has 4 positions: travel
(swung all the way into the machine), full-out, and 2
intermediate positions.
1. Using the drive pendant, drive the machine to the
location that you have prepared for it, ensuring that
the front of the machine is the proper distance back
from entry point and the drill frame is in line with the
bore path.
2. Drive up to the location and make sure that all utilities
are located and marked prior to drilling.
3. Loosen the 4 screws that secure the covers over the
operator consoles and remove the covers (Figure 75).
Note: Store them someplace safe for the day.
Figure 77
1. Rear platform latch
6. Move the operator station to the desired angle, switch
the Drill/Drive switch to the Drill position, and raise
the pipe elevators, so that the pipe is resting on the
elevators; refer to Starting the First Pipe (page 63).
7. Load the first pipe and install the sonde and the drill
head; refer to Starting the First Pipe (page 63).
8. Place the drill head on the drill frame, and take a pitch
reading using the receiver; refer to the Tracking System
Operator’s Manual.
9. Lower the thrust frame, tilting the drill frame until the
plate contacts the ground (Figure 78).
Figure 75
1. Cover
2. Screw
4. Lower the pedestrian safety bar and secure it in place
(Figure 76).
Figure 78
1. Thrust frame
2. Stake-down plate
10. Lower the rear stabilizers until they contact the ground
firmly, or until the desired entry angle is achieved
(Figure 79).
Figure 76
1. Pedestrian safety bar (lowered position shown)
Note: The rear of the tracks should just start to lift
off the ground.
5. Push down on the rear platform latch securing the
operator platform, and swing it out to the desired
position, ensuring that it locks in place (Figure 77).
Note: If the ground is soft, place timber below the
stabilizers, and lower the stabilizers.
60
Connecting to a Drilling-fluid Source
When drilling and reaming, you pump a mixture of bentonite
clay, water, and sometimes other ingredients, collectively
called drilling fluid or “Mud”, through the pipe and into the
bore. This drilling fluid, or “Mud”, does the following for
your bore:
• Lubricates the drill head
• Loosens the soil into which the drill is cutting
• Penetrates and binds loose soil to keep them from
collapsing on the bore pipe.
The specific mixture you need will vary depending on your
soil type and the operation you are performing; refer to your
mixing system Operator’s Manual for details.
Conversely, for some jobs (depending on the soil type and
distance), you can pump screened water from a natural water
source, such as a lake or river, through the drill in lieu of
mixed drilling fluid.
• To connect the machine to a mixing system, refer to
Setting Up the Mixing System (page 61)
• To connect the machine to a natural water source, refer to
Setting Up the Pump to Use a Natural Water Source (page
62)
Figure 79
1. Rear stabilizers
11. Press the 2 right stake levers in to lower and spin the
right stake auger until it seats fully (Figure 80).
Setting Up the Mixing System
Set up your mixing system near the directional drill location,
preferably down wind so fumes from the mixing system
engine will not bother you while drilling. Follow the
instructions provided in the mixing system Operator’s Manual
for setting it up and using it.
Complete the following to connect the exit hose from the
mixing system to the drilling-fluid pump on the machine:
1. Raise the cam-lock levers on the pump-inlet cap and
remove the cap (Figure 81).
1
2
3
4
g021835
Figure 80
1. Left-stake-raise/lower
lever
2. Left-stake-spin lever
3. Right-stake-raise/lower
lever
4. Right-stake-spin lever
12. Repeat step 11 for the left-side stake.
Figure 81
1. Cam-lock levers
2. Pump-inlet cap
2. Insert the hose from the mixing system over the pump
inlet and secure it with the cam-lock levers.
61
Setting Up the Pump to Use a Natural Water Source
Deploying the Zap-Alert System
To set up a pump to use a natural water source, you must
ensure that you use the Y-screen to filter all materials other
than water.
The Zap-Alert system is an electric strike sensing device on
the machine that triggers a strobe light and audible alarm in
the event that the drill bit, reamer, or stake breaks into an
energized power line. In the event of an electric strike, the
machine will become energized, setting off the alarm. The
operator’s platform is electrically isolated from the rest of
the machine to protect you.
To install the Y-screen perform the following tasks:
1. Remove the pump-inlet cap (Figure 82).
DANGER
If the Zap-Alert system activates while drilling, the
machine, except for the operator’s platform, will
become energized. If you step off the operator
platform or if someone touches the machine or wet
ground near the machine or in the bore, you or
they could be electrocuted causing serious injury
or death.
• Test the Zap-Alert system before drilling.
• Deploy the grounding stake before drilling.
Ensure that the stake is fully inserted into moist
soil.
• If the Zap-Alert is triggered:
Figure 82
1. Pump threads
– Stay in the seat and do not touch the ground
or any other part of the machine until the
power has been turned off. Do not pour
liquids or urinate from the operator platform
onto the ground.
3. Y-screen
2. Pump-inlet cap
2. Align the Y-screen with the threads on the pump
(Figure 82).
– Stop drilling, stop the drilling-fluid flow, and
retract the drill out of the ground.
3. Rotate and tighten the Y-screen onto the pump.
4. Attach the hose to the Y-screen, and begin pumping
from the natural water source.
– Keep everyone away from the machine,
wet ground near the machine or running
from the machine, and any open sources of
water/mud that is in the bore and contacting
the broken line.
– Contact the utility company to have power
shut off to the broken line. Do not reset the
Zap-Alert system until the power has been
turned off.
1. Remove the grounding stake from the holder on the
side of the operator platform (Figure 83).
62
4. Lower the pipe elevators to load a pipe into the pipe
gripper.
1
5. Rotate the pipe gripper with the pipe toward the drill
frame, and extend the pipe until the pipe is centered
over the frame and in front of the spindle on the drill
carriage.
6. Rotate the drill spindle clockwise and move the carriage
slowly forward to insert the spindle into the female end
of the pipe (Figure 85).
g021838
Figure 83
1. Grounding stake
2. Move the stake directly away from the machine,
perpendicular to the drill frame and drive it into the
ground until the handle touches the ground.
3. If the ground is dry where you put the stake, soak it
with water before using the machine to ensure good
electrical contact.
Drilling the Bore
Figure 85
1. Drill spindle
Starting the First Pipe
1. Ensure that all bystanders are away from the machine
and that the exit-side lockout is On.
2. Pipe
7. Continue to move the drill carriage slowly down the
frame until the male threads on the pipe are under
the thread-joint-compound applicator and apply
thread-joint compound to the threads.
2. Move the drill carriage fully down the drill frame and
spray the spindle threads with thread joint compound,
then return the drill carriage to the upper end of the
frame (Figure 83).
8. Release and retract the pipe gripper, rotating it all the
way out to the third row of pipes.
Important: Ensure that you fully retract the
pipe gripper and rotate it all the way out or the
carriage may collide with the gripper, damaging
the machine.
9. Continue to rotate the drive spindle clockwise, until
the male pipe threads are fully seated into the sonde
housing or the lead bar.
Note: Torque the threads to 2305 N-m (1700 ft-lb).
Figure 84
1. Drill spindle
2. TJC-applicator nozzle
3. Rotate the pipe gripper to the first row of pipes in
the pipe holder by aligning the row indicator to row
number 1.
63
Installing the Drill Head
5. Using the upper wrench, clamp the lead bar and tighten
it to full machine torque.
1. Using the exit-side-lockout transmitter, enable the exit
side lockout.
6. Using the exit-side-lockout transmitter, enable the
exit-side lockout.
WARNING
7. Double check the drill head and bit to ensure that the
fluid ports are clean and free from obstructions.
If the drill rotates or extends while you or
others are manually working on the drill bit or
pipe in front of the machine, the worker could
get caught in the bit or pipe causing serious
injury, amputation, or death.
• Enable the exit-side lockout on the
exit-side-lockout transmitter before
approaching the dill bit or pipe when
attached to the machine. This will disable
the drill carriage.
• Do not wear loose clothing or jewelry when
working on a drill bit or pipe attached to
the machine. Tie long hair up and out of
the way.
8. Install the drill head onto the end of the lead bar as
directed by the drill head manufacturer, then clear away
from the front of the machine.
Important: Do not pull the drill head into the
pipe guide or you may damage the machine or the
drill head.
Boring the Entry Shaft
The first boring step is to create the entry shaft. In this step,
you push and bore the drill bit and first few pipes into the
ground at an angle from 0 to 16 degrees (with the tracks flat
on the ground) until you reach the desired depth of your
installation.
Important: Drill and ream in a clockwise rotation.
If you use a counterclockwise rotation the pipe will
disconnect from each other and may be disconnected
underground.
2. Hand thread the lead bar onto the pipe threads then
clear away from the front of the machine.
3. When the area is clear of people, disable the exit-side
lockout using the exit-side-lockout transmitter
(the OK-to-Drill light on the control panel should
illuminate); press the exit-side-lockout, reset switch on
the control panel.
1. When the area is clear of people, disable the exit-side
lockout using the exit-side-lockout transmitter
(the OK-to-Drill light on the control panel should
illuminate); press the exit-side-lockout, reset switch on
the control panel.
4. Pull the drill pipe and lead bar back through the pipe
guide and into the wrenches, aligning the thickened
upper joint of the lead bar with the upper wrench
(Figure 86).
2. Turn on the drilling fluid pump switch and allow the
fluid pressure to build to 200 to 300 psi.
Important: Do not clamp the wrench on the body
of a pipe or it may damage the pipe. Grip the pipes
on the thickened area near the joint.
3. Rotate the drill head until the bit is at the 6 o’clock
position.
4. Move the carriage forward driving the bit straight into
the ground until the entire dill housing is underground.
5. Continue pushing forward and begin rotating the drill
spindle clockwise to initiate the drilling action.
6. Drill forward until the carriage reaches the end of the
frame, then retract it about 6 mm (1/4 inch).
Adding Drill Pipes
1. Align the pipe joint in the wrench assembly.
2. Close the lower wrench (stationary wrench) onto the
first pipe.
Figure 86
1. Drill pipe
3. Lower wrench (stationary
wrench)
2. Upper wrench
(makeup/breakout
wrench)
4. Lead bar
Note: The drilling fluid will automatically shut off
when you activate the upper wrench (makeup/breakout
wrench).
3. Pull back the carriage approximately 12.7 mm (0.5
inch).
64
Note: This will allow the carriage to float, and will not
damage the pipe threads.
transmitter temperature, and orientation in the soil. The
remote console is a screen that remains near you (the drill
operator) to show you the information from the receiver
while drilling so you can make steering decisions.
4. Rotate the drill head counterclockwise until the spindle
is completely removed from the pipe.
For detailed information on using the receiver and remote
console to guide the drill head, refer to the Operator’s Manual
that came with your receiver.
5. Spray the spindle with thread joint compound, then
return the drill carriage to the upper end of the frame.
6. Rotate the pipe gripper to the closest row of pipes in
the pipe holder.
Important: Do not steer the drill head more than 20 cm
(8 inches) off center for every 10 feet of forward travel. If
you steer more than this you will damage the drill pipes.
7. Lower a pipe into the pipe gripper and grip it in place.
8. Rotate the pipe gripper toward the thrust frame, and
extend it until the pipe is centered over the frame and
in front of the spindle on the drill carriage.
Boring the Horizontal Shaft
After creating the entry shaft, you gradually steer the drill
head up while pushing forward, following the planned bore
path. When you reach the desired depth, level out the drill
head and bore the horizontal shaft, adding pipes as you go.
While boring, pay close attention to the information relayed
back to you by the receiver operator about the status and
location of the drill head to ensure that you are following the
planned path.
9. Rotate the drill spindle clockwise and move the carriage
slowly forward to insert the spindle into the female end
of the pipe (Figure 85).
Note: Tighten the joint until the pipe is rotating with
the spindle.
10. Move the drill carriage slowly down the frame
until the male threads on the pipe are under
the thread-joint-compound applicator and apply
thread-joint compound to the threads.
Important: While drilling, watch the sonde temperature.
All sondes have a maximum temperature above which
they will be damaged. Friction between the drill head
and the soil will cause the temperature to raise. To
reduce the temperature, slow down, decrease forward
pressure, and increase the drilling fluid flow. If the drill
head is entering a soil type other than what it is designed
for, that can also raise temperature. Assess the situation
and pull out the drill head and change it if necessary.
11. Rotate the drill spindle clockwise and move the carriage
slowly forward to insert the male end of the pipe into
the female end of the previous pipe. Tighten the joint
until you reach no more than 2,304 N-m (1,700 ft-lb).
12. Release and retract the pipe gripper, rotating it all the
way out past the third row of pipes.
Important: Ensure that you fully retract the
pipe gripper and rotate it all the way out or the
carriage may collide with the gripper, damaging
the machine.
If you run into an obstruction, do the following:
1. Increase the flow of the drilling fluid for a few seconds
without drilling, then attempt to continue drilling
forward.
13. Release the wrench and continue the drilling operation.
This may loosen the obstruction and allow you to push
past it.
Steering the Drill Head
2. If the obstruction persists, try one or more of the
following options:
The drill bit is shaped like a wedge, angled from one side of
the bit to the other. When you push the bit through the soil
without rotating it, it will veer toward the direction the wedge
is pointing. When you rotate the pipe and drill head it bores
through the soil in a straight path.
• If the obstruction is in an area where you can dig,
stop the drill head with the Exit Side Lockout
and dig down to the obstruction to identify it and
remove it if possible.
• Pull the drill head back 15 m (50 ft) or more and
steer the drill head to the side, marking a new drill
path around the obstacle.
Important: Do not steer the drill head more
than 20 cm (8 inches) off center for every 10
feet of forward travel. If you steer more than
this you will damage the drill pipes.
Figure 87
1. Drill bit
• If the obstruction is actually a change in soil types,
When drilling, the receiver operator follows the drill head as it
progresses. The receiver receives signals from the sonde in
the drill head identifying its position, depth, pitch, direction,
such as a zone of rocky soil, pull the drill head all
the way back and change to a drill bit appropriate
for drilling through the new soil type.
65
Exiting the Ground
Backreaming and Pullback
As you approach the end of the bore, steer the drill head to
the exit point, keeping the steering limits in mind as you do
so. Before exiting the ground, ensure that everyone is away
from the exit point. As soon as you break through, stop the
drilling-fluid flow. Extend the drill forward until the entire
drill head is out of the ground.
After drilling the initial bore, you attach a reamer to the pipe
which is then connected to a the product you are installing.
The reamer is designed to widen the bore, pack the walls and
lubricate the passage of the product into the bore.
The following reamers are available from your Authorized
Toro Dealer in various sizes to meet your needs and soil
conditions:
• Carbide step-wing cutter—Use this reamer in sandy
and medium clay soil conditions to mix the drilling fluid
with the soil, making a mixture that flows easily around
the product being pulled.
• Cast cone packer—Use this reamer in soils that pack
easily, such as soft clay, peat, and loam, to pack the sides
of the bore, maintaining the bore opening.
• Fluted reamer—Use this reamer in hard clay and rocky
soils; it combines the features of the other two reamers.
Connecting the Reamer and Product
WARNING
If the drill rotates or extends while you or others are
manually working on the drill bit or pipe in front of
the machine, the worker could get caught in the bit
or pipe causing serious injury, amputation, or death.
• Enable the exit-side lockout on the
exit-side-lockout transmitter before approaching
the dill bit or pipe when attached to the machine.
This will disable the drill carriage.
• Do not wear loose clothing or jewelry when
working on a drill bit or pipe attached to the
machine. Tie long hair up and out of the way.
1. Using the exit-side-lockout transmitter, enable the exit
side lockout.
2. Remove the drill head from the lead bar.
3. Double check the reamer to ensure that the fluid ports
are clean and free from obstructions.
4. Install the reamer and swivel onto the end of the lead
bar as directed by the reamer manufacturer
5. Connect the product to the reamer using an appropriate
pulling connection; refer to your Authorized Toro
Dealer to acquire the appropriate puller to meet your
requirements.
66
Removing Drill Pipes
13. Move the drill carriage back until the male-pipe threads
just clear the female end of the lower pipe, then close
the upper wrench onto the pipe end, but not on the
threads.
1. Using the exit-side-lockout transmitter, enable the exit
side lockout.
2. Install a drill-pipe wiper around the pipe and into the
retaining bracket on the front of the machine.
14. Rotate the drill spindle counterclockwise until the
upper-pipe joint is loose but not separated.
This will remove most of the dirt and mud from the
pipe as you pull it back into the machine, keeping the
machine clean. Contact your Authorized Toro Dealer
to purchase drill-pipe wipers.
15. Release the upper wrench.
16. Move the drill carriage back until the pipe is lined up
with the pipe holder.
17. Rotate the drill spindle counterclockwise moving
rearward slowly until the spindle fully separates from
the pipe.
1
18. Retract the pipe gripper arms.
19. Rotate the pipe cam to the desired row.
Note: Fill the outside rows first.
20. Release the pipe gripper and raise the pipe into the
holder row.
21. Raise the pipe into the pipe basket with the pipe
elevators.
22. Rotate the pipe gripper past the third row of pipes.
2
Important: Ensure that you fully retract the
pipe gripper and rotate it all the way out or the
carriage may collide with the gripper, damaging
the machine.
g021841
Figure 88
1. Drill-pipe wiper
2. Drill pipe
3. Disengage the exit-side lockout and reset the system.
23. Move the drill spindle down the frame under the
thread-joint-compound applicator, and spray the
spindle with thread joint compound.
4. Begin rotating the drill spindle clockwise and slowly
retract the drill carriage to pull the pipe back into the
machine
24. Rotate the drill spindle clockwise and move the carriage
slowly forward to insert the spindle into the female end
of the pipe secured in the lower wrench.
5. When the joint between the pipes is centered between
the two wrenches, the drill carriage will stop, and a
green light will illuminate below the spray valve.
Note: Tighten the joint until you reach no more than
2,304 N-m (1,700 ft-lb).
25. Release the wrench and continue reaming/retraction
as needed.
6. Close the lower wrench onto the pipe joint.
Note: The drilling fluid will automatically shut off
when you close the lower wrench.
Removing the Last Pipe and the Reamer
7. Rotate the pipe gripper to the drill frame, extend the
pipe-gripper arms to the pipe, and grip the pipe to
support it.
Important: Do not pull the drill head into the pipe
guide or you may damage the machine or the drill head.
1. Using the exit-side-lockout transmitter, enable the exit
side lockout.
8. Close the upper wrench onto the pipe joint.
9. Rotate the upper wrench counterclockwise until the
joint is loosened.
10. Release the upper wrench.
2. After the reamer has cleared the ground, if you have
not already done so, disconnect the product being
installed from the reamer.
11. Pull back the carriage approximately 12.7 mm (0.5
inch).
3. Connect the drilling fluid pump to a source of clean
water.
Note: This will allow the carriage to float, and will not
damage the pipe threads.
4. Turn the pump on to flush clean water through the
pump, spindle, and reamer until the water runs clear.
5. Remove and store the last pipe; refer to Removing Drill
Pipes (page 67).
12. Rotate the drill spindle counterclockwise moving
rearward slowly until the pipes are separated.
67
6. Leave the lead bar clamped in the lower wrench, but do
not connect the drill spindle to the lead bar.
Using the TJC Applicator
7. Remove the reamer from the end of the lead bar as
directed by the reamer manufacturer.
Adjusting the Applicator Nozzle
You can adjust the applicator nozzle to spray thread-joint
compound (TJC) either in a fan-shaped spray or as a stream.
8. Release the lower wrench and pull the lead bar out of
the pipe guide.
• For fan-shaped spray—turn the spray valve on the side
of the nozzle horizontal (Figure 89).
Finishing the Job
• For a stream—turn the spray valve on the side of the
nozzle vertical (Figure 89).
Complete the following after each day of use:
• Connect the hand spray gun to the pump and clean the
machine with clean water; refer to Cleaning with the
Spray-hose Attachment (page 102).
• Add grease to the grease fittings; refer to Greasing the
Machine (page 75).
• If the air temperature is below freezing or will be before
the next use, refer to Preparing the Drilling-fluid System
for Cold Weather (page 101).
• Install the controls covers; refer to Operator-Controls
Covers (page 21).
• Flush the drilling fluid out of the drilling-fluid pump with
water or antifreeze.
Note: The drilling-fluid pump may be damaged if the
drilling-fluid dries up in the pump.
Figure 89
1. Spray valve—fan-shaped
spray (horizontal)
68
2. Spray valve—stream
(vertical)
Adjusting the TJC-spray Volume
Filling the TJC Applicator
1. Stop the machine and stop the engine.
To adjust the volume of thread-joint compound that is
delivered by the applicator, complete the following:
2. Open the stake-down-guard door.
1. Loosen the jam nut on the adjustment bolt located on
top of the TJC-applicator piston (Figure 90).
1
2
3. Loosen the wing nuts securing the cover straps to the
machine (Figure 91).
3
1
2
3
4
5
g021846
g021845
Figure 91
Figure 90
1. Adjustment bolt
3. TJC-applicator piston
2. Jam nut
2. Adjust the bolt as follows:
1. TJC-applicator piston
4. Wingnut
2. Cover
3. Strap
5. TJC bucket
4. Rotate the cover and pull the cover straps off the
retaining bolts (Figure 91).
• To increase the applied volume of compound,
thread the bolt out (up).
5. Lift the cover assembly off and out of the empty
thread-joint-compound bucket (Figure 91).
• To decrease the applied volume of compound,
thread the bolt in (down).
6. Replace the empty bucket with a new full bucket.
3. When you have attained the desired application volume,
tighten the jam nut to secure the adjustment.
7. Place the plunger into the new bucket and lower the
cover assembly onto the bucket (Figure 91).
8. Slide the cover straps over the retaining bolts and rotate
the cover to seat the straps on the bolts (Figure 91).
9. Tighten the wing nuts.
69
Moving a Disabled Machine
Whenever the machine is stopped and the engine is not
running, the hydrostatic brakes automatically engage. Do not
attempt to tow the machine if it cannot move under its own
power. If possible, repair the machine at the site. If this is not
possible, use a crane and a spreader bar to lift the machine
onto a trailer, using the lift points shown in Figure 92.
Figure 92
Repeat lift points on other side
1. Spreader bar
2. Lift point
70
Maintenance
Note: Determine the left and right sides of the machine from the normal operating position.
Recommended Maintenance Schedule(s)
Maintenance Service
Interval
Maintenance Procedure
After the first 100 hours
• Check the gearbox drive oil.
• Change the gearbox-drive oil.
After the first 250 hours
• Adjust the valve clearance.
• Change the planetary oil.
Before each use or daily
•
•
•
•
•
•
•
•
•
•
Check the fuel level.
Grease the machine. (Grease immediately after every washing).
Check the crankcase-vent tube and clean it if necessary.
Check the indicator on the display screen for a restricted air filter.
Check the engine-oil level.
Check the track tension.
Check the coolant level in the reservoir for the radiator.
Check the hydraulic fluid level.
Check the drilling-fluid-pump oil level.
Clean the machine with the spray-hose attachment.
Every 50 hours
•
•
•
•
•
•
Check and clean the dust valve.
Remove air cleaner cover and clean out debris. Do not remove the filter.
Check the fuel-water separator for water and sediment.
Check the battery condition
Check the planetary-drive oil level (Also, check if external leakage is observed).
Check the coolant level in the radiator.
Every 250 hours
•
•
•
•
•
•
Clean or replace the air-cleaner filter.
Change the engine-oil filter.
Change the engine oil.
Clear the spark arrestor in the muffler of carbon buildup.
Replace the primary and secondary, fuel filters.
Check the condition of the engine-drive belt.
Every 300 hours
• Check the condition of the coolant system components. Clean dirt and debris from
them and repair or replace the components as necessary.
Every 500 hours
•
•
•
•
•
•
Every 800 hours
• Change the planetary oil (or yearly, whichever comes first).
Inspect the fuel lines and connections.
Check the gearbox drive oil (or yearly, whichever comes first).
Change the gearbox-drive oil (or yearly, whichever comes first).
Change the hydraulic-fluid return filter.
Change the hydraulic-pressure filter.
Change the drilling-fluid pump oil.
Every 1,000 hours
• Drain and clean the fuel tank.
• Check the concentration of the coolant before the winter season.
• Clean the cooling system. (Clean the cooling system if the coolant becomes dirty or
rust colored.)
• Check the tension on the engine drive belt.
• Change the hydraulic fluid.
Every 2,000 hours
• Adjust the valve clearance.
Yearly or before storage
• Touch up chipped paint.
Every 2 years
• Replace moving hoses.
Important: Refer to your Engine Operator's Manual for additional maintenance procedures.
71
CAUTION
If you leave the key in the ignition switch, someone could accidently start the engine and seriously injure
you or other bystanders.
Remove the key from the ignition before you do any maintenance.
WARNING
Improperly servicing or repairing the machine may cause injury or death.
If you do not understand the service procedures for this machine, contact your dealer or see the service
manual for this machine.
WARNING
Raised equipment on the machine without an operator may cause injury or death.
Before you leave the operator’s compartment, support or lower the equipment and stop the engine.
WARNING
Replace all covers and guards after you service or clean the machine. Do not operate the machine without
the covers or guards in place.
Premaintenance
Procedures
3. Lift up on the handle as shown in Figure 94.
Opening the Front Hood
1. Park the machine on a level surface, stop the engine,
and remove the ignition key.
2. Push down on the hood latch as shown in Figure 93.
Figure 94
1. Hood handle
Figure 93
1. Hood latch
72
Opening the Rear Hood
3. Lift up the handle as shown in Figure 96.
1. Park the machine on a level surface, stop the engine,
and remove the ignition key.
2. Pull the hood latch out (Figure 95).
Figure 96
1. Hood handle
Figure 95
1. Hood latch
73
Removing and Storing the Cylinder
Lock
Using the Cylinder Lock
WARNING
1. Start the engine.
The thrust frame may lower when it is in the raised
position, causing serious injury or death.
2. Lower the thrust frame to the fully lowered position.
3. Stop the engine.
Install the cylinder lock before performing
maintenance that requires the thrust frame to be
raised.
4. Remove the cotter pin and the clevis pin that secure the
cylinder lock (Figure 97).
5. Remove the cylinder lock.
6. Turn the engine to the On position, and raise the thrust
frame.
Installing the Cylinder Lock
1. Start the engine.
7. Store the cylinder lock next to the anti-freeze tank
(Figure 98).
2. Lower the thrust frame to the fully-lowered position.
3. Stop the engine.
4. Position the cylinder lock over the cylinder rod (Figure
97).
5. Secure the cylinder lock with the cotter pin and clevis
pin (Figure 97).
6. Turn the engine to the On position, and raise the thrust
frame until it rests on the cylinder lock.
Figure 98
1. Location behind the rear of the pipe holder
Figure 97
1. Cotter pin
4. Clevis pin
2. Cylinder lock
5. Lift cylinder
3. Lift cylinder rod
74
Lubrication
Greasing the Machine
Service Interval: Before each use or daily (Grease
immediately after every washing).
Grease type: General-purpose grease.
1. Park the machine on a level surface, stop the engine,
and remove the ignition key.
2. Clean the grease fittings with a rag.
3. Connect a grease gun to each fitting.
4. Pump grease into the fittings until grease begins to
ooze out of the bearings (approximately 3 pumps).
5. Wipe up any excess grease.
Figure 101
Rear-pipe elevator and cam cylinder (drill/carriage side)
Figure 102
Stabilizer cylinder and foot (drill/carriage side; repeat on
other side)
Figure 99
Lift cylinder (drill/carriage side; lower grease fitting is behind
the track roller)
Figure 103
Thrust-frame pivot pin (Under side of machine)
Figure 100
Front-pipe elevator and cam cylinder (drill/carriage side)
75
Figure 104
Rear-pipe elevator (operator’s side)
Figure 107
Carriage-roller bearings (operator’s side shown; repeat on
other side)
Figure 105
Front-pipe elevator (operator’s side)
Figure 108
Gearbox float (operator’s side shown; repeat on other side)
Figure 106
Stakedown motors
76
Figure 109
Track roller (operator’s side shown; repeat on other side)
Engine Maintenance
Cleaning the Crankcase-vent
Tube
Service Interval: Before each use or daily—Check the
crankcase-vent tube and clean it if
necessary.
1. Park the machine on a level surface, stop the engine,
and remove the ignition key.
Figure 110
Rear-cam bearing (operator’s side)
2. Open the front hood; refer to Opening the Front
Hood (page 72).
3. Gently pull the crankcase-vent tube out (Figure 112).
4. Clean the end of the crankcase-vent tube (Figure 112).
Figure 111
Front-cam bearing (drill/carriage side)
Figure 112
1. Crankcase vent tube
77
Servicing the Air-cleaning
System
B.
Important: Do not remove the elements from the
machine to check for dirty filters; use the following
procedure instead.
Repeat steps 1 and 2; if the restricted air-cleaner
indicator is still shown on the display screen,
replace the secondary, air-cleaner filter; refer to
Servicing the Air-cleaner Filter (page 80).
Cleaning the Dust Valve
Important: Do not replace the old air-cleaner filter with
a filter that is more than 5 years old; check the date of
manufacture on the end cap of the element.
Service Interval: Every 50 hours
1. Park the machine on a level surface, stop the engine,
and remove the ignition key.
Note: Every time you service the air-cleaner system, ensure
that all hose connections and flanges are air tight. Replace
all damaged parts.
• Check the air-cleaner body for damage which could cause
an air leak. Replace it if it is damaged. Check the whole
intake system for leaks, damage or loose hose clamps.
Also, inspect the rubber intake hose connections at the
air cleaner and turbo to make sure the connections are
complete.
• Service the air-cleaner filter only when “Check Air Filter”
is displayed on the screen. Changing the air filter before
it is necessary only increases the chance of dirt entering
the engine when the filter is removed.
• Be sure the cover is seated correctly and seals with the
air-cleaner body.
2. Open the front hood; refer to Opening the Front
Hood (page 72).
3. Squeeze the sides of the dust valve on the air-cleaner
cover to release any collected water, dust, or dirt from
the valve. (Figure 114).
Note: Ensure that there are no obstructions inside
the dust valve.
Checking the Air-cleaner Indicator
Service Interval: Before each use or daily
1. Start the engine.
2. Check the restricted, air-cleaner indicator on the display
screen as shown in Figure 113.
1
5
1
Figure 114
6
2
1. Dust valve
2. Latch
18
12
24
3. Air-cleaner cover
7
3
6
n/min
x 100
30
8
4
ESC
Servicing the Air-cleaner Cover
Service Interval: Every 50 hours—Remove air cleaner cover
and clean out debris. Do not remove the
filter.
OK
G021619
Figure 113
Removing the Air-cleaner Cover
1. Restricted air-cleaner indicator
1. Park the machine on a level surface, stop the engine,
and remove the ignition key.
3. Replace the air-filter element(s) as follows:
2. Open the front hood; refer to Opening the Front
Hood (page 72).
A. Replace the primary, air-cleaner filter; refer to
Servicing the Air-cleaner Filter (page 80).
78
Installing the Air-cleaner Cover
3. Clean the outside of the air-cleaner canister with a
clean, damp cloth.
1. Park the machine on a level surface, stop the engine,
and remove the ignition key.
4. Check the air-cleaner canister for damage which could
cause an air leak. Replace a damaged air cleaner body.
2. Align the dust cap on the air cleaner filter cover to the
5 o’clock position.
Important: Service the air-cleaner filter only when
“Check Air Filter” is displayed on the screen.
Changing the air filter before it is necessary only
increases the chance of dirt entering the engine
when the filter is removed.
3. Align the air cleaner filter cover with the filter housing
(Figure 116).
4. Rotate the air cleaner filter cover clockwise, so that the
dust cap is at the 4 o’clock position (Figure 115).
5. Pull the latch for the air-cleaner cover outward (Figure
114).
5. Push the latch on the air cleaner filter cover inward
until it is fully seated (Figure 115).
6. Rotate the filter cover counterclockwise so that the
dust cap is at the 4 o’clock position (Figure 115).
Figure 115
1. Air-cleaner cover
7. Pull the air-cleaner cover away from the filter housing
and remove the cover (Figure 116).
Figure 116
1. Air-cleaner cover
2. Filter housing
8. Clean any debris from inside the cover.
Important: If “Check Air Filter” is not displayed
on the screen, do not remove the air filters.
79
Servicing the Air-cleaner Filter
Service Interval: Every 250 hours
Replace the filters only when the “Check Air Filter”
indicator appears on the display screen; refer to
Checking the Air-cleaner Indicator (page 78).
Note: Contact your Authorized Toro Dealer to order
replacement filters.
1. Park the machine on a level surface, stop the engine,
and remove the ignition key.
2. Open the front hood; refer to Opening the Front
Hood (page 72).
Figure 118
1. Safety filter
3. Before removing the filter, clean out all debris from
the inside of the filter body using low-pressure air (40
psi, clean and dry).
6. Insert the new primary filter by applying pressure to
the outer rim of the filter to seat it in the canister. Do
not apply pressure to the flexible center of the filter.
Important: Avoid using high pressure air which
could force dirt through the filter into the intake
tract. This cleaning process prevents debris from
migrating into the intake when the primary filter
is removed.
7. Remove the rubber outlet valve from the cover, clean
the cavity, and replace the outlet valve.
8. Install the cover; refer to Installing the Air-cleaner
Cover (page 79).
4. Remove the primary filter (Figure 117).
Important: Do not clean the used filter.
2
Servicing the Engine Oil and
Filter
4
3
The engine is shipped with oil in the crankcase; however,
check the oil level before and after you first start the engine.
Crankcase capacity: 7.5 L (8 US qt) with the filter.
Use only high-quality SAE 15W-40 heavy-duty engine oil with
an API classification of CH-4 or higher.
1
While SAE 15W-40 oil with an API classification of CH-4 or
higher is recommended for most climates, refer to Figure 119
for oil viscosity recommendations for extreme climates.
°C -40 -30 -20 -10 0 10 20 30 40 50
°F -40 -22 -4 14 32 50 68 86 104 122
G022176
Figure 117
1. Rubber-outlet valve
3. Air-cleaner, primary filter
2. Air-cleaner latch
4. Air-cleaner body
All Seasons
15W-40
Winter Conditions
5. Inspect the new filter for shipping damage, checking
the sealing end of the filter and the body. Do not use
a damaged element.
Arctic Conditions
10W-30
5W-30
°C -40 -30 -20 -10 0 10 20 30 40 50
°F -40 -22 -4 14 32 50 68 86 104 122
Important: Do not clean the used safety filter
(Figure 118). Replace the safety filter with a new
one after every 3 primary filter services, or when
indicated by the “Check Air Filter” on the display
screen. If you are not replacing it, do not remove
the safety filter.
G022415
Figure 119
Note: Limited use of low-viscosity oils such as SAE 10W-30
with an API classification of CH-4 or higher can be used for
easier starting and providing sufficient oil flow at ambient
temperatures below -5°C (23°F). However, continuous use
80
of low viscosity oil can decrease engine life because of wear
(Figure 119).
Toro Premium Engine Oil is available from an Authorized
Toro Service Dealer in either 15W-40 or 10W-30 viscosity
with API classification CH-4 or higher. See the parts catalog
for part numbers.
Checking the Engine-oil Level
G021582
Service Interval: Before each use or daily—Check the
engine-oil level.
1. Park the machine on a level surface, stop the engine,
and remove the ignition key.
1
2. Open the front hood; refer to Opening the Front
Hood (page 72).
Figure 121
1. Oil-fill cap
3. Remove the dipstick (Figure 120), and wipe it clean.
B.
Install the oil fill cap and the dipstick.
Changing the Engine-oil Filter
Service Interval: Every 250 hours
1. Park the machine on a level surface, stop the engine,
and remove the ignition key.
2. Open the front hood; refer to Opening the Front
Hood (page 72).
3. Align a drain pan or several rags under the oil filter and
the oil-filter adapter (Figure 122).
Figure 120
Operator’s side
1. Dipstick
4. Insert the dipstick into the oil fill tube, pull the dipstick
out again, and read the oil level on the dipstick.
Note: The oil level on the dipstick should be at the
High mark or between the Low and High marks. If
the oil is below the Low mark, complete the following
procedure:
Figure 122
1. Oil-filter adapter
2. Oil filter
4. Rotate the oil filter counterclockwise and remove the
oil filter (Figure 122).
A. Remove the fill cap (Figure 121) and add oil until
the level reaches the High mark. Do not overfill.
Note: Discard the oil filter.
Important: Use an oil canister with a
bendable hose or a funnel to fill the machine
with oil.
5. Using a clean rag, wipe clean the surface of the oil-filter
adapter where the oil filter seats with a clean rag.
6. Fill the new oil filter with the specified-engine oil.
81
7. Apply a thin layer of the specified-engine oil to the seal
of the oil filter.
8. Align the oil filter to the oil-filter adapter and rotate
it clockwise until the seal of the oil filter contacts the
oil-filter adapter (Figure 122).
Note: Do not use an oil filter strap wrench to install
the new oil filter. The wrench can dent an oil filter and
therefore cause a leak.
9. Hand tighten the oil filter an additional 1/2 turn
(Figure 122).
Figure 124
10. Remove the oil pan or rags you placed in step 3 and
dispose of the used oil according to local codes.
1. Filler neck
2. Oil-fill cap
3. Funnel
Changing the Engine Oil
Service Interval: Every 250 hours
Note: Use a funnel with a flexible, attached hose to
direct the engine oil into the engine.
1. Park the machine on a level surface, stop the engine,
and remove the ignition key.
9. Fill the crankcase with approximately 7.5 L (8 US qt) of
the specified engine oil; refer to Servicing the Engine
Oil and Filter (page 80).
2. Remove the drain plug (Figure 123).
10. Install the oil-fill cap.
11. Start the engine, run it at idle for about 2 minutes, and
check for oil leaks.
12. Stop the engine and remove the key.
13. Wait for 2 or 3 minutes and check the oil level; refer to
Checking the Engine-oil Level (page 81).
Adjusting the Valve Clearance
Service Interval: After the first 250 hours
Every 2,000 hours
Refer to the engine owner’s manual, included with the
machine, for the adjustment procedure.
If you cannot adjust the valve clearance, contact your
Authorized Toro Service Dealer for valve adjustment.
Figure 123
1. Engine-oil drain plug
3. Clean the threads on the drain plug and apply 3 layers
of PTFE sealing tape.
4. Drain the oil into a drain pan.
5. When the oil stops, install the drain plug.
6. Change the engine-oil filter; refer to Changing the
Engine-oil Filter (page 81).
7. Install the drain plug onto the drain fitting (Figure 123).
8. Remove the oil-fill cap from the filler neck by pulling
the cap upward.
82
Servicing the Spark Arrestor
(If Equipped)
Fuel System
Maintenance
Service Interval: Every 250 hours—Clear the spark arrestor
in the muffler of carbon buildup.
DANGER
1. Park the machine on a level surface, stop the engine,
and remove the ignition key.
Under certain conditions, diesel fuel and fuel
vapors are highly flammable and explosive. A fire
or explosion from fuel can burn you and others and
can cause property damage.
• Use a funnel and fill the fuel tank outdoors, in
an open area, when the engine is off and is cold.
Wipe up any fuel that spills.
• Do not fill the fuel tank completely full. Add fuel
to the fuel tank until the level is 25 mm (1 inch)
below the bottom of the filler neck. This empty
space in the tank allows the fuel to expand.
• Never smoke when handling fuel, and stay away
from an open flame or where fuel fumes may be
ignited by a spark.
• Store fuel in a clean, safety-approved container
and keep the cap in place.
2. Remove the pipe plug from the clean-out port at the
lower side of the muffler.
WARNING
The muffler may be hot and could cause
injury.
Be careful not to touch the hot muffler.
3. Start the engine.
4. Plug the normal muffler exit with a block of wood or
metal plate so that the exhaust flow will be forced out
of the clean-out port. Continue to block the exit until
carbon deposits cease coming out of the port.
WARNING
Draining Water from the Fuel
Filter
Do not stand in line with the clean-out port;
hot elements could cause serious injury.
Wear safety glasses.
Service Interval: Every 50 hours—Check the fuel-water
separator for water and sediment.
5. Stop the engine and replace the pipe plug.
1. Park the machine on a level surface, stop the engine,
and remove the ignition key.
2. Open the front hood; refer to Opening the Front
Hood (page 72).
3. Align a drain pan under the secondary-fuel filter
(Figure 125).
Figure 125
1. Secondary-fuel filter
2. Drain valve
4. Rotate the drain valve at the bottom of the
secondary-fuel filter 2 or 3 turns counterclockwise,
83
Priming the Fuel System
and drain any water and sediment from the fuel filter
(Figure 125).
Note: Prime the fuel system whenever any of the following
occur:
Note: If the fuel-water separator has any water or
sediment, also drain the water and sediment from
the fuel tank; refer to Draining Water from the Fuel
Tank (page 84).
• You drained water from the fuel filter.
• You replaced the fuel filter.
5. When clean fuel appears, rotate the drain valve
clockwise until it is closed.
• You ran the engine until the fuel tank is empty or drained
Note: Do not overtighten the drain valve.
1. Park the machine on a level surface, stop the engine,
and remove the ignition key.
the fuel tank.
6. Prime the fuel system; refer to Priming the Fuel
System (page 84).
2. Open the front hood; refer to Opening the Front
Hood (page 72).
Draining Water from the Fuel
Tank
3. Ensure that the engine and the exhaust system are cool.
4. Ensure that the fuel tank is at least 1/4 full.
5. Rotate the battery-disconnect switch clockwise to the
On position.
1. Park the machine on a level surface, stop the engine,
and remove the ignition key.
6. Locate the priming button on the top of the filter
adapter for the secondary-fuel filter (Figure 127).
2. Place a drain pan under the drain plug in the fuel tank.
3. Loosen the drain plug until the water and sediment
drain out (Figure 126).
1
G021798
2
3
Figure 126
1. Fuel tank
3. Drain pan
2. Drain plug
Figure 127
1. Priming button
4. Clean the threads on the drain plug and apply 3 layers
of PTFE sealing tape.
5. When clean fuel appears, install the drain plug and
tighten it securely.
2. Filter adapter
7. Press down and release the priming button repeatedly
until you feel resistance when pressing the priming
button (Figure 127).
6. Check the fuel tank drain plug for leaks.
8. If the engine does not start after priming the fuel
system and making several attempts to start the engine,
bleed the high-pressure fuel lines; refer to your engine
owner’s manual or contact your Authorized Toro
Service Dealer for assistance.
84
WARNING
The fuel system is under high pressure.
Bleeding the system without proper
precautions and training could result in injury
to you from injected fluid or fire or explosion.
Read the engine owner’s manual for the
proper bleeding procedure or contact your
Authorized Toro Dealer.
Replacing the Fuel Filters
Service Interval: Every 250 hours—Replace the primary
and secondary, fuel filters.
Replacing the Primary, Fuel Filter
1. Park the machine on a level surface, stop the engine,
and remove the ignition key.
Figure 128
2. Open the front hood; refer to Opening the Front
Hood (page 72).
3. Place clean rags under the primary, fuel filter.
4. Loosen the hose clamps and separate the primary, fuel
filter from the fuel hoses (Figure 128).
1. Filter adapter
6. Hose clamp
2. Secondary-filter element
7. Arrow
3. O-ring
8. Primary fuel filter
4. Water sensor
9. Fitting
5. Fuel sensor
Note: Do not remove the hose clamps from the hoses.
D.
Note: Discard the fuel filter.
5. Align the new, primary, fuel filter to the hoses with the
arrow printed on the filter pointing forward (Figure
128).
Note: Discard the filter element.
E. Clean the filter adapter with a clean rag.
6. Slip the hoses over the hose fitting of the primary, fuel
filter, and tighten the hose clamps (Figure 128).
2. Install the secondary, fuel filter as follows:
A. Apply a thin film of clean fuel to the seal on the
fuel-filter element.
7. Replace the secondary, fuel filter; refer to Replacing the
Secondary, Fuel Filter (page 85).
Replacing the Secondary, Fuel Filter
1. Remove the secondary, fuel filter as follows:
B.
Align the new secondary-filter element to the
filter adapter (Figure 128).
C.
Rotate the secondary-filter element until the seal
contacts the filter adapter, then rotate the filter
element an additional 3/4 turn.
A. Clean the secondary, fuel-filter assembly and the
surrounding area.
B.
Completely drain water from the filter; refer to
Draining Water from the Fuel Filter (page 83).
C.
Firmly grasp the secondary-fuel-filter element,
and rotate the water sensor counterclockwise, and
remove the water sensor (Figure 128).
Firmly grasp the secondary-fuel-filter element,
and rotate it counterclockwise, and remove the
filter from the filter adapter (Figure 128).
Important: Do not use a filter wrench to
tighten the filter. You could damage the filter
and cause a leak.
D.
Align the new O-ring over the water sensor
(Figure 128).
E. Align the water sensor to the bottom of the
secondary, fuel filter (Figure 128).
Note: Retain the water sensor and discard the
O-ring.
F.
Firmly grasp the secondary-filter element and
rotate the water sensor clockwise until hand-tight
(Figure 128).
3. Prime the fuel system; refer to Priming the Fuel
System (page 84).
4. Start the engine and check for leaks at the fuel filters.
85
Checking Fuel Lines and
Connections
Electrical System
Maintenance
Service Interval: Every 500 hours/Yearly (whichever
comes first)—Inspect the fuel lines and
connections.
Servicing the Battery
Inspect the fuel lines and connections for deterioration,
damage, or loose connections.
Service Interval: Every 50 hours—Check the battery
condition
WARNING
Draining and Cleaning the Fuel
Tank
CALIFORNIA
Proposition 65 Warning
Battery posts, terminals, and related
accessories contain lead and lead compounds,
chemicals known to the State of California
to cause cancer and reproductive harm.
Wash hands after handling.
Service Interval: Every 1,000 hours/Yearly (whichever
comes first)—Drain and clean the fuel
tank.
Drain and clean the tank if the fuel system becomes
contaminated or if the machine will be stored for an extended
period of time. Use clean fuel to flush out the tank. Refer to
Draining Water from the Fuel Tank (page 84) for draining
instructions.
Important: Before welding on the machine, disconnect
the negative cable from the battery to prevent damage to
the electrical system. Also, disconnect the engine and
machine controllers before welding on the machine.
Note: Perform this procedure when the fuel level is low, to
avoid the need to drain large volumes of fuel.
Note: Check the battery condition weekly or after every
50 hours of operation. Keep the terminals and the entire
battery case clean because a dirty battery will discharge slowly.
To clean the battery, wash the entire case with a solution
of baking soda and water. Rinse with clear water. Coat
the battery posts and cable connectors with Grafo 112X
(skin-over) grease (Toro Part No. 505-47) or petroleum jelly
to prevent corrosion.
WARNING
Exposure to battery acid or a battery explosion can
cause serious personal injury.
Before you service a battery, wear face protection,
protective gloves, and protective clothing.
86
Charging the Battery
WARNING
A battery contains sulfuric acid, which can cause
serious burns; and they can produce explosive
gases.
WARNING
Charging the battery produces gasses that can
explode.
• Avoid contact with skin, eyes, or clothing; flush
affected areas with water.
Do not smoke near the battery and keep sparks and
flames away from battery.
• If taken internally, drink large quantities of water
or milk. Do not induce vomiting. Seek medical
attention immediately.
Important: Keep the battery fully charged. This is
especially important to prevent battery damage when
the temperature is below 32° F (0° C).
• Keep sparks, flames, and lit cigarettes and cigars
away from the battery.
1. Park the machine on a level surface, stop the engine,
and remove the ignition key.
• Ventilate the battery when you are charging it or
using it in an enclosed area.
2. Open the front hood; refer to Opening the Front
Hood (page 72).
• Wear eye protection when working near a
battery.
3. Clean the exterior of the battery case and the battery
posts.
• Wash your hands after handling a battery.
Note: Connect the leads of the battery charger to
battery posts before connecting the charger to the
electrical source.
• Keep the battery out of the reach of children.
4. Look at the battery and identify the positive and
negative battery posts.
WARNING
If you try to charge or jump start a frozen battery, it
could be explosive, causing personal injury to you
or others in the area.
5. Connect the positive lead of the battery charger to the
positive battery post (Figure 129).
To prevent the battery electrolyte from freezing,
keep the battery fully charged.
4
2
3
WARNING
1
• Sparks or a flame can cause hydrogen gas in a
battery to explode.
• When you disconnect the battery cables,
disconnect the negative (-) cable first.
G003792
• When you connect the battery cables, connect
the negative (-) cable last.
Figure 129
• Do not short-circuit the battery posts with a
metal object.
1. Positive battery post
3. Red (+) charger lead
2. Negative battery post
4. Black (-) charger lead
• Do not weld, grind, or smoke near a battery.
6. Connect the negative lead of the battery charger to the
negative battery post (Figure 129).
Note: The electrical system in this machine is 12 volts.
7. Connect the battery charger to the electrical source.
Important: Do not overcharge the battery.
Note: Charge the battery a shown in battery charging
table.
87
Battery-charger Table
Charger setting
Charging time
4 to 6 amperes
30 minutes
25 to 30 amperes
10 to 15 minutes
8. When the battery is fully charged, unplug the charger
from the electrical source, then disconnect the charger
leads from the battery posts (Figure 129).
Jump-starting the Machine
WARNING
Figure 130
Jump-starting the battery can produce gasses that
can explode.
Do not smoke near the battery and keep sparks and
flames away from battery.
1. Jumper-cable clamp
(positive)
4. Ground point (unpainted
bolt)
2. Jump post
5. Jumper-cable clamp
(negative)
3. Cover
Note: This procedure requires 2 people to perform. Ensure
that the person making the connections wears the proper face
protection, protective gloves, and clothing.
7. Connect the positive (+) jumper cable to the jump post
(Figure 130).
8. Connect the negative (-) jumper cable to a ground
point, such as an unpainted bolt or chassis member
(Figure 130).
1. Park the machine on a level surface, stop the engine,
and remove the ignition key.
2. Open the front hood; refer to Opening the Front
Hood (page 72).
9. Start the engine; refer to Starting/Stopping the
Engine (page 57).
3. Ensure that all controls are in the Neutral position.
Important: If the engine starts and then stops,
do not operate the starter motor until the starter
motor stops turning. Do not operate the starter
motor for more than 30 seconds at one time. Wait
30 seconds before operating the starter motor to
cool the motor and to build up the charge in the
battery.
4. Sit in the operator seat and have the other person make
the connections.
Note: Ensure that the jumper battery is a 12-volt
battery.
Important: If you are using another machine
for power, ensure that the 2 machines are not
touching each other.
10. When the engine starts, have the other person
disconnect the negative (-) jumper cable from the
frame and then disconnect the positive (+) jumper
cable (Figure 130).
5. Prepare to start the engine; refer to Starting/Stopping
the Engine (page 57).
6. Remove the cover from the jump post (Figure 130).
88
Changing the Oil for the
Planetary Drive
Drive System
Maintenance
Service Interval: After the first 250 hours—Change the
planetary oil.
Checking the Oil Level for the
Planetary Drive
Every 800 hours—Change the planetary oil (or yearly,
whichever comes first).
Note: Change the oil when it is warm, if possible.
Service Interval: Every 50 hours—Check the planetary-drive
oil level (Also, check if external leakage
is observed).
1. Park the machine on a level surface.
2. Clean the area around the oil-level plug (Figure 131).
Oil specification: SAE 85W-140 API classification level GL4
3. Rotate the planetary drive until the oil-drain plug is
directly below the oil-level plug (Figure 131).
Planetary drive oil capacity: approximately 1.4 L (1.5 US qt)
4. stop the engine and remove the ignition key.
Toro Premium Gear Oil is available from an Authorized Toro
Service Dealer. See the parts catalog for part numbers.
5. Place a drain pan under the oil-drain plug.
1. Park the machine on a level surface, stop the engine,
and remove the ignition key.
6. Remove the oil-level plug and the oil-drain plug.
7. Install the oil-drain plug.
2. Clean the area around the oil-level plug with a cleaning
solvent (Figure 131).
8. Fill the chain drive planetary with oil until the oil even
with the bottom of the oil-level plug hole.
9. Install the oil-level plug.
10. Repeat steps 1 through 9 to change the planetary-drive
oil on the other side of the machine.
Checking the Oil for the
Gearbox Drive
Service Interval: After the first 100 hours—Check the
gearbox drive oil.
Every 500 hours—Check the gearbox drive oil (or
yearly, whichever comes first).
Figure 131
1. Oil-level plug
Oil specification: SAE 85W-140 API classification level GL4
2. Oil-drain plug (6 o’clock
position)
Planetary-drive oil capacity: approximately 2.7 L (5.75 US
pt)
1. Park the machine on a level surface, stop the engine,
and remove the ignition key.
3. Rotate the planetary drive until the oil level and the
oil-drain plugs are vertical to the ground (at the 6
o’clock position) as shown in Figure 131.
2. Check the oil level on the sight-glass on the gearbox
drive (Figure 132).
4. Remove the oil-level plug (Figure 131).
Note: The oil level should cover half of the sight-glass.
Note: The oil level is correct when it is up to the
bottom of the oil-level plug hole.
5. If the oil is below the bottom of the hole, add the
specified oil until the oil is level with the bottom of
the hole.
6. Install and tighten the oil-level plug.
7. Repeat steps 1 through 6 to check the planetary-drive
oil level on the other side of the machine.
89
Figure 132
1. Sight-glass
3. Remove the breather cap and add the oil into the
gearbox drive until the oil level on the sight-glass is at
least half full (Figure 132).
Figure 133
Changing the Oil for the
Gearbox Drive
2. Stop the engine and remove the ignition key.
3. Remove the 4 bolts on the guard plate and gearbox
(Box A of Figure 133).
Service Interval: After the first 100 hours—Change the
gearbox-drive oil.
4. Remove the guard plate (Box A of Figure 133).
Every 500 hours—Change the gearbox-drive oil (or
yearly, whichever comes first).
5. Remove the cover on the gearbox and syphon the oil
out (Box B of Figure 133).
Note: Change the oil when it is warm, if possible.
6. Fill the gearbox with oil until the oil level in the sight
glass is more than half full (Figure 132).
1. Park the machine on a level surface and move the
carriage all the way to the rear stop.
7. Clean the sealant off of the gearbox box and cover
(Figure 134).
Figure 134
8. Put new automotive-grade RTV sealant around the
edge of the cover (Box B of Figure 134).
90
9. Place the guard back into place and install the 2 bolts
(Box A of Figure 133).
5. Remove excess grease from around the valve.
6. Install the cover and retaining bolts.
10. Install the 2 other bolts securing the lid onto the
gearbox (Box A of Figure 133).
7. Repeat steps 2 through 6 to tighten the track tension
on the other side.
11. Torque the bolts to 23 to 29 N∙m (17 to 21 ft-lb).
Loosening the Track Tension
Servicing the Tracks
If the track seems tight, loosen the track tension as follows:
Service Interval: Before each use or daily—Check the track
tension.
1. Park the machine on a level surface, stop the engine,
and remove the ignition key.
2. Remove dirt and debris found around the track-tension
grease valve (Figure 135).
WARNING
Grease in the hydraulic track is highly pressurized;
ensure that the track-tension grease valve is not
loosened more than one revolution at a time.
Important: Ensure that the entire area
surrounding the track-tension grease valve is clean
before beginning to adjust the track tension.
If you remove the track-tension grease valve found
in the hydraulic-track tensioner or loosen it too
much, grease can be released and may cause
serious injury or death.
3. Remove the retaining bolts and cover that house the
track-tension grease valve.
4. Turn the track-tension grease valve counterclockwise
no more than 1 revolution (Figure 135).
Note: A one-revolution turn will release grease and
loosen the track.
Tightening the Track Tension
If the track seems loose, tighten the track tension as follows:
5. When the tension reaches 3,200 psi, turn the
track-tension grease valve clockwise to tighten it.
1. Park the machine on a level surface, stop the engine,
and remove the ignition key.
6. Remove excess grease from around the valve.
2. Remove dirt and debris found around the track-tension
grease valve (Figure 135).
7. Install the cover and retaining bolts.
8. Repeat steps 2 through 7 to loosen the track tension on
the other side.
Important: Ensure that the area surrounding
the track-tension grease valve is clean before
beginning to adjust the track tension.
3. Remove the retaining bolts and cover that house the
track-tension grease valve.
4. Apply grease to the fitting until the tension reaches
22,063 kPa (3,200 psi) as shown in Figure 135.
Figure 135
Track-tension grease valve shown
91
Checking the Coolant Level in
the Reservoir
Cooling System
Maintenance
Service Interval: Before each use or daily
Coolant specification: 50/50 solution of ethylene-glycol
antifreeze and water or equivalent
Important: Do not remove the radiator filler cap during
this procedure.
Engine and Radiator coolant capacity: 16.77 L (17.7 US
qt)
1. Park the machine on a level surface, stop the engine,
and remove the ignition key.
2. Allow the engine to cool.
WARNING
If you remove the radiator cap from a hot engine,
hot coolant could spray, causing scalding.
3. Open the front hood; refer to Opening the Front
Hood (page 72).
• Wear face protection when opening the radiator
cap.
4. Check the coolant level in the reservoir (Figure 136).
2
1
• Allow the cooling system to cool down to below
50°C (120°F) before removing the radiator cap.
• Follow the instructions for checking the
maintaining the engine cooling system.
WARNING
Coolant is toxic.
• Keep coolant away from children and pets.
G022007
• If you are not using the same coolant again,
dispose of it according to local environmental
regulations.
Figure 136
1. Reservoir
2. Coolant level (1/2 reservoir
height)
5. Add the specified coolant until the coolant level is 1/2
the reservoir capacity.
Note: Ensure that the coolant solution is thoroughly
mixed before filling the reservoir.
Checking the Coolant Level in
the Radiator
Service Interval: Every 50 hours
WARNING
If the engine has been running, the radiator will be
pressurized and the coolant inside will be hot. If
you remove the cap, coolant may spray out, causing
severe burns.
• Do not remove the radiator cap to check coolant
levels.
• Do not remove the radiator cap when the engine
is hot. Allow the engine to cool for at least 15
minutes or until the radiator cap is cool enough
to touch without burning your hand.
92
Checking the Concentration of
the Coolant
Note: The cooling system is filled with a 50/50 solution of
water and ethylene-glycol antifreeze.
1. Park the machine on a level surface, stop the engine,
and remove the ignition key.
2. Allow the engine to cool.
3. Open the front hood and rear hood; refer to Opening
the Front Hood (page 72) and Opening the Rear
Hood (page 73).
4. Remove the radiator cap from the filler neck of the
radiator and check the coolant level (Figure 136 and
Figure 137),
Service Interval: Every 1,000 hours/Yearly (whichever
comes first)—Check the concentration
of the coolant before the winter season.
Test the concentration of ethylene glycol-based antifreeze
in the coolant . Ensure that the coolant has a 50% ethylene
glycol and 50% water mixture or equivalent.
Note: A 50% ethylene glycol and 50% water mixture will
protect the engine to -37° C (-34° F) throughout the year.
Note: The coolant should be up to the filler neck.
Using a concentration tester, check the concentration of
the coolant mixture to ensure that it is 50% ethylene glycol
and 50% water or equivalent; refer to the manufacturer’s
instructions for testing.
Cleaning the Cooling System
Service Interval: Every 1,000 hours/Yearly (whichever
comes first) (Clean the cooling system
if the coolant becomes dirty or rust
colored.)
Draining the Coolant from the System
Important: Do not pour coolant onto the ground or into
an unapproved container that can leak.
Figure 137
1. Reservoir
3. Coolant level (bottom of
radiator neck)
1. Park the machine on a level surface, stop the engine,
and remove the ignition key.
2. Coolant level (1/2 reservoir 4. Radiator cap
height)
2. Allow the engine to cool.
3. Open the front hood; refer to Opening the Front
Hood (page 72).
5. If the coolant level is low, add coolant until the level is
up to the bottom of the filler neck (Figure 137).
4. Remove the radiator cap (Figure 137).
Important: Do not overfill the radiator.
5. Place a drain pan under the drain plug (Figure 138).
Note: If the radiator coolant level is low and the
coolant reservoir level is at the Full mark, check for air
leaks in the hose between the radiator and the coolant
reservoir.
6. Install the radiator filler cap, ensuring that it is tightly
sealed (Figure 137).
7. If the air temperature is below 0°C (32°F), mix the
ethylene glycol and water completely by running the
engine at operating temperature for 5 minutes.
Note: The coolant capacity of both the engine and
the radiator is 16.8 L (17.7 US qt).
Checking the Condition of
Cooling-system Components
Service Interval: Every 300 hours/Yearly (whichever comes
first)
Figure 138
Check the condition of the cooling system for leaks, damage,
dirt, and loose hoses and clamps. Clean, repair, tighten, and
replace the components as necessary.
1. Radiator drain plug
93
6. Open the drain plug for the radiator and allow the
coolant system to drain completely.
E. Open the drain plug for the radiator, and drain
the cleaning solution into a drain pan.
Note: Dispose of the used coolant properly according
to local codes.
7. Clean the threads on the drain plug and apply 3 layers
of PTFE sealing tape.
F.
Clean the threads on the drain plug and apply 3
layers of PTFE sealing tape.
G.
Close the drain plug.
3. Flush the cooling system as follows:
8. Close the drain plug (Figure 138).
A. Open the filler-neck cap.
B.
Flushing the Cooling System
Fill the radiator with clean water (Figure 140).
Engine and radiator coolant capacity: 16.8 L (17.7 US qt)
1. Park the machine on a level surface, stop the engine,
and remove the ignition key.
2. Condition the cooling system as follows:
A. Ensure that the coolant is drained from the
radiator and that the drain plug is closed; refer to
Checking the Cooling System (page 57).
B.
Add a cooling system cleaning solution to the to
the radiator through the filler neck (Figure 139).
Figure 140
Note: Use cleaning solution of 21 g (12 oz dry)
of sodium carbonate for every 17 L (18 US qt)
of water; otherwise, use a commercially available
equivalent. Follow the directions that come with
the cleaning solution.
1. Filler neck
2. Funnel
3. Clean water
C.
Close the filler-neck cap.
D.
Operate the engine for 5 minutes or until the
coolant temperature indicates 82°C (180°F), and
then stop the engine.
CAUTION
The water is hot and can cause burns.
Stay away from the discharge end of the
coolant drain plug.
E. Open the drain plug and drain the water into a
drain pan.
Figure 139
1. Filler neck (radiator)
3. Coolant system cleaning
solution
F.
Clean the threads on the drain plug and apply 3
layers of PTFE sealing tape.
G.
If the water drained from the radiator is dirty,
perform steps 3-A through 3-E until the water
drained from the radiator is clean.
2. Funnel
C.
Close the drain plug (Figure 138).
Important: Do not install the radiator cap.
D.
H. Close the drain plug (Figure 138).
Operate the engine for 5 minutes or until the
coolant temperature indicates 82° C (180° F), and
then stop the engine.
CAUTION
The cleaning solution is hot and can
cause burns.
Stay away from the discharge end of the
coolant drain.
94
Belt Maintenance
Filling the System with Coolant
Important: You must fill the cooling system properly to
prevent air locks in the cooling passages. Failing to vent
the cooling system properly can severely damage the
cooling system and engine.
Servicing the Engine-drive
Belt
Important: Use a mixture of 50% ethylene glycol and
50% water mixture or equivalent in the machine. The
lowest ambient operating temperature for this mixture
is above -37° C (-34° F). If the ambient temperature is
lower, adjust the mixture. Use a mixture of ethylene
glycol and water or equivalent in the machine all year.
WARNING
Contacting a rotating belt can cause serious injury
or death.
Stop the engine and remove the ignition key before
working near belts.
1. Park the machine on a level surface, stop the engine,
and remove the ignition key.
2. Remove the radiator cap (Figure 137).
Checking the Condition of the Belt
3. Fill the radiator with coolant until the fluid level is up
to the bottom of the filler neck (Figure 141).
Service Interval: Every 250 hours
1. Park the machine on a level surface, stop the engine,
and remove the ignition key.
Note: The coolant capacity of both the engine and
the radiator is 16.8 L (17.7 US qt).
2. Open the front hood; refer to Opening the Front
Hood (page 72).
3
3. Inspect the belt for cuts, cracks, loose cords, grease, oil,
twisting, or signs of abnormal wear (Figure 142).
2
Note: Replace the belt if it is excessively worn or
damaged.
1
G022028
Figure 141
1. Coolant level (at the
bottom of the filler neck)
3. Coolant (50/50 ethylene
glycol and water or
equivalent)
2. Filler neck
4. Install the radiator cap (Figure 137).
5. Fill the coolant reservoir with coolant until it is full.
6. Install the coolant reservoir cap.
7. Start the engine and run it at half throttle for 5 minutes.
8. Stop the engine and remove the key.
9. Wait 30 minutes, then check the fluid level in the
coolant reservoir. If it is low, add coolant.
95
Adjusting the Tension of the Belt
Checking the Tension of the Belt
1. Park the machine on a level surface, stop the engine,
and remove the ignition key.
Service Interval: Every 1,000 hours
1. Park the machine on a level surface, stop the engine,
and remove the ignition key.
2. Open the front hood; refer to Opening the Front
Hood (page 72).
2. Open the front hood; refer to Opening the Front
Hood (page 72).
3. Loosen the nut and bolt at the pivot point for the
alternator (Figure 143).
3. Align a straight edge over the drive belt and across the
pulleys as shown in Figure 142.
Figure 143
1. Adjustment bolt
3. Alternator
2. Nut (alternator pivot point)
4. Bolt (alternator pivot point)
4. Loosen the adjustment bolt on the alternator (Figure
143).
5. Move the alternator away from the engine to increase
the belt tension; move the alternator toward the engine
to decrease the belt tension (Figure 143).
Figure 142
6. Tighten the alternator adjustment bolt (Figure 143).
4. Press the belt down at the midway point between the
fan pulley and the alternator pulley as shown in Figure
142.
7. Check the tension of the belt; refer to Checking the
Tension of the Belt (page 96).
8. If the belt tension is correct, tighten the nut and bolt
at the pivot point for the alternator (Figure 143);
otherwise repeat steps 4 through 7.
Note: The range of belt deflection between the
straight edge and the belt should be 7 to 9 mm (0.28 to
0.35 inches), under a load of 10 kg (22 lb).
5. If the tension of the belt is above or below the specified
range, adjust the drive belt tension; refer to Adjusting
the Tension of the Belt (page 96).
96
Checking the Hydraulic Fluid
Hydraulic System
Maintenance
Service Interval: Before each use or daily
Check the hydraulic fluid as follows:
Servicing the Hydraulic Fluid
1. Park the machine on a level surface, stop the engine,
and remove the ignition key.
The hydraulic reservoir is filled at the factory with
approximately 102 L (27 US gallons) of high-quality hydraulic
fluid. Check the level of the hydraulic fluid before
the engine is first started and daily thereafter. The
recommended replacement fluid follows:
2. Open the front hood; refer to Opening the Front
Hood (page 72).
3. Look at the sight gauge on the hydraulic tank and check
the level of the oil (Figure 144).
1
Toro Premium All Season Hydraulic Fluid (Available in
5 gallon pails or 55 gallon drums. Contact your Authorized
Toro Dealer for part numbers.)
Alternate fluids: If the Toro fluid is not available, other
fluids may be used provided they meet all the following
material properties and industry specifications. We do not
recommend the use of synthetic fluid. Consult with your
lubricant dealer to identify a satisfactory product.
2
Note: Toro will not assume responsibility for damage
caused by improper substitutions, so use only products
from reputable manufacturers who will stand behind their
recommendation.
High Viscosity Index/Low Pour Point
Anti-wear Hydraulic Fluid, ISO VG 46
Material Properties:
Viscosity, ASTM D445
42.2 cSt at 40° C (104° F)
7.8 cSt at 100° C (212° F)
Viscosity Index ASTM
D2270
158
Pour Point, ASTM D97
-6° C (-42° F)
3
Vickers I-286-S (Quality Level),
Vickers M-2950-S (Quality
Level), Denison HF-0
4
Industry Specifications:
G022167
Note: Many hydraulic fluids are almost colorless, making it
difficult to spot leaks. A red dye additive for the hydraulic
system oil is available in 20 mL (2/3 oz) bottles. One bottle
is sufficient for 15-22 L (4-6 gallons) of hydraulic oil. Order
part no. 505-150 from your Authorized Toro Dealer.
Figure 144
1. Hydraulic-tank breather
2. Hydraulic-tank cap
3. Full oil level
4. Low oil level
Note: If ambient operating temperatures exceed 43° C (110°
F), contact Toro for fluid recommendations.
4. If the level is low, open the hydraulic-tank cap, and add
the appropriate fluid until it reaches Full on the sight
gauge (Figure 144).
5. Install cap onto the filler neck.
97
Changing the Hydraulic-fluid Return
Filter
Changing the Hydraulic-pressure Filter
Service Interval: Every 500 hours/Every 6 months
(whichever comes first)
Service Interval: Every 500 hours/Every 6 months
(whichever comes first)
1. Park the machine on a level surface, stop the engine,
and remove the ignition key.
1. Park the machine on a level surface, stop the engine,
and remove the ignition key.
2. Open the front hood; refer to Opening the Front
Hood (page 72).
2. Open the front hood; refer to Opening the Front
Hood (page 72).
3. Place a drain pan under the filter.
3. Clean the area around the filler neck and cap of the
hydraulic tank.
4. Using a filter wrench, remove the hydraulic-pressure
filter (Figure 146).
4. Open the hydraulic-tank cap (Figure 145).
Figure 146
1. Hydraulic-pressure filter
5. Discard the old filter.
6. Apply a thin layer of hydraulic oil to the o-ring of the
filter.
Figure 145
7. Install and tighten the new filter with a filter wrench.
1. Hydraulic-tank cap
8. Start the engine, let it run idle for approximately
1 minute, then check for leaks around the
hydraulic-pressure filter.
5. Discard the old hydraulic-fluid return filter.
6. Install a new hydraulic-fluid return filter.
Changing the Hydraulic Fluid
Service Interval: Every 1,000 hours/Yearly (whichever
comes first)
Important: If the fluid becomes contaminated, contact
your Authorized Toro Dealer, because the system must
be flushed. Contaminated fluid looks milky or black
when compared to clean oil.
Important: Use of any other filter may void the warranty
on some components.
1. Park the machine on a level surface, stop the engine,
and remove the ignition key.
2. Open the front hood; refer to Opening the Front
Hood (page 72).
3. Raise the machine using proper equipment.
98
Inspect the hydraulic lines and hoses daily for leaks, kinked
lines, loose mounting supports, wear, loose fittings, weather
deterioration, and chemical deterioration. Make all necessary
repairs before operating.
WARNING
Raising the rear of the unit relying solely
on mechanical or hydraulic jacks could be
dangerous. The mechanical or hydraulic
jacks may not be enough support or may
malfunction allowing the unit to fall, which
could cause injury or death.
WARNING
Hydraulic fluid escaping under pressure can
penetrate skin and cause injury.
Do not rely solely on mechanical or hydraulic
jacks for support.
Use adequate jack stands or equivalent
support.
• Make sure that all hydraulic fluid hoses and
lines are in good condition and all hydraulic
connections and fittings are tight before
applying pressure to the hydraulic system.
4. Place a large draining container under the hydraulic
fluid tank.
• Keep your body and hands away from pin
hole leaks or nozzles that eject high pressure
hydraulic fluid.
5. Remove the drain plug from the bottom of the tank.
• Use cardboard or paper to find hydraulic leaks.
6. Clean the threads on the drain plug and apply 3 layers
of PTFE sealing tape.
• Safely relieve all pressure in the hydraulic system
before performing any work on the hydraulic
system.
7. Drain the hydraulic fluid flow into the container.
Important: The capacity of the hydraulic-fluid
tank is 102 L (27 US gallons), so ensure that you
have a container of at least 114 L (30 US gallons)
to drain the fluid into.
• Seek immediate medical attention if fluid is
injected into skin.
Hydraulic System Test Ports
8. Install the drain plug when the hydraulic fluid stops
draining.
The test ports are used to test the pressure in the hydraulic
circuits. Contact your Authorized Toro Dealer for assistance.
9. Clean the area around the filter mounting areas.
10. Place a drain pan under the filter and remove the filter
(Figure 145).
11. Lubricate the filter gasket of each new filter and fill
them with hydraulic fluid.
12. Ensure that the filter mounting areas are clean.
13. Screw the filters on until the gaskets contacts the
mounting plates; then tighten the filter an additional
1/2 turn.
14. Fill the reservoir with hydraulic fluid.
Important: Use only the hydraulic fluids
specified. Other fluids could cause system
damage.
15. Install the reservoir cap. Start the engine and use all
of the hydraulic controls to distribute hydraulic fluid
throughout the system. Also check for leaks; then stop
the engine.
16. Check the fluid level and add enough to raise level the
level to the Full mark on the dipstick. Do not overfill.
Checking the Hydraulic Lines and
Hoses
Service Interval: Every 2 years—Replace moving hoses.
99
Drilling-fluid Pump
Maintenance
4. Ensure that the oil is at the oil-fill line as shown in
Figure 147.
Note: If the oil is below the oil-fill line, refer to step
8 of Changing the Drilling-fluid Pump Oil (page 100)
and add the necessary amount of oil.
Servicing the
Drilling-fluid-pump Oil
Changing the Drilling-fluid Pump Oil
The drilling-fluid pump is shipped with oil in the crankcase;
however, check the oil level before and after you first start
the engine.
Service Interval: Every 500 hours—Change the drilling-fluid
pump oil.
1. Park the machine on a level surface, stop the engine,
and remove the ignition key.
The crankcase capacity is 1.9 L (2 US qt).
Use only high-quality engine oil that meets the following
specifications:
• API Classification Level Required: CH-4, CI-4 or
higher
• Oil: SAE 30-weight, non-detergent oil above 0° C (32° F)
2. Open the rear hood; refer to Opening the Rear
Hood (page 73).
3. Allow the engine to cool.
4. Remove the drain plug and place a drain pan under the
drain-plug hole (Figure 148).
Toro Premium Engine Oil is available from your dealer. See
the parts catalog for part numbers. Also, refer to the Engine
Operator's Manual, included with the machine, for further
recommendations.
1
Checking the Drilling-fluid-pump Oil
Level
Service Interval: Before each use or daily—Check the
drilling-fluid-pump oil level.
1. Park the machine on a level surface, stop the engine,
and remove the ignition key.
2. Open the rear hood; refer to Opening the Rear
Hood (page 73).
3. Remove the oil dipstick (Figure 147).
G0221 18
2
3
Figure 148
1. Oil-filler cap
3. Drain pan
2. Drain plug
5. Clean the threads on the drain plug and apply 3 layers
of PTFE sealing tape.
1
6. Allow all of the oil to drain from drain plug into the
oil pan (Figure 148).
7. Install the drain plug.
8. Remove the oil-filler cap (Figure 148) and add
approximately 1.9 L (2 qt) of oil, or until the oil reaches
the oil-fill line on the dipstick as shown in Figure 147.
G0221 19
Figure 147
1. Oil-fill line
100
Preparing the Drilling-fluid
System for Cold Weather
1
Prepare the machine as follows after drilling if the temperature
will be below 0° C (32° F).
1. Park the machine on a level surface, stop the engine,
and remove the ignition key.
2. Prepare the machine to circulate the antifreeze as
follows:
A. Open the rear hood; refer to Opening the Rear
Hood (page 73).
B.
G022141
Place a drain pan under the drill spindle for the
leaked antifreeze (Figure 149).
2
Figure 151
1
1. Antifreeze-tank cap
2. Antifreeze tank
E. Ensure that the tank is full of antifreeze (Figure
151).
3. Circulate the antifreeze as follows:
A. Open the antifreeze valve on the front side of the
drilling-fluid pump (the lower valve) as shown in
Figure 152.
1
G022139
2
Figure 149
1. Drill spindle
C.
2. Drain pan
Ensure that the cap is installed on the drilling-fluid
pump inlet (Figure 150).
G022142
2
Figure 152
1. Valve in the closed position 2. Valve in the open position
B.
Start the machine and turn On the drilling-fluid
pump.
C.
Add antifreeze to the tank as needed (Figure 151).
D.
When the antifreeze comes out of the drill spindle
(Figure 149), turn the pump off.
G022140
1
Figure 150
1. Drilling-fluid pump inlet
D.
4. Turn the machine off.
Remove the cap from the antifreeze tank for the
drilling-fluid pump (Figure 151).
5. Install the cap onto the antifreeze tank (Figure 151).
6. Close the antifreeze valve (Figure 152).
101
Cleaning
Cleaning with the Spray-hose
Attachment
Service Interval: Before each use or daily
The machine comes with a spray-hose attachment that you
can use to clean the machine and pipes.
Figure 154
Important: Do not spray any electronic component of
the machine and ensure that the hood is down before
cleaning the machine with the spray-hose attachment.
1. Drilling-fluid valve (Off position)
Important: If the outside temperature is below freezing,
refer to Preparing the Drilling-fluid System for Cold
Weather (page 101) before cleaning the machine.
5. Connect the spray-hose attachment to the fitting
(Figure 155).
To use the spray-hose attachment, perform the following
procedure:
1. Park the machine on a level surface, stop the engine,
and remove the ignition key.
2. Ensure that the spray-hose attachment switch is in the
Off position (Figure 153).
Figure 155
1. Fitting for the spray-hose attachment (end)
6. Turn the spray-hose attachment switch to the On
position (Figure 156).
Figure 153
1. Spray-hose attachment switch (Off position)
3. Open the rear hood; refer to Opening the Rear
Hood (page 73).
4. Turn the drilling-fluid valve clockwise to the Off
position (Figure 154).
Figure 156
1. Spray-hose attachment switch (On position)
102
Storage
7. Turn the drilling-fluid pump to the On position
through the display screen; refer to Main Drill
Functions Displayed in Pressure Screen (page 24).
1. Stop the engine and remove the key.
8. Using the spray-hose attachment, hold down the lever
and spray down the machine and pipes.
2. Remove dirt and grime from the entire machine.
Important: You can wash the machine with mild
detergent and water. Avoid excessive use of water,
especially near the control panel, engine, hydraulic
pumps, and motors.
Cleaning Plastic and Resin
Parts
3. Service the air cleaner; refer to Servicing the Air-cleaner
Cover (page 78).
Avoid using gasoline, kerosene, paint thinner, etc. when
cleaning plastic windows, the console, the instrument cluster,
the monitor, gauges, etc. Use only water, mild soap , and a
soft cloth when you clean these parts.
4. Grease the machine; refer to Greasing the Machine
(page 75).
5. Charge the battery; refer to Charging the Battery (page
87).
Using gasoline, kerosene, paint thinner, etc. to clean a plastic
or resin part will cause it to discolor, crack, or deform.
6. Check and adjust the track tension; refer to Servicing
the Tracks (page 91).
7. Check the coolant before winter storage; refer to
Checking the Cooling System (page 57).
8. Prepare the drilling-fluid pump for cold weather;
refer to Preparing the Drilling-fluid System for Cold
Weather (page 101).
9. Check and tighten all bolts, nuts, and screws. Repair or
replace any part that is damaged.
10. Paint all scratched or bare metal surfaces. Paint is
available from your Authorized Service Dealer.
11. Store the machine in a clean, dry garage or storage area.
Remove the key from the ignition switch and keep it in
a memorable place.
12. Cover the machine to protect it and keep it clean.
103
Troubleshooting
Problem
The starter does not crank.
The engine cranks, but will not start.
Possible Cause
Corrective Action
1. The battery-disconnect switch is in the
Off position.
1. Turn the battery-disconnect switch to
the On position.
2. The electrical connections are
corroded or loose.
3. A fuse is blown or loose.
4. The battery is discharged.
5. The relay or switch is damaged.
6. A starter or starter solenoid is
damaged.
7. The internal engine components have
seized.
2. Check the electrical connections for
good contact.
3. Correct or replace the fuse.
4. Charge the battery or replace it.
5. Contact your Authorized Service
Dealer.
6. Contact your Authorized Service
Dealer.
7. Contact your Authorized Service
Dealer.
1. An incorrect starting procedure was
used.
1. Refer to Starting and Stopping the
Engine.
2. The fuel tank is empty.
3. The fuel shut-off valve is closed.
4. Dirt, water, stale fuel, or incorrect fuel
is in the fuel system.
5. The fuel line is clogged.
6. There is air in the fuel.
2. Fill the tank with fresh fuel.
3. Open the fuel shut-off valve.
4. Drain and flush the fuel system, then
add fresh fuel.
5. Clean or replace the fuel line.
6. Bleed the nozzles and check for air
leaks at the fuel hose connections and
fittings between the fuel tank and the
engine.
7. Check the fuse, glow plugs, and wiring.
8. Check the battery, oil viscosity, and
starting motor (contact your Authorized
Service Dealer).
9. Service the air filters.
10. Replace the fuel filter.
11. Drain the fuel system and replace
the fuel filter. Add fresh fuel of the
proper grade for ambient temperature
conditions. You may need to warm the
entire machine.
12. Contact your Authorized Service
Dealer.
13. Contact your Authorized Service
Dealer.
14. Contact your Authorized Service
Dealer.
7. The glow plugs are inoperative.
8. The cranking speed is slow.
9. The air cleaner filters are dirty.
10. The fuel filter is clogged.
11. The fuel grade is improper for cold
weather use.
12. There is low compression.
13. The injection nozzles or pump are
malfunctioning.
14. The ETR solenoid is broken.
104
Problem
The engine starts, but does not keep
running.
Possible Cause
1. The fuel tank vent is restricted.
1. Loosen the cap. If the engine runs with
the cap loosened, replace the cap.
2. Dirt or water is in the fuel system.
2. Drain and flush the fuel system; add
fresh fuel.
3. Replace the fuel filter.
4. Bleed the nozzles and check for air
leaks at fuel hose connections and
fittings between the fuel tank and
engine.
5. Drain the fuel system and replace
the fuel filter. Add fresh fuel of
proper grade for ambient temperature
conditions.
6. Clean or replace the spark arrestor
screen.
7. Contact your Authorized Service
Dealer.
3. The fuel filter is clogged.
4. There is air in the fuel.
5. The fuel grade is improper for cold
weather use.
6. The spark arrestor screen is clogged.
7. The fuel pump is damaged.
The engine runs, but knocks or misses.
1. Dirt, water, stale fuel, or incorrect fuel
is in the fuel system.
1. Drain and flush the fuel system; add
fresh fuel.
2. The engine is overheating.
3. There is air in the fuel.
2. Refer to Engine Overheats.
3. Bleed nozzles and check for air leaks at
the fuel hose connections and fittings
between the fuel tank and engine.
4. Contact your Authorized Service
Dealer.
5. Contact your Authorized Service
Dealer.
6. Contact your Authorized Service
Dealer.
7. Contact your Authorized Service
Dealer.
8. Contact your Authorized Service
Dealer.
4. The injection nozzles are damaged.
5. There is low compression
6. The injection pump timing is incorrect.
7. There is excessive carbon build-up.
8. There is internal wear or damage.
The engine will not idle.
Corrective Action
1. The fuel tank vent is restricted.
1. Loosen the cap. If the engine runs with
the cap loosened, replace the cap.
2. Dirt, water, stale fuel, or incorrect fuel
is in the fuel system.
3. The air cleaner filters are dirty.
4. The fuel filter is clogged.
5. There is air in the fuel.
2. Drain and flush the fuel system; add
fresh fuel.
3. Service the air filters.
4. Replace the fuel filter.
5. Bleed the nozzles and check for air
leaks at fuel hose connections and
fittings between the fuel tank and
engine.
6. Contact your Authorized Service
Dealer.
7. Contact your Authorized Service
Dealer.
6. The fuel pump is damaged.
7. There is low compression
105
Problem
The engine overheats.
Possible Cause
1. More coolant is needed.
1. Check and add coolant.
2. There is restricted air flow to the
radiator.
3. The crankcase oil level is incorrect.
4. There is excessive loading.
2. Inspect and clean the side panel
screens with every use.
3. Fill or drain to the full mark.
4. Reduce the load and use a lower
ground speed.
5. Drain and flush the fuel system; add
fresh fuel.
6. Contact your Authorized Service
Dealer.
7. Contact your Authorized Service
Dealer.
8. Contact your Authorized Service
Dealer.
9. Contact your Authorized Service
Dealer.
5. The incorrect fuel is in the fuel system.
6. The thermostat is damaged.
7. The fan belt is loose or broken.
8. Injection timing is incorrect.
9. The coolant pump is damaged.
There is excessive black smoke in the
exhaust.
1. There is excessive loading.
1. Reduce the load and use a lower
ground speed.
2. The air cleaner filters are dirty.
3. Incorrect fuel is in the fuel system.
2. Service the air filters.
3. Drain the fuel system and refill with
specified fuel.
4. Contact your Authorized Service
Dealer.
5. Contact your Authorized Service
Dealer.
6. Contact your Authorized Service
Dealer.
4. The injection pump timing is incorrect.
5. The injection pump is damaged.
6. The injection nozzles are damaged.
There is excessive white smoke in the
exhaust.
1. The engine temperature is low.
1. Check the thermostat.
2. The glow plugs are inoperative.
3. The injection pump timing is incorrect.
2. Check the fuse, glow plugs, and wiring.
3. Contact your Authorized Service
Dealer.
4. Contact your Authorized Service
Dealer.
5. Contact your Authorized Service
Dealer.
4. The injection nozzles are damaged.
5. There is low compression
The engine loses power.
Corrective Action
1. The engine load is excessive.
1. Reduce ground speed.
2. The crankcase oil level is incorrect.
3. The air cleaner filters are dirty.
4. Dirt, water, stale fuel, or incorrect fuel
is in the fuel system.
5. The engine is overheating.
6. The spark arrestor screen is clogged.
2. Fill or drain to the full mark.
3. Service the air filters.
4. Drain and flush the fuel system; add
fresh fuel.
5. Refer to Engine Overheats.
6. Clean or replace the spark arrestor
screen.
7. Bleed the nozzles and check for air
leaks at fuel hose connections and
fittings between the fuel tank and
engine.
8. Contact your Authorized Service
Dealer.
9. Contact your Authorized Service
Dealer.
10. Contact your Authorized Service
Dealer.
11. Contact your Authorized Service
Dealer.
7. There is air in the fuel.
8. There is low compression
9. The fuel tank vent is restricted.
10. The injection pump timing is incorrect.
11. The injection pump is damaged.
106
Index
811 ............................. 4, 40–41
A
Accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Adding drill pipes . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Adding fuel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Air-cleaning system
Checking the air-cleaner indicator. . . . . 80
Cleaning the dust valve . . . . . . . . . . . . . . . . 78
Cover latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Installing the cover. . . . . . . . . . . . . . . . . . . . . . 80
Removing the cover . . . . . . . . . . . . . . . . . . . . 78
Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Servicing the air-cleaner cover . . . . . . . 103
Servicing the filters . . . . . . . . . . . . . . . . . . . . . 80
Antifreeze tank
Drilling-fluid system. . . . . . . . . . . . . . . . . . . . 101
Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Auto-drill-speed controls . . . . . . . . . . . . . . 32–33
Auxiliary-Activations screen . . . . . . . . . . . . . . 30
B
Backreaming. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Battery
Charging. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Disconnect switch . . . . . . . . . . . . . . . . . . . . . . 57
Jump-starting . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8, 86
Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Battery-disconnect switch . . . . . . . . . . . . . . . . 57
Beginning-of-bore-at-depth point. . . . . . . . . 43
Belt
Engine-drive
Adjusting tension . . . . . . . . . . . . . . . . . . . . . 96
Checking condition. . . . . . . . . . . . . . . . . . . 95
Checking tension. . . . . . . . . . . . . . . . . . . . . 96
Bent blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Bentonite clay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Biodiesel fuel
( See Fuel )
Bits
Drill. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Blade
bent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Straight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Triangle point (rock) . . . . . . . . . . . . . . . . . . . . 58
Bleeding the fuel system
( See Priming the fuel system )
Bore
Adding drill pipes . . . . . . . . . . . . . . . . . . . . . . . 64
Beginning-of, at-depth point . . . . . . . . . . . 43
Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Depth table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Drilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
End-of, at-depth point . . . . . . . . . . . . . . . . . . 43
Entry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Determining. . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Entry pitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Entry shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Exit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Exiting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Horizontal shaft . . . . . . . . . . . . . . . . . . . . . . . . . 65
Mapping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Marking and preparing . . . . . . . . . . . . . . . . . 52
Obstacles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41, 43
Starting the first pipe . . . . . . . . . . . . . . . . . . . 63
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Boring the entry shaft . . . . . . . . . . . . . . . . . . . . . 64
Button
Engine-start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Engine-stop . . . . . . . . . . . . . . . . . . . . .31, 37, 88
Front
Left joystick . . . . . . . . . . . . . . . . . . . . . . . 32–33
Right joystick . . . . . . . . . . . . . . . . . . . . . 34–35
Lower
Left joystick . . . . . . . . . . . . . . . . . . . . . . . 32–33
Right joystick . . . . . . . . . . . . . . . . . . . . . 34–35
Rear
Left joystick . . . . . . . . . . . . . . . . . . . . . . . 32–33
Right joystick . . . . . . . . . . . . . . . . . . . . . 34–35
C
Cam
( See Pipe cam )
Carbide step-wing cutter. . . . . . . . . . . . . . . . . . 66
Carriage
( See Drill carriage )
Carriage pressure
Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Carriage-pressure screen . . . . . . . . . . . . . . . . 28
Carriage-Pressure screen . . . . . . . . . . . . . . . 103
Carriage-Speed screen . . . . . . . . . . . . . . . . . . 103
Cast cone packer. . . . . . . . . . . . . . . . . . . . . . . . . . 66
Charging the battery . . . . . . . . . . . . . . . . . . . . . 103
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102–103
Cleaning the crankcase vent tube . . . . . . . 77
Clear-service-reminder Screen. . . . . . . . . . . 26
Cold weather
Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Communication lines
Safety precautions. . . . . . . . . . . . . . . . . . . . . . . .7
Connecting the reamer and product . . . . . 66
Control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18, 21
Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Control-select screen . . . . . . . . . . . . . . . . . . . . . 22
Controls
Auto-drill speed . . . . . . . . . . . . . . . . . . . . . 32–33
Drill frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Drill pendant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Drilling fluid. . . . . . . . . . . . . . . . . . . . . . . . . . 34–35
Drive pendant . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Horsepower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Left joystick—Mode I . . . . . . . . . . . . . . . . . . . 32
Left joystick—Mode II . . . . . . . . . . . . . . . . . . 33
Mode selection. . . . . . . . . . . . . . . . . . . . . . . . . . 22
Right joystick—Mode I . . . . . . . . . . . . . . . . . 34
Right joystick—Mode II. . . . . . . . . . . . . . . . . 35
Section contents . . . . . . . . . . . . . . . . . . . . . . . . 21
Stabilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Stake-down levers . . . . . . . . . . . . . . . . . . 38, 60
Coolant
Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Checking the concentration . . . . . . . . . . . . 93
Checking the level in the radiator. . . . . . 92
Checking the level in the reservior . . . . 92
Draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Coolant-temperature guage . . . . . . . . . . . . . . 23
Cooling system
Checking the condition of components 93
107
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coolant concentration
Checking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coolant level in the radiator
Checking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coolant level in the reservior
Checking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Covers
Operator-controls . . . . . . . . . . . . . . . . . . . . . . .
Crystalline silica
Safety precautions. . . . . . . . . . . . . . . . . . . . . .
Cylinder lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
93
93
92
92
93
95
94
68
41
74
74
74
D
Danger zone
Drilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Decals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Deploying the Zap-Alert system. . . . . . . . . . 62
Depth table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Determining the bore entry point . . . . . . . . . 43
Diesel fuel
( See Fuel )
Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Directional Drilling
Concept . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Disabled machine
Moving. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Draining the fuel tank . . . . . . . . . . . . . . . . . . . . . 86
Draining water
Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Drill bits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Drill carriage
Adjusting the pressure . . . . . . . . . . . . . . . . . 57
High-speed movement . . . . . . . . . . . . . 34–35
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18, 20
Pull rearward . . . . . . . . . . . . . . . . . . . . . . . . 34–35
Thrust forward . . . . . . . . . . . . . . . . . . . . . . 34–35
Drill frame
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Drill head
Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Drill pendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Drill pipe
Adding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Loading into the pipe holder . . . . . . . . . . . 55
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Starting the first . . . . . . . . . . . . . . . . . . . . . . . . . 63
Wiper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Drill spindle
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Spin clockwise . . . . . . . . . . . . . . . . . . . . . . 33–34
Spin counterclockwise. . . . . . . . . . . . . . 33–34
Drill-frame tilt lever . . . . . . . . . . . . . . . . . . . . . . . . 37
Drill-pendant receptacle . . . . . . . . . . . . . . 36, 38
Drilling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Adding drill pipes . . . . . . . . . . . . . . . . . . . . . . . 64
Directional
Concept . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Entry shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Horizontal shaft . . . . . . . . . . . . . . . . . . . . . . . . . 65
Setting up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Starting the first pipe . . . . . . . . . . . . . . . . . . . 63
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Drilling danger zone. . . . . . . . . . . . . . . . . . . . . . . . .6
Drilling fluid
Pump
Changing the oil . . . . . . . . . . . . . . . . . . . . . 100
Checking the oil level . . . . . . . . . . . . . . . 100
Connecting to a fluid source. . . . . . . . . 61
Connecting to a natural water
source. . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Connecting to mixing system. . . . . . . . 61
Servicing the oil . . . . . . . . . . . . . . . . . . . . . 100
Drilling fluid controls. . . . . . . . . . . . . . . . . . . 34–35
Drilling safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Drilling-Fluid Flow-Rate screen . . . . . . . . . 103
Drilling-fluid system
Cold weather preparation . . . . . . . . . . . . . 103
Drilling-fluid-information screen . . . . . . . . . . 30
Drilling-fluid-pump inlet
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Drive pendant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Drive-direction joystick . . . . . . . . . . . . . . . . . . . . 37
Drive/drill switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Drive-pendant receptacle . . . . . . . . .36, 38, 57
Drive-speed switch . . . . . . . . . . . . . . . . . . . . 37–38
Driving danger zone. . . . . . . . . . . . . . . . . . . . . . . . .5
Driving the machine . . . . . . . . . . . . . . . . . . . . . . . 57
Dust valve
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
E
Electric strike alarm
( See Zap-Alert system )
Electrical lines
Safety precautions. . . . . . . . . . . . . . . . . . . 7, 41
Elevator
( See Pipe elevator )
End-of-bore-at-depth point . . . . . . . . . . . . . . . 43
Engine
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . 92
Drive belt
Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Jump-starting . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Key Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Oil
Changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Checking the level . . . . . . . . . . . . . . . . . . . 82
Oil fliter
Changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Servicing the Air-cleaning system . . . . . 78
Servicing the Oil and Filter . . . . . . . . . . . . . 82
Spark arrestor
Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Speed switch. . . . . . . . . . . . . . . . . . . . . . . . 31, 37
Start button. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Stop button . . . . . . . . . . . . . . . . . . . . . . . . . . 31, 37
Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Valve clearance . . . . . . . . . . . . . . . . . . . . . . . . . 82
Vent tube
( See Cleaning )
Engine-heating light . . . . . . . . . . . . . . . . . . . . . . . 36
Entry pitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Entry shaft
Boring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Error Codes screen . . . . . . . . . . . . . . . . . . . . . . . 28
Exit-side lockout
Drill-enabled light . . . . . . . . . . . . . . . . . . . . . . . 31
Reciever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reset light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reset switch . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exit-side-lockout System
Reciever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exiting the ground . . . . . . . . . . . . . . . . . . . . . . . . .
31
31
31
36
36
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Guage
Coolant-temperature . . . . . . . . . . . . . . . . . . .
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
36
36
36
66
H
F
Fiber-optic lines
Safety precautions. . . . . . . . . . . . . . . . . . . . . . . .7
Filter
Air-cleaner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Fuel
Draining water . . . . . . . . . . . . . . . . . . . . . . . . 85
Hydraulic-fluid return
Changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Hydraulic-pressure
Changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Fluid
Hydraulic
Changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Checking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Return filter . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . 97
Fluid-pump switch . . . . . . . . . . . . . . . . . . . . . . . . . 36
Flushing the cooling system . . . . . . . . . . . . . . 94
Fluted reamer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Frame
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18, 20
Front button
Left joystick. . . . . . . . . . . . . . . . . . . . . . . . . . 32–33
Right joystick . . . . . . . . . . . . . . . . . . . . . . . . 34–35
Front hood
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Fuel
Adding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Biodiesel fuel. . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Checking lines and connections . . . . . . . 86
Filter
Draining water . . . . . . . . . . . . . . . . . . . . . . . . 85
Fuel filters
Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Low-fuel indicator . . . . . . . . . . . . . . . . . . . . . . . 23
Priming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Safety precautions. . . . . . . . . . . . . . . . . . . . . . 55
Tank
Draining and cleaning. . . . . . . . . . . . . . . . 86
Draining water . . . . . . . . . . . . . . . . . . . . . . . . 86
Tank capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Fuel guage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
G
Gas lines
Safety precautions. . . . . . . . . . . . . . . . . . . 7, 41
Gearbox drive
Changing the oil . . . . . . . . . . . . . . . . . . . . . . . . 90
Checking the oil. . . . . . . . . . . . . . . . . . . . . . . . . 89
Greasing the machine . . . . . . . . . . . . . . . . . . . . 75
Gripper
( See Pipe gripper )
( See Piper gripper )
Ground-strike-reset switch. . . . . . . . . . . . . . . . 31
Grounding stake
108
54
23
23
23
Hard hat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Hearing protection. . . . . . . . . . . . . . . . . . . . . . . . . . .4
Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Hood
Front
Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Opening . . . . . . . . . . . . . . . . . . . . . . . . . . . .98, 102
Rear
Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Horizontal Directional Drilling
( See Directional Drilling )
Horizontal shaft
Boring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Horsepower control . . . . . . . . . . . . . . . . . . . . . . . 23
Horsepower-control screen. . . . . . . . . . . . . . . 25
Hour meter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Hydraulic fluid
Changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Return filter
Changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Hydraulic system
Lines and hoses
Checking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Test ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Hydraulic-pressure filter
Changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
I
Indicator
Air-cleaner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ingnition switch . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Initial planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspecting the job site. . . . . . . . . . . . . . . . . . . . .
Installing the drill head . . . . . . . . . . . . . . . . . . . .
80
36
41
41
64
J
Job site
Inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Joystick
Drive-direction . . . . . . . . . . . . . . . . . . . . . . . . . .
Left
Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mode I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mode II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Right
Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mode I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mode II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Jump-starting the machine . . . . . . . . . . . . . . .
41
52
37
21
32
33
21
34
35
88
L
Labels
( See Decals )
Latch
Operator-platform. . . . . . . . . . . . . . . . . . . . . . . 21
Lead bar
Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Left joystick
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Mode I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Mode II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Left-stabilizer lever . . . . . . . . . . . . . . . . . . . . . . . . 37
Length. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Lever
Drill-frame tilt . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Left-stabilizer. . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Right-stabilizer . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Stake-down . . . . . . . . . . . . . . . . . . . . . . . . . 38, 60
Life jacket pendant
( See Drill pendant )
Lifter
( See Pipe elevator )
Lifting the machine . . . . . . . . . . . . . . . . . . . . . . . . 70
Light
Drill-enabled
Exit-side lockout. . . . . . . . . . . . . . . . . . . . . . 31
Engine-heating. . . . . . . . . . . . . . . . . . . . . . . . . . 36
Receiver-battery-status . . . . . . . . . . . . . . . . 31
Reset
Exit-side lockout. . . . . . . . . . . . . . . . . . . . . . 31
Transmitter-battery-status. . . . . . . . . . . . . . 31
Lights switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Loading drill pipes . . . . . . . . . . . . . . . . . . . . . . . . . 55
Loading the machine
Unloading the machine. . . . . . . . . . . . . . . . . 58
Low-fuel indicator . . . . . . . . . . . . . . . . . . . . . . . . . 23
Lower button
Left joystick. . . . . . . . . . . . . . . . . . . . . . . . . . 32–33
Right joystick . . . . . . . . . . . . . . . . . . . . . . . . 34–35
Lower wrench
Close . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32, 35
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Open. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32, 35
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Lubrication and Maintenance Screens . . 27
Mode II controls
Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Model and Serial Plate
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Model Number
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2, 23
Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Auxiliary-Activations screen. . . . . . . . . . . . 30
Carriage-pressure screen . . . . . . . . . . . . . . 28
Carriage-Pressure screen. . . . . . . . . . . . . 103
Carriage-Speed screen . . . . . . . . . . . . . . . 103
Clear-service-reminder Screen . . . . . . . . 26
Control-select screen. . . . . . . . . . . . . . . . . . . 22
Drilling-Fluid Flow-Rate screen . . . . . . . 103
Drilling-fluid-information screen. . . . . . . . 30
Error Codes screen. . . . . . . . . . . . . . . . . . . . . 28
Horsepower-control screen . . . . . . . . . . . . 25
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Lubrication and Maintenance Screens 27
Machine-use screen . . . . . . . . . . . . . . . . . . . . 23
Main Operating Screen. . . . . . . . . . . . . . . . . 29
Rotary and Carriage-Service screen . . 29
Rotary-Pressure screen . . . . . . . . . . . . . . . 103
Start-up screen . . . . . . . . . . . . . . . . . . . . . . . . . 22
Stored/Reset Error Codes screen . . . . . 28
Torque screen. . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Track-drive-information screen . . . . . . . . 30
Moving a disabled machine . . . . . . . . . . . . . . 70
Moving the machine. . . . . . . . . . . . . . . . . . . . . . . 57
Mud
( See Drilling fluid )
M
O
Machine-use screen . . . . . . . . . . . . . . . . . . . . . . 23
Magazine
( See Pipe holder )
Main Operating Screen . . . . . . . . . . . . . . . . . . . 29
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Belt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . 92
Drilling-fluid pump . . . . . . . . . . . . . . . . . . . . . 100
Drive system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Electrical system. . . . . . . . . . . . . . . . . . . . . . . . 86
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . 97
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Premaintenance procedures. . . . . . . . . . . 72
Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Tracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Mapping the bore. . . . . . . . . . . . . . . . . . . . . . . . . . 47
Meter
Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Mixing system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Mode I
Left joystick. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Right joystick . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Mode I controls
Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Mode II
Left joystick. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Right joystick . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Obstacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Oil
Changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Checking the level . . . . . . . . . . . . . . . . . . . . . . 82
Drilling-fluid-pump . . . . . . . . . . . . . . . . . . . . . 100
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Gearbox drive
Changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Checking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Planetery drive
Changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Checking the level . . . . . . . . . . . . . . . . . . . 89
Oil Filter
Changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
One-Call System Directory . . . . . . . . 4, 40–41
Opening the front hood . . . . . . . . . . . . . . . . . . . 98
Opening the rear hood . . . . . . . . . . . . . . . . . . . 102
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Operator platform . . . . . . . . . . . . . . . . . . . . . . . . . 21
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Operator seat
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Operator-controls covers . . . . . . . . . . . . . . . . . 68
Operator-platform latch . . . . . . . . . . . . . . . . . . . 21
Operator-presence switch . . . . . . . . . . . . 37–38
N
Noise information. . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Number
Model and Serial
Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2, 23
P
Pedestrian safety bar
Lowering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Pendant
109
Drill. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Pipe
Adding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Flexibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Starting the first . . . . . . . . . . . . . . . . . . . . . . . . . 63
Utility product
Connecting to a reamer. . . . . . . . . . . . . . 66
Wiper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Pipe cam
Rotate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32–33
Sensor-failure override . . . . . . . . . . . . . 32–33
Pipe elevator
Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32, 35
Raise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32, 35
Pipe gripper
Close . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32–33
Extend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32–33
Open. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32–33
Retract. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32–33
Pipe holder
Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Pipe loader
Enable controls . . . . . . . . . . . . . . . . . . . . . 32–33
Pipe magazine
( See Pipe holder )
Pipe wiper
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Pipes
Loading into the pipe holder . . . . . . . . . . . 55
Pitch
Setting the thrust frame . . . . . . . . . . . . . . . . 60
Planetary drive
Changing the oil . . . . . . . . . . . . . . . . . . . . . . . . 89
Checking the oil level. . . . . . . . . . . . . . . . . . . 89
Oil specification and capacity . . . . . . . . . . 89
Planning
Initial . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Planning the bore path. . . . . . . . . . . . . . . . . . . . 43
Plate
Stake-down
Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Platform
Operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Preparation
Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Preparing for drilling. . . . . . . . . . . . . . . . . . . . . . . 60
Preparing the job site and machine . . . . . . 52
Priming the fuel system . . . . . . . . . . . . . . . . . . . 85
Product
Connecting to a reamer . . . . . . . . . . . . . . . . 66
Product overview illustration
Left side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Right side. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Top view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Product safety decals . . . . . . . . . . . . . . . . . . . . . . .9
Pullback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66–67
Pump
Drilling fluid
Connecting to a fluid source. . . . . . . . . 61
Connecting to a natural water
source. . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Connecting to mixing system. . . . . . . . 61
Drilling-fluid
Changing the oil . . . . . . . . . . . . . . . . . . . . . 100
Checking the oil level . . . . . . . . . . . . . . . 100
Servicing the oil . . . . . . . . . . . . . . . . . . . . . 100
Inlet
Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
R
Reamer
Carbide step-wing cutter . . . . . . . . . . . . . . . 66
Cast cone packer . . . . . . . . . . . . . . . . . . . . . . . 66
Connecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Fluted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Rear button
Left joystick. . . . . . . . . . . . . . . . . . . . . . . . . . 32–33
Right joystick . . . . . . . . . . . . . . . . . . . . . . . . 34–35
Rear control panel. . . . . . . . . . . . . . . . . . . . . . . . . 36
Rear hood
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Receiver-battery-status light. . . . . . . . . . . . . . 31
Receptacle
Drill-pendant . . . . . . . . . . . . . . . . . . . . . . . . 36, 38
Drive-pendant . . . . . . . . . . . . . . . . . . .36, 38, 57
Removing drill pipes . . . . . . . . . . . . . . . . . . . . . . 67
Removing the last pipe . . . . . . . . . . . . . . . . . . . 67
Removing the reamer . . . . . . . . . . . . . . . . . . . . . 67
Replacing the fuel filters . . . . . . . . . . . . . . . . . . 85
Right joystick
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Mode I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Mode II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Right-stabilizer lever . . . . . . . . . . . . . . . . . . . . . . 37
Rock blade
( See Triangle point blade )
Rotary and Carriage-Service screen. . . . . 29
Rotary-Pressure screen . . . . . . . . . . . . . . . . . 103
RPM guage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
S
Safe attire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Safety
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8, 86
Clothing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Communication lines . . . . . . . . . . . . . . . . . . . . .7
Crystalline silica. . . . . . . . . . . . . . . . . . . . . . . . . 41
Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Drilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Drilling danger zone . . . . . . . . . . . . . . . . . . . . . .6
Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Driving danger zone . . . . . . . . . . . . . . . . . . . . . .5
Electrical lines. . . . . . . . . . . . . . . . . . . . . . . . 7, 41
Fiber-optic lines . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4, 55
Gas lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7, 41
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Hard hat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Hearing protection . . . . . . . . . . . . . . . . . . . . . . . .4
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Noise information . . . . . . . . . . . . . . . . . . . . . . . . .8
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Safety glasses . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Training. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Utility lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Water lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Zap-Alert system
Deploying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Safety Alert Symbol . . . . . . . . . . . . . . . . . . . . . . 2, 4
Safety bar
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Safety glasses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Screen
Auxiliary-Activations . . . . . . . . . . . . . . . . . . . . 30
Carriage Pressure . . . . . . . . . . . . . . . . . . . . . 103
Carriage-pressure . . . . . . . . . . . . . . . . . . . . . . 28
Carriage-Speed . . . . . . . . . . . . . . . . . . . . . . . . 103
Clear-service-reminder . . . . . . . . . . . . . . . . . 26
Control-select . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Drilling-fluid Flow Rate . . . . . . . . . . . . . . . . 103
Drilling-fluid-information . . . . . . . . . . . . . . . . 30
Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Horsepower-control. . . . . . . . . . . . . . . . . . . . . 25
Machine-use . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Main Operating . . . . . . . . . . . . . . . . . . . . . . . . . 29
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Reset-Error. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Rotary and Carriage-Service . . . . . . . . . . 29
Rotary-Pressure . . . . . . . . . . . . . . . . . . . . . . . 103
Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Track-drive-information. . . . . . . . . . . . . . . . . 30
Seat
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Serial Number
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2, 23
Servicing the tracks . . . . . . . . . . . . . . . . . . . . . . 103
Setting up for drilling . . . . . . . . . . . . . . . . . . . . . . 60
Sonde . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Sonde housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Spark arrestor
Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Spindle
( See Drill spindle )
Spray-hose attachment
Cleaning with. . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Spreader bar
Lifting the machine . . . . . . . . . . . . . . . . . . . . . 70
Stabilizer
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18–19
Stabilizer controls . . . . . . . . . . . . . . . . . . . . . . . . . 37
Stabilizer levers . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Stabilizers
Lowering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Stake-down cage
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Stake-down levers . . . . . . . . . . . . . . . . . . . . . . . . 38
Stake-down plate. . . . . . . . . . . . . . . . . . . . . . . . . . 60
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Start-up screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Starting the engine . . . . . . . . . . . . . . . . . . . . . . . . 88
Starting the first pipe . . . . . . . . . . . . . . . . . . . . . . 63
Steering the drill head. . . . . . . . . . . . . . . . . . . . . 65
Stopping the engine. . . . . . . . . . . . . . . . . . . . . . . 88
Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Stored/Reset Error Codes screen. . . . . . . . 28
Straight blade. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Switch
Battery-disconnect. . . . . . . . . . . . . . . . . . . . . . 57
Drive/drill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Drive-speed . . . . . . . . . . . . . . . . . . . . . . . . . 37–38
Engine, key. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Engine-speed . . . . . . . . . . . . . . . . . . . . . . . 31, 37
Fluid-pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Ground-strike-reset . . . . . . . . . . . . . . . . . . . . . 31
Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Operator-presence . . . . . . . . . . . . . . . . . 37–38
Reset
Exit-side lockout. . . . . . . . . . . . . . . . . . . . . . 31
Toggle
Left joystick . . . . . . . . . . . . . . . . . . . . . . . 32–33
110
Right joystick . . . . . . . . . . . . . . . . . . . . . 34–35
Symbol
Safety Alert. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2, 4
T
Temperature
Sonde. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Testing the Zap-Alert system . . . . . . . . . . . . . 53
Thread joint compound
Applicator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Applicator nozzle
Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Spray volume
Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Thrust frame
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18, 20
Lowering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Setting the pitch. . . . . . . . . . . . . . . . . . . . . . . . . 60
Tie-down points . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
TJC
Thread joint compound. . . . . . . . . . . . . . . . . 68
Toggle switch
Left joystick. . . . . . . . . . . . . . . . . . . . . . . . . . 32–33
Right joystick . . . . . . . . . . . . . . . . . . . . . . . . 34–35
Torque screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Track
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Track-drive-information screen. . . . . . . . . . . 30
Tracking system . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Tracks
Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Tension
Loosening. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Tightening . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Trailering the machine . . . . . . . . . . . . . . . . . . . . 58
Training
Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Tramming
( See Driving the machine )
Transmitter
( See Sonde )
Transmitter-battery-status light. . . . . . . . . . . 31
Tread-joint compound
Application controls. . . . . . . . . . . . . . . . . 34–35
Triangle point blade . . . . . . . . . . . . . . . . . . . . . . . 58
Trigger
Left joystick. . . . . . . . . . . . . . . . . . . . . . . . . . 32–33
Right joystick . . . . . . . . . . . . . . . . . . . . . . . . 34–35
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 104
U
Upper wrench
Close . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32–33
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Open. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32–33
Rotate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32–33
Using the TJC applicator . . . . . . . . . . . . . . . . . 68
Utility lines
Connecting to a reamer . . . . . . . . . . . . . . . . 66
Safety precautions. . . . . . . . . . . . . . . . . . . . . . 40
Utility Lines
Marking
811 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4, 40–41
Color codes (US and Canada) . . . . . . . .7
One-Call System Directory . . . 4, 40–41
V
Valve clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Vent tube
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Vibration information . . . . . . . . . . . . . . . . . . . . . . . .8
W
Water as drilling fluid. . . . . . . . . . . . . . . . . . . . . . 62
Water lines
Safety precautions. . . . . . . . . . . . . . . . . . . . . . . .7
Weight. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Wiper
Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Wire
Connecting to a reamer . . . . . . . . . . . . . . . . 66
Wrench
Enable controls . . . . . . . . . . . . . . . . . . . . . 32–33
Lower
Close . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32, 35
Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32, 35
Upper
Close . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32–33
Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32–33
Rotate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32–33
Z
Zap-Alert system . . . . . . . . . . . . . . . . . . . . . . . 7, 41
Deploying. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Ground-strike-reset switch . . . . . . . . . . . . . 31
Grounding stake
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Strobe
Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
111
Underground
Equipment
The Toro Underground Warranty
A Limited Warranty
Conditions and Products Covered
The Toro Company and its affiliate, Toro Warranty Company, pursuant
to an agreement between them, jointly warrant your Toro Underground
Equipment (“Product”) to be free from defects in materials or workmanship.
Where a warrantable condition exists, we will repair the Product
at no cost to you including diagnostics, labor, and parts.
The following warranty applies from the date the Product is delivered to the
original retail purchaser or rental owner.
Products
RT600, RT1200, DD2024, and
DD4045
All Other Engine Powered Base
Units and Fluid Mixers
All Serialized Attachments
Rock Hammer
Engines
Warranty Period
2 years or 1500 operating hours,
whichever occurs first
1 year or 1000 operating hours,
whichever occurs first
1 year
6 months
Through engine manufacturers:
2 years or 2000 operating hours,
whichever occurs first
Instructions for Obtaining Warranty Service
You are responsible for notifying the Underground Dealer from whom you
purchased the Product as soon as you believe a warrantable condition
exists. If you need help locating a Underground Dealer, or if you have
questions regarding your warranty rights or responsibilities, you may
contact us at:
Toro Customer Care
Toro Warranty Company
8111 Lyndale Avenue South
bulbs, belts, tracks or tires, digging teeth, digging booms, digging,
drive, or track chains, track pads, drive sprockets, idlers, rollers,
blades, cutting edges, or other ground engaging components.
•
Failures caused by outside influence. Conditions considered to be
outside influence include, but are not limited to, weather, storage
practices, contamination, use of unapproved fuels, coolants, lubricants,
additives, water, or chemicals, etc.
•
Failure or performance issues due to the use of fuels (e.g. gasoline,
diesel, or biodiesel) that do not conform to their respective industry
standards.
•
•
Normal noise, vibration, wear and tear, and deterioration.
•
Hauling expenses, travel time, mileage, or overtime associated with
transporting product to the authorized Toro dealer.
Normal “wear and tear” includes, but is not limited to, damage to seats
due to wear or abrasion, worn painted surfaces, scratched decals, etc.
Parts
Parts scheduled for replacement as required maintenance in the
Operator’s Manual,are warranted for the period of time up to the scheduled
replacement time for that part. Parts replaced under this warranty are
covered for the duration of the original product warranty and become the
property of Toro. Toro will make the final decision whether to repair any
existing part or assembly or replace it. Toro may use remanufactured parts
for warranty repairs.
Maintenance is at Owner’s Expense
Bloomington, MN 55420-1196
Toll Free at 855-493-0088 (U.S. Customers)
1-952-948-4318 (International Customers)
Owner Responsibilities
As the Product owner, you are responsible for required maintenance and
adjustments stated in your Operator's Manual. Failure to perform required
maintenance and adjustments can be grounds for disallowing a warranty
claim.
Items and Conditions Not Covered
Not all product failures or malfunctions that occur during the warranty
period are defects in materials or workmanship. This warranty does not
cover the following:
Engine tune-up, lubrication, cleaning and polishing, replacement of filters,
coolant, and completing recommended maintenance are some of the
normal services Toro products require that are at the owner’s expense.
General Conditions
Repair by an Authorized Toro Underground Dealer is your sole remedy
under this warranty.
Neither The Toro Company nor Toro Warranty Company is liable for
indirect, incidental or consequential damages in connection with the
use of the Toro Products covered by this warranty, including any
cost or expense of providing substitute equipment or service during
reasonable periods of malfunction or non-use pending completion
of repairs under this warranty. Except for the Emissions warranty
referenced below, if applicable, there is no other express warranty. All
implied warranties of merchantability and fitness for use are limited to
the duration of this express warranty.
•
Product failures which result from the use of non-Toro replacement
parts, or from installation and use of add-on, or modified non-Toro
branded accessories and products. A separate warranty may be
provided by the manufacturer of these items.
•
Some states do not allow exclusions of incidental or consequential
damages, or limitations on how long an implied warranty lasts, so the above
exclusions and limitations may not apply to you. This warranty gives you
specific legal rights, and you may also have other rights which vary from
state to state.
Product failures which result from failure to perform recommended
maintenance and/or adjustments. Failure to properly maintain your
Toro product per the Recommended Maintenance listed in the
Operator’s Manual can result in claims for warranty being denied.
Note regarding engine warranty:
•
Product failures which result from operating the Product in an abusive,
negligent, or reckless manner.
•
Parts subject to consumption through use unless found to be defective.
Examples of parts which are consumed, or used up, during normal
Product operation include, but are not limited to: brakes, filters, lights,
The Emissions Control System on your Product may be covered by
a separate warranty meeting requirements established by the U.S.
Environmental Protection Agency (EPA) and/or the California Air Resources
Board (CARB). The hour limitations set forth above do not apply to the
Emissions Control System Warranty. Refer to the Engine Emission Control
Warranty Statement supplied with your product or contained in the engine
manufacturer’s documentation for details.
Countries Other than the United States or Canada
Customers who have purchased Toro products exported from the United States or Canada should contact their Toro Distributor (Dealer) to obtain
guarantee policies for your country, province, or state. If for any reason you are dissatisfied with your Underground Dealer’s service or have difficulty
obtaining guarantee information, contact the Toro importer.
Australian Consumer Law: Australian customers will find details relating to the Australian Consumer Law either inside the box or at your local Toro
Dealer.
374-0292 Rev A