Toro 2226, Operator'S Manual

Page 1: ...Form No 3414 730 Rev A 2226 Directional Drill Model No 23803 Serial No 400000000 and Up Register at www Toro com Original Instructions EN 3414 730 A ...

Page 2: ...o 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 You may contact Toro directly at www Toro com for product safety and operation training materials accessory information help finding a dealer or to register your product Whenever you need service genuine Toro parts or additional informat...

Page 3: ...aintenance 72 Engine Safety 72 Servicing the Air Cleaner 72 Servicing the Engine Oil 74 Adjusting the Engine Valve Clearance 76 Cleaning the Engine EGR Cooler 76 Inspecting the Engine Crankcase Breather System 76 Checking and Replacing Fuel Hoses and Engine Coolant Hoses 76 Lapping or Adjusting the Engine Intake and Exhaust Valves 76 Inspecting and Cleaning Engine Emission Control Components and T...

Page 4: ...oduct is capable of amputating hands and feet and of throwing objects Always follow all safety instructions to avoid serious personal injury Using this product for purposes other than its intended use could prove dangerous to you and bystanders Read and understand the contents of this Operator s Manual before starting the engine Do not put your hands or feet near moving components of the machine D...

Page 5: ...ng radius is the end of the track Move slowly when using the pendant for tramming Use care when loading or unloading the machine onto a trailer Watch for traffic when crossing roadways Check for overhead clearances i e doorways branches electrical wires before tramming under any objects and do not contact them When tramming on a slope you should be uphill from the machine Use the following illustr...

Page 6: ...tion including movement of the carriage Use the following illustration to ensure that bystanders do not enter the danger zone while you are drilling g217462 Figure 4 Drilling Danger Zone 1 3 m 10 ft safety distance 2 1 8 m 6 ft safety distance Drilling Near Utility Lines Important Before operating in an area with high voltage lines or cables contact a One Call System Directory service In the USA c...

Page 7: ...e is charged with power Note Immediately contact the proper emergency and utility authorities to secure the area in case the machine is charged and you cannot leave the seat of the machine 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 Do not attempt to leave the machine Note You will be safe a...

Page 8: ...ear eye protection 9 Flush eyes immediately with water and get medical help fast 5 Read the Operator s Manual 10 Contains lead do not discard g228534 Figure 5 1 137 7160 decal137 7160 137 7160 1 Emergency engine stop release 10 Tramming direction forward right 2 Emergency engine stop engage 11 Tramming speed fast 3 Setup operator presence on 12 Tramming speed slow 4 Setup operator presence off 13 ...

Page 9: ... 10 ft away from the front and rear of the machine and 1 8 m 6 ft away from the sides of the machine decal125 6128 125 6128 1 High pressure fluid hazard injection into the body read the Operator s Manual before performing maintenance decal125 6115 125 6115 1 Crushing hazard deploy cylinder locks before performing maintenance 9 ...

Page 10: ...2 Figure 7 1 137 7166 decal137 7166 137 7166 1 Crushing hazard do not stand under the machine g228523 Figure 8 1 137 7167 decal137 7167 137 7167 1 Thrown object hazard keep bystanders away from the machine 10 ...

Page 11: ... 1 137 7168 decal137 7168 137 7168 1 Electrocution hazard do not touch the machine when the alarm is sounding g228525 Figure 10 1 137 7172 decal137 7172 137 7172 1 Runover backover hazard read the Operator s Manual 11 ...

Page 12: ...s Manual rotate counter clockwise to disconnect the battery rotate clockwise to connect the battery the negative post is located below the switch the positive post is located to the side of the switch decal137 7174 137 7174 1 Read the Operator s Manual for information on fuses 8 Operator platform 2 Emergency engine stop button 9 Display 3 Electric 10 Cam 4 Key switch 11 Stake 5 Headlights 12 Auto ...

Page 13: ...6152 125 6152 1 Move seat forward and backward decal137 7171 137 7171 1 Falling hazard do not ride on the machine while it is moving decal137 7175 137 7175 1 Rotate the operator platform g228528 Figure 13 1 125 6694 decal125 6694 125 6694 1 Tie down location 13 ...

Page 14: ...us area keep at least 3 m 10 ft away from the machine during operation decal137 7178 137 7178 1 Entanglement hazard keep away from moving parts g228533 Figure 15 1 125 6197 2 125 4967 decal125 6197 125 6197 1 Max weight limit 1342 kb 2 958 lb decal125 4967 125 4967 1 Lift point 14 ...

Page 15: ...e Operator s Manual decal125 8473 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 decal125 6119 125 6119 1 Entanglement hazard keep away from moving objects 15 ...

Page 16: ...g228960 Figure 17 1 117 2718 2 137 7161 decal117 2718 117 2718 decal137 7161 137 7161 1 Engine stop 5 Headlights 2 Engine run 6 On 3 Engine start 7 Off 4 Spray gun 16 ...

Page 17: ...g228527 Figure 18 1 125 6140 3 137 7182 2 137 7183 4 125 6124 decal125 6140 125 6140 1 Rotate the chair decal137 7183 137 7183 1 Read the Operator s Manual 17 ...

Page 18: ...decal137 7182 137 7182 1 Load pipes from back row first decal125 6124 125 6124 1 Center the pipe joint between the upper and lower wrenches 18 ...

Page 19: ...decal137 7169 137 7169 1 Warning read the Operator s Manual 4 Warning keep away from moving parts keep all guards and covers in place 2 Warning all operators must be trained before operating the machine 5 Warning hearing protection must be worn 3 Warning keep bystanders away from the machine 6 Explosion and electrical shock hazard do not dig call your local utility company 19 ...

Page 20: ... 7170 1 Falling hazard do not climb on the machine while it is moving decal127 1829 127 1829 1 Oil drain g228520 Figure 20 1 125 6107 decal125 6107 125 6107 1 Crushing hazard of hand and foot keep hands and feet away 20 ...

Page 21: ...er the stake setup mode 4 Mud flow increase 11 Rotate the drill spindle clockwise drill mode I rotate the stake counter clockwise setup mode 5 Mud flow decrease 12 Rotate the stake clockwise setup mode rotate the drill spindle counter clockwise drill mode I 6 Rotate the wrench clockwise and counter clockwise make and break rotation 13 Raise the stake setup mode pull the carriage back drill mode I ...

Page 22: ...embly 4 Pipe gripper arm retract 13 Lower the stake setup mode rotate drill spindle counter clockwise drill mode II 5 Pipe gripper arm extend 14 Rotate stake counter clockwise setup mode 6 Apply tread joint compound 15 Rotate the stake clockwise setup mode 7 Elevator raise 16 Raise the stake setup mode rotate drill spindle clockwise drill mode II 8 Elevator lower 17 Left stake controls 9 Pipe grip...

Page 23: ...Drilling 3 Ground strike reset 7 Work lights on 4 Ground strike switch 8 Work lights off decal125 6194 125 6194 1 Exit side lockout receiver battery status light 4 Emergency engine stop engage 2 Exit side lockout drill enabled light 5 Emergency engine stop release 3 Exit side lockout standby light 23 ...

Page 24: ...Product Overview g218957 Figure 22 Left Side View 1 Pipe box 3 Stabilizer foot 2 Safety bar g218958 Figure 23 Rear View 1 Rear control panel 3 Zap alert stake 2 Drilling fluid source connection 24 ...

Page 25: ...g218959 Figure 24 Right Side View 1 Carriage 6 Thrust frame 2 Zap alert strobe 7 Stabilizer foot 3 Front hood 8 Rear hood 4 Front control panel 9 Tracks 5 Operator seat 25 ...

Page 26: ...g218960 Figure 25 Top view 1 Carriage 5 Lower wrench 2 Drill spindle 6 Pipe wiper 3 Thrust frame 7 Stake down tube 4 Upper wrench 26 ...

Page 27: ...t joystick 2 Left joystick 4 Operator display Operator Controls Covers 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 Operator Platform Latch The operator platform swings out away from the machine making room for you to sit It has 5 positions travel ...

Page 28: ...ator Console Bolts Tighten the console bolts to add friction to the consoles refer to Figure 28 The left console can rotate 10 degrees in The right console can rotate 10 degrees in and 45 degrees out g230008 Figure 28 28 ...

Page 29: ...e 29 to immediately shut off the engine and all drilling operations You must pull this button out before you can start the engine again Exit Side Lockout Standby Light This light Figure 29 illuminates orange when the exit side lockout is turned off indicating that you may reset the system Exit Side Lockout Drill enabled Light This light Figure 29 illuminates green when the exit side lockout system...

Page 30: ...e Left Joystick in Setup Mode Forward Push the joystick forward to lower the left stake down Rearward Pull the joystick rearward to raise the left stake down Left Move the joystick to the left to rotate the left stake counter clockwise Right Move the joystick to the right to rotate the left stake clockwise Right Joystick in Setup Mode Forward Push the joystick forward to lower the right stake down...

Page 31: ...h mode g226143 Figure 32 Left Joystick Directional Controls 1 Rotate the drill spindle counter clockwise Drill Mode II 3 Rotate the drill spindle clockwise Drill Mode II 2 No action 4 No action Push the joystick left and hold the cam rocker switch at the same time to use the cam override function Important This overrides the anti crash prevention warning and could cause damage to the machine Push ...

Page 32: ...ncrease the mud flow momentarily 5 Open and close the front wrench 8 Set the carriage to high speed 3 Decease the mud flow momentarily 6 Rotate the wrench clockwise and counter clockwise make and break rotation 9 Max flow of mud Right Joystick Drill Mode I g226144 Figure 34 Right Joystick Drill Mode I 1 Thrust the carriage forward 3 Pull the carriage back 2 Rotate the drill spindle counter clockwi...

Page 33: ...position to shut off 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 positio...

Page 34: ...itch to raise and lower the thrust frame Right Stabilizer Foot Switch Use this switch to raise and lower the right stabilizer foot Left Stabilizer Foot Switch Use this switch to raise and lower the left stabilizer foot Emergency Engine Stop Button Push this button to immediately shut off the engine and all movement drilling operations You must pull this button out before you can start the engine a...

Page 35: ...ines 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 When installing cabling or pipe using a directional drill complete the following steps 1 Gather site information...

Page 36: ...instructions on backreaming and pulling cable or pipe 6 Finish the bore and leave the job site After completing the operation disconnect and clean the machine and load it on the trailer refer to Finishing the Job page 63 Gathering Site Information Planning the Initial Path Before drilling plan the path you will bore and prepare as follows Create a basic plan for the bore mapping out the proposed p...

Page 37: ...e near gas lines or at either end of a bore that will be crossing a gas line Keep bystanders and spectators away from the job site including the complete bore path Locate and expose all gas lines that you will be crossing by careful hand digging Have the gas company turn off the gas to any lines you will be crossing before drilling Use the receiver to track the exact position of the drill head whe...

Page 38: ... 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 gr...

Page 39: ... 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 needed for steering the drill to the surface typicall...

Page 40: ...nd 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 The steeper your entry pitch is the deeper your bore must be due to the limitations o...

Page 41: ...15 inches 38 109 cm 43 inches 14 43 cm 17 inches 39 112 cm 44 inches 15 46 cm 18 inches 40 114 cm 45 inches 16 48 cm 19 inches 41 117 cm 46 inches 17 51 cm 20 inches 42 117 cm 46 inches 18 53 cm 21 inches 43 119 cm 47 inches 19 56 cm 22 inches 44 122 cm 48 inches 20 61 cm 24 inches 45 124 cm 49 inches 21 64 cm 25 inches 46 127 cm 50 inches 22 66 cm 26 inches 47 130 cm 51 inches 23 69 cm 27 inches ...

Page 42: ...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 changes 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 p...

Page 43: ... 18 cm 7 inches and is now 114 cm 45 inches deep 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 3 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 Important You can use the information contained in this section t...

Page 44: ...ct the pipe or lines after pulling them back Checking the Safety Interlock Switches Checking the Operator Presence Safety Interlock Functions on the Operator Platform 1 Start the engine 2 With the engine running rise from the seat and press a joystick function Note The drill functions should not engage If they do engage there is a malfunction in the interlock system that you should correct before ...

Page 45: ...ay 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 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 The Zap Alert system is an electric strike sensing device on the machine that triggers a strobe...

Page 46: ...r is a dry chemical fire extinguisher approved for class B and C fires Operate and maintain the fire extinguisher per the instructions on the fire extinguisher g218948 Figure 50 Loading the Drill Pipes Refer to the Software Guide for the procedure on loading drill pipes into the pipe box or onto the drill string Filling the Fuel Tank Fuel Tank Capacity 114 L 30 US gallons Fuel Specification Import...

Page 47: ...TM D975 EN590 or JIS K2204 Important The petroleum diesel portion must be ultra low sulfur Observe the following precautions Biodiesel blends may damage painted surfaces Use B5 biodiesel content of 5 or lesser blends in cold 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 blends...

Page 48: ...he joystick to move the machine as desired Note For more information on the travel pendant refer to Travel Pendant page 33 Loading and Unloading the Machine WARNING 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 Follow the tie down procedures described in this ...

Page 49: ...ated chains and binders to secure the rings on the left and right track frames and through the tube on the stake down plate to the trailer Figure 53 g239626 Figure 53 1 Tie down points only left side shown 10 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 11 Remove the block from the trailer tires ...

Page 50: ...st of available blades 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 sys...

Page 51: ...ctric strike the machine becomes energized setting off the alarm DANGER If the Zap Alert system activates while drilling the machine including 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 b...

Page 52: ...rst Pipe page 57 2 Switch the DRILL SETUP switch to the SETUP position lower the thrust frame tilting the drill frame until the plate contacts the ground Figure 60 g218964 Figure 60 1 Thrust frame 2 Stake down plate 3 Lower the rear stabilizers until they contact the ground firmly or until the desired entry angle is achieved Figure 61 Note The rear of the tracks should just start to lift off the g...

Page 53: ...ollow 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 62 g218943 Figure 62 2 Insert the hose from the mixing system over the pump inlet and secure it with the cam ...

Page 54: ... When operating the machine on a slope the operator must account for many variables such as the amount distribution and height of the load the stability of the ground uneven terrain and obstacles and the condition of the brakes These and other variables make it impractical to designate the maximum angle at which the operator can safely use the machine for all slopes and situations Slopes are a maj...

Page 55: ...F parked regeneration or recovery regeneration Hot exhaust gas can harm you or other people Never operate the engine in an enclosed area Make sure that there are no flammable materials around the exhaust system Never touch a hot exhaust system component Never stand near or around the exhaust pipe of the machine DPF Soot Accumulation Over time the DPF accumulates soot in the soot filter The compute...

Page 56: ...et Regeneration page 57 Types of diesel particulate filter regeneration that require you to park the machine Type of Regeneration Conditions for DPF regeneration DPF description of operation Soot buildup occurs as a result of prolonged operation at low engine speed or low engine load May also occur as a result of using incorrect fuel or oil The computer detects back pressure due to soot buildup an...

Page 57: ...ank of fuel before performing the parked regeneration Recovery Regeneration Ensure that you have 1 2 tank of fuel before performing the recovery regeneration Move the machine outside to an area away from combustible materials Refer to the Software Guide for the procedure to perform the parked or recovery regeneration Drilling the Bore Starting the First Pipe The Software Guide is used in this proc...

Page 58: ...e 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 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 push the exit side lockout reset switch on the front control panel 4 Pull the dri...

Page 59: ...e grippers until the pipe is centered over the drill string and in front of the spindle on the carriage 9 Rotate the drill spindle clockwise and move the carriage slowly forward to insert the spindle into the female end of the pipe Figure 65 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 und...

Page 60: ...n is actually a change in soil types 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 Exiting the Ground 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...

Page 61: ...kwise and slowly retract the drill carriage to pull the pipe back into the machine 5 When the joint between the pipes is centered between the 2 wrenches the drill carriage stops and a green light illuminates behind the spray valve 6 Close the lower wrench onto the pipe joint Note The drilling fluid automatically shuts off when you close the lower wrench 7 Close the upper wrench onto the pipe joint...

Page 62: ...nch and continue reaming retraction as needed Removing the Last Pipe and the Reamer 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 2 After the reamer has cleared the ground if you have not already done so disconnect the product being installed from the reamer 3 Connect t...

Page 63: ... applicator nozzle to spray thread joint compound TJC either in a fan shaped spray or as a stream For fan shaped spray turn the spray valve on the side of the nozzle horizontal Figure 70 For a stream turn the spray valve on the side of the nozzle vertical Figure 70 g023077 Figure 70 1 Spray valve fan shaped spray horizontal 2 Spray valve stream vertical Adjusting the TJC spray Volume To adjust the...

Page 64: ... new bucket and lower the cover assembly onto the bucket 7 Slide the cover straps over the retaining bolts and rotate the cover to seat the straps on the bolts 8 Tighten the wing nuts 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 ...

Page 65: ... oil Before each use or daily Grease the machine Grease immediately after every washing Check the engine oil level Drain the water separator Check the rotary gearbox drive oil 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 Remove...

Page 66: ... fluid Every 1 500 hours Clean the engine EGR cooler Inspect the engine crankcase breather system Every 2 000 hours Lap or adjust the engine intake and exhaust valves if necessary Every 3 000 hours Inspect and clean if necessary the engine emission control components and turbocharger Yearly or before storage Touch up chipped paint Every 2 years Replace moving hoses WARNING Improperly servicing or ...

Page 67: ...ts to stop Allow machine components to cool before performing maintenance If possible do not perform maintenance while the engine is running Keep away from moving parts Use adequate support to support the machine or components when required Carefully release pressure from components with stored energy Accessing Internal Components Opening the Front and Rear Hoods Use 1 key to unlock the latch and ...

Page 68: ...ith the cotter pin and clevis pin Figure 75 6 Turn the engine to the ON position and raise the thrust frame until it rests on the cylinder lock g230470 Figure 75 Lubrication Greasing the Machine Service Interval Before each use or daily Grease immediately after every washing Grease type General purpose grease Total number of grease fittings 51 1 Clean the grease fittings with a rag 2 Connect a gre...

Page 69: ...g220078 Figure 78 Cam Assembly Operator Side 2 fittings g222835 Figure 79 Left Side Front Cam Assembly 4 fittings 69 ...

Page 70: ...g222836 Figure 80 Left Side Rear Cam Assembly 4 fittings g222837 Figure 81 Tracks 12 fittings 6 on each side 70 ...

Page 71: ...g220081 Figure 82 Stabilizer Feet 8 fittings 4 on each foot g220082 Figure 83 Stakedown Motors 2 fittings g224193 Figure 84 Stakedown Cylinders 4 fittings 2 fittings on each cylinder 71 ...

Page 72: ...spect the rubber intake hose connections at the air cleaner and turbocharger to ensure that the connections are complete Service the air cleaner filter only when the Check Air Filter message is displayed on the display refer to the Software Guide for the machine Changing the air filter before it is necessary only increases the chance of dirt entering the engine when you remove the filter Ensure th...

Page 73: ...operate the engine without the air cleaner elements as this would allow foreign material to enter the engine and damage it 1 Release the latches securing the air cleaner cover to the air cleaner body Figure 88 g008909 Figure 88 1 Air cleaner cover 2 Air cleaner latch 2 Remove the cover from the air cleaner body 3 Before removing the filter use low pressure air 275 kPa or 40 psi clean and dry to he...

Page 74: ...plug or cause engine damage Use the following engine oil viscosity grade Preferred oil SAE 15W 40 above 0 F Alternate oil SAE 10W 30 or 5W 30 all temperatures Toro Premium Engine Oil is available from your Authorized Service Dealer in either 15W 40 or 10W 30 viscosity grades See the parts catalog for part numbers Checking the Engine Oil Level Service Interval Before each use or daily Check the eng...

Page 75: ...nd filter more frequently when the operating conditions are extremely dusty or sandy 1 Start the engine and let it run 5 minutes to allow the oil to warm up 2 Move the machine to a level surface shut off the engine and remove the key 3 Change the engine oil as shown in Figure 93 g220852 g220851 Figure 92 4 Change the engine oil filter Figure 94 Note Ensure that the oil filter gasket touches the en...

Page 76: ... Crankcase Breather System Service Interval Every 1 500 hours For information on inspecting the engine crankcase breather system refer to your engine owner s manual Checking and Replacing Fuel Hoses and Engine Coolant Hoses Service Interval Every 400 hours For information on checking and replacing fuel hoses and engine coolant hoses refer to your engine owner s manual Lapping or Adjusting the Engi...

Page 77: ... and clean the fuel tank Drain and clean the tank also if the fuel system becomes contaminated or if you are storing the machine for an extended period of time Use clean fuel to flush out the tank Servicing the Water Separator Service Interval Before each use or daily Drain the water separator Every 400 hours Replace the fuel water separator element Draining the Water Separator 1 Place a drain pan...

Page 78: ...lter 9 When fuel flows from the vent plug close the vent plug start the engine and check for leaks Note Correct as necessary with the engine off Replacing the Fuel Filter Element Service Interval Every 400 hours Replace the fuel filter element 1 Clean the area around the fuel filter head Figure 96 g220797 Figure 96 1 Engine oil filter 2 Fuel filter 2 Remove the filter and clean the filter head mou...

Page 79: ...ctors 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 WARNING A battery contains sulfuric acid which can cause serious burns and they can produce explosive gases Avoid conta...

Page 80: ...o not overcharge the battery Note Charge the battery a shown in battery charging table Battery Charger Table Charger setting Charging time 10 A 8 to 10 hours 20 A 4 to 6 hours do not exceed 6 hours 8 When the battery is fully charged unplug the charger from the electrical source then disconnect the charger leads from the battery posts Figure 97 Jump Starting the Machine WARNING Jump starting the b...

Page 81: ...ive Oil Level Planetary Drive Service Interval Every 50 hours Check the planetary drive oil level Also check if external leakage is observed Oil specification SAE 85W 140 API classification level GL4 Planetary drive oil capacity approximately 1 4 L 1 5 US qt Toro Premium Gear Oil is available from an Authorized Service Dealer See the Parts Catalog for part numbers 1 Move the machine to a level sur...

Page 82: ...with oil until the oil is 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 Rotary Gearbox Drive Oil Service Interval Before each use or daily Check the rotary gearbox drive oil Every 800 hours Check the rotary gearbox drive oil or yearly whichever comes first Oil ...

Page 83: ...sible 1 Move the machine to a level surface and move the carriage all the way to the rear stop 2 Shut off the engine and remove the key 3 Remove the drain plug and drain the oil Figure 101 g235823 Figure 101 4 Install the drain plug 5 Remove the breather cap Figure 102 g235824 Figure 102 6 Fill the gearbox with oil until the oil level in the sight glass is more than half full Figure 100 7 Install ...

Page 84: ...63 kPa 3 200 psi as shown in Figure 103 g220084 Figure 103 Track tension grease valve shown 6 Remove excess grease from around the valve 7 Install the cover and retaining bolts 8 Repeat steps 3 through 7 to tighten the track tension on the other side Loosening the Track Tension If the track seems tight loosen the track tension as follows 1 Move the machine to a level surface and raise the thrust f...

Page 85: ...oolant can cause poisoning keep it out of reach of children and pets Discharge of hot pressurized coolant or touching a hot radiator and surrounding parts can cause severe burns Always allow the engine to cool at least 15 minutes before removing the radiator cap Use a rag when opening the radiator cap and open the cap slowly to allow steam to escape Checking the Coolant Level in the Reservoir Serv...

Page 86: ...lant 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 105 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 Checking the Condition...

Page 87: ...ng the Cooling System Engine and radiator coolant capacity 16 8 L 17 7 US qt 1 Move the machine to a level surface shut off the engine and remove the 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 Draining the Coolant from the System page 87 B Add a cooling system cleaning solution to the radiator thro...

Page 88: ... passages Failing to vent the cooling system properly can severely damage the cooling system and engine 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 mach...

Page 89: ...excessively worn or damaged Checking the Belt Tension Service Interval Every 800 hours 1 Move the machine to a level surface shut off the engine and remove the key 2 Open the front hood 3 Align a straight edge over the drive belt and across the pulleys Figure 110 g220794 Figure 110 4 Push the belt down at the midway point between the fan pulley and the alternator pulley as shown in Figure 110 Note...

Page 90: ...raulic system Keep your body and hands away from pinhole leaks or nozzles that eject high pressure hydraulic fluid Use cardboard or paper to find hydraulic leaks Safely relieve all pressure in the hydraulic system before performing any work on the hydraulic system Servicing the Hydraulic Fluid The hydraulic reservoir is filled at the factory with approximately 102 L 27 US gallons of high quality h...

Page 91: ...3 C 110 F contact Toro for fluid recommendations Checking the Hydraulic Fluid Service Interval Before each use or daily Check the hydraulic fluid as follows 1 Move the machine to a level surface shut off the engine and remove the key 2 Wait 10 minutes to allow the engine to cool and the hydraulic oil to stabilize 3 If the level is low open the hydraulic tank cap add a small amount of oil and wait ...

Page 92: ...erval Every 800 hours Every 6 months whichever comes first 1 Move the machine to a level surface shut off the engine and remove the key 2 Open the front hood 3 Place a drain pan under the filter 4 Using a filter wrench remove the hydraulic charge filter Figure 114 g229100 Figure 114 5 Discard the old filter 6 Apply a thin layer of hydraulic oil to the o ring of the filter 7 Install and tighten the...

Page 93: ...ce a large draining container under the hydraulic fluid tank 5 Remove the drain plug from the bottom of the tank Figure 115 g229374 Figure 115 6 Clean the threads on the drain plug and apply 3 layers of PTFE sealing tape 7 Drain the hydraulic fluid 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 U...

Page 94: ...ed into skin Hydraulic System Test Ports The test ports are used to test the pressure in the hydraulic circuits Contact your Authorized Service Dealer for assistance Drilling fluid Pump Maintenance Servicing the Drilling Fluid Pump Oil The drilling fluid pump is shipped with oil in the crankcase however check the oil level before and after you first start the engine The crankcase capacity is 1 9 L...

Page 95: ...o the oil pan Figure 117 7 Install the drain plug 8 Remove the oil filler cap Figure 117 and add approximately 1 9 L 2 US qt of oil or until the oil reaches the oil fill line on the dipstick as shown in Figure 116 Preparing the Drilling Fluid System for Cold Weather Prepare the machine as follows after drilling if the temperature will be below 0 C 32 F 1 Move the machine to a level surface shut of...

Page 96: ... antifreeze Figure 120 3 Circulate the antifreeze as follows A Open the antifreeze valve on the front side of the drilling fluid pump as shown in Figure 120 B Start the machine and turn On the drilling fluid pump C Add antifreeze to the tank as needed Figure 120 D When the antifreeze comes out of the drill spindle Figure 118 turn the pump off 4 Turn the machine off 5 Install the cap onto the antif...

Page 97: ...od is down before cleaning the machine with the spray hose attachment Important If the outside temperature is below freezing refer to Preparing the Drilling Fluid System for Cold Weather page 95 before cleaning the machine To use the spray hose attachment perform the following procedure 1 Move the machine to a level surface shut off the engine and remove the key 2 Ensure that the spray hose attach...

Page 98: ...pump to the ON position through the display screen refer to the Main Drill Functions Displayed in the Pressure Screen in the Software Guide 8 Using the spray hose attachment hold down the lever and spray down the machine and pipes Cleaning Plastic and Resin Parts Avoid using gasoline kerosene paint thinner etc when cleaning plastic windows the console the instrument cluster the monitor gauges etc ...

Page 99: ... Check and adjust the track tension refer to Servicing the Tracks page 84 7 Check the coolant before winter storage refer to Cooling System Maintenance page 85 8 Prepare the drilling fluid pump for cold weather refer to Preparing the Drilling Fluid System for Cold Weather page 95 9 Check and tighten all bolts nuts and screws Repair or replace any part that is damaged 10 Paint all scratched or bare...

Page 100: ... the Engine 2 The fuel tank is empty 2 Fill the tank with fresh fuel 3 The fuel shut off valve is closed 3 Open the fuel shut off valve 4 Dirt water stale fuel or incorrect fuel is in the fuel system 4 Drain and flush the fuel system then add fresh fuel 5 The fuel line is clogged 5 Clean or replace the fuel line 6 There is air in the fuel 6 Bleed the nozzles and check for air leaks at the fuel hos...

Page 101: ...the fuel 3 Bleed nozzles and check for air leaks at the fuel hose connections and fittings between the fuel tank and engine 4 The injection nozzles are damaged 4 Contact your Authorized Service Dealer 5 There is low compression 5 Contact your Authorized Service Dealer 6 The injection pump timing is incorrect 6 Contact your Authorized Service Dealer 7 There is excessive carbon build up 7 Contact yo...

Page 102: ... injection nozzles are damaged 6 Contact your Authorized Service Dealer 1 The engine temperature is low 1 Check the thermostat 2 The glow plugs are inoperative 2 Check the fuse glow plugs and wiring 3 The injection pump timing is incorrect 3 Contact your Authorized Service Dealer 4 The injection nozzles are damaged 4 Contact your Authorized Service Dealer There is excessive white smoke in the exha...

Page 103: ...e condition of the components 86 Cleaning 87 Coolant concentration Checking 86 Coolant level in the radiator Checking 86 Coolant level in the reservior Checking 85 Draining 87 Filling 88 Flushing 87 Covers Operator controls 63 Crystalline silica Safety precautions 36 Cylinder lock 68 Installing 68 D Danger zone Drilling 6 Driving 5 Decals 8 Deploying the Zap Alert system 52 Depth table 39 Determin...

Page 104: ...Joystick 30 Jump starting the machine 80 L Labels See Decals Latch Operator platform 27 Lead bar Installing 58 Removing 62 Left joystick Location 27 Left Joystick 31 Setup Mode 30 Left stabilizer 33 Length 34 Lever Stake down 52 Lifting the machine 64 Light Drill enabled Exit side lockout 29 Error indicator 33 OK to start 33 OK to Start 33 Receiver battery status 29 Reset Exit side lockout 29 Tran...

Page 105: ...erial Number Location 2 Servicing the air cleaner 99 Servicing the air cleaner cover 72 Servicing the air cleaner filter elements 73 Servicing the Engine Oil 74 Servicing the tracks 99 Servicing the water separator 77 Setting up for drilling 51 Sonde 50 Temperature 60 Sonde housing 50 Specifications 34 Spray hose attachment Cleaning with 97 Spreader bar Lifting the machine 64 Stabilizer 33 Left 33...

Page 106: ...Deploying 52 Ground strike reset switch 29 Grounding stake Storage 46 Tester 45 Testing 45 106 ...

Page 107: ...Notes ...

Page 108: ......