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Toro 4045 Operator's Manual

Directional drill
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Original Instructions (EN)
4045 Directional Drill
Model No. 23825—Serial No. 313000501 and Up
Model No. 23825—Serial No. 314000501 and Up
Form No. 3401-924 Rev A
*3401-924* A

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Summary of Contents for Toro 4045

  • Page 1 Form No. 3401-924 Rev A 4045 Directional Drill Model No. 23825—Serial No. 313000501 and Up Model No. 23825—Serial No. 314000501 and Up *3401-924* A Register at www.Toro.com. Original Instructions (EN)
  • Page 2 This product complies with all relevant European directives; You may contact Toro directly at www.Toro.com for product for details, please see the separate product specific Declaration and accessory information, help finding a dealer, or to register of Conformity (DOC) sheet.

  • Page 3: Table Of Contents

    Contents Adjusting the Valve Clearance ........89 Fuel System Maintenance ...........90 Draining Water from the Fuel Filter......90 Safety ................4 Draining Water from the Fuel Tank ......90 Training ..............4 Priming the Fuel System ..........91 Preparation............. 4 Replacing the Fuel Filters.........91 General Operation ..........

  • Page 4: Safety

    Use extra care when handling fuels. They are flammable Manual . Modifications to this machine should only be and vapors are explosive. made by either the manufacturer or an Authorized Toro – Use only an approved container. Dealer. – Do not remove the fuel cap or add fuel with the This product is capable of amputating hands and feet.

  • Page 5: Driving Safety

    Driving Safety • Check for overhead clearances (i.e. branches, doorways, electrical wires) before driving under any objects and do You drive the machine to and from the work site with the use not contact them. of a tethered remote. When driving the machine, observe the •...

  • Page 6: Drilling Safety

    Drilling Safety Drilling Danger Zone The danger zone is the area within and around the machine • Always lower the pedestrian safety bar before drilling where a person is exposed to the risk of injury. This proximity (Figure includes where a person is reachable by operational movement •...
  • Page 7 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 Telecommunication, alarm or signal, cables, or conduit Orange Natural gas, oil, steam, petroleum, or other gaseous or flammable Yellow material Sewer and drain...

  • Page 8: Maintenance And Storage

    Clean debris from attachments, drives, mufflers, and filling. 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.

  • Page 9: Safety And Instructional Decals

    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.
  • Page 10 125-6137 125-6694 1. Tie-down point 125-8473 1. Explosion hazard—wear 3. Fire hazard—keep open eye protection. flames away. 2. Caustic liquid/chemical 4. Poison hazard—do not burn hazard—rinse tamper with the battery. affected area and seek medical assistance. 125-6108 1. Thrown object hazard—read the Operator’s Manual.
  • Page 11 125-6114 125-6126 1. Stored energy hazard—do not use tools; read the 1. Entanglement hazard—keep away from moving parts. Operator’s Manual. 125-6119 1. Entanglement hazard—keep away from moving objects. 125-6131 1. Warning—stay at least 3 m (10 ft) away from the machine.
  • Page 12 125-6128 125-6115 1. High pressure fluid hazard, injection into the body—read 1. Crushing hazard—deploy cylinder locks before performing the Operator’s Manual before performing maintenance. maintenance. 125-6110 1. Crushing hazard—do not stand under any part of the machine. 125-6130 1. Warning—read the Operator’s Manual; stay at least 3 m (10 ft) away from the front and rear of the machine and 1.8 m (6 ft) away from the sides of the machine.
  • Page 13 125-6123 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.
  • Page 14 125-6140 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.
  • Page 15 125-6158 Model with Cab only 1. Engine—start 13. With trigger released, rock forward to rotate basket toward pipe cam, rock backward to rotate basket toward drill frame. 2. Press down to stop the engine 14. With trigger released, upper button closes pipe gripper, lower button opens pipe gripper.
  • Page 16 125-6142 1. Exit-side lockout—reset light 14. Work lights—Off 2. Exit-side lockout—drill-enabled light 15. Press and hold to increase engine speed. 3. Transmitter-battery-status light 16. Engine speed 4. Engine—start 17. Press and hold to decrease engine speed. 5. Press down to stop the engine; pull up to start the engine. 18.
  • Page 17 125-1641 1. Forward left 6. Forward right 2. Increase rpm 7. High 3. Engine speed 8. Track speed 4. Decrease rpm 9. Low 5. Reverse left 10. Reverse right 125-6125 1. Warning—read the 6. Press and hold to move Operator’s Manual. the drill carriage at high speed up or down the drill frame.
  • Page 18 125-6127 1. Cutting/dismemberment hazard, fan—keep away from moving parts. 125-6129 1. Hot surface—keep away from hot surfaces. 125-6157 1. Disconnect the battery 3. On/Start power. 2. Off/Stop 4. Read the Operator’s Manual. 125-6141 1. Engine—heating light 4. Engine—start 2. Engine—stop 5.
  • Page 19 125-6113 1. Warning—read the Operator’s Manual. 4. Warning—keep away from moving parts; keep all guards and shields in place. 2. Warning—do not operate the machine unless you are trained. 5. Warning—wear hearing protection. 3. Warning—keep bystanders away from the machine. 6.
  • Page 20 125-1623 1. Forward left track/forward rotary 11. Wrench makeup (for upper wrench) 12. Raise pipe elevator 2. Reverse left track/reverse rotary 3. Drilling fluid pump on 13. Lower pipe elevator 14. Reverse cam rotation 4. Forward right track/forward carriage 5. Reverse right track/reverse carriage 15.

  • Page 21: Product Overview

    Product Overview Figure 5 1. Drill carriage 6. Front hood 2. Zap-alert strobe 7. Right stabilizer 8. Rear-access door 3. Cab 4. Monitor 9. Rear hood 5. Track 10. Thrust frame...
  • Page 22 Figure 6 1. Stake-down cage 5. Rear-control panel 2. Pipe holder 6. Left stabilizer 3. Pedestrian safety bar 7. Stake-down plate 4. Drilling-fluid-pump inlet...
  • Page 23 Figure 7 1. Cab 5. Upper wrench (makeup/breakout wrench) 2. Thrust frame 6. Lower wrench (stationary wrench) 3. Drill carriage 7. Pipe wiper 4. Drill spindle...

  • Page 24: Controls

    Controls Refer to the following sections for the appropriate machine controls: • Operator Platform • Monitor • Control Panel • Left Joystick—Mode I • Left Joystick—Mode II • Right Joystick—Mode I • Right Joystick—Mode II • Exit-Side-Lockout System • Rear Control Panel •...
  • Page 25 Figure 13 Control-select Screen 1. Mode I 2. Mode II DD 4045 Note: If a selection is not made within 5 seconds, the screen will default to the previous setting and will go to the Machine-information Screen (page 26).
  • Page 26 Machine-information Screen Main Operating Screen This screen contains the following information: To access this screen, press button 4 or the down arrow on Machine-information Screen (page 26). • The machine model and serial number (Figure 14). The main operating screen displays the engine-speed (rpm) •...
  • Page 27 Main Drill Functions Displayed in Pressure Screen Main Drill Functions Displayed in Torque Screen To access this screen, press the down-arrow button on the To access this screen, press the down arrow on the Main Drill Main Drill Functions Displayed in Torque Screen (page 27).
  • Page 28 Drill-rotation-speed Screen Thrust-control Screen To access this screen, press the OK button on the Main This screen allows the user to increase or decrease the thrust Operating Screen (page 26). output of the machine. This screen allows the user to increase or decrease the To access this screen, press button number 3 on the Main rotation speed of the drill.
  • Page 29 Horsepower-control Screen Pipe-row-selector Screen To access this screen, press button number 4 on the Main This screen allows you to select the row of pipe(s) that you Operating Screen (page 26). want to use. The horsepower control allows the user to change the To access this screen, press button number 8 on the Main speed setting that the engine can droop to before the...
  • Page 30 Main-selection Screen Lubrication and Maintenance Screens To access this screen, press the down arrow on the Main Drill To access this screen, press button number 2 on the Functions Displayed in Torque Screen (page 27). Main-selection Screen (page 30). This screen allows the user to choose from the following These screens provide the user with maintenance schedules options: at 10-hour, 50-hour, 250-hour, 500-hour, and 1,000-hour...
  • Page 31 To access this screen, press button number 5 on the Main-selection Screen (page 30). Contact your Authorized Toro Service Dealer to diagnose and adjust parameters. Note: To access the Diagnose and Adjust Parameters Screen, you are required to have the access PIN for the machine.
  • Page 32 Loader-calibration Screen Loader-cam-calibration Screen To access this screen, press button number 6 on the To access this screen, press button number 1 on the Main-selection Screen (page 30). Loader-calibration Screen (page 32). This screen allows you to calibrate the loader cam or to This screen allows the user to set the row positions for the calibrate the loader arm.
  • Page 33 Loader-arm-calibration Screen Clear-service-reminder Screen To access this screen, press button number 2 on the To access this screen, press button number 7 on the Loader-calibration Screen (page 32). Main-selection Screen (page 30). This screen allows the user to set the loader arm to the In To clear a service reminder, enter the 8-digit PIN (13236573) position (fully inward toward the machine), or to the Home into this screen...
  • Page 34 Rotary and Carriage-service Screen Auxiliary-activations Screen From the Main Operating Screen (page 26), press button Press the down arrow on the Rotary and Carriage-service numbers 1 and 5 simultaneously to access this screen. Screen (page 34) to access this screen. The rotary and carriage service screen (Figure 34) provides...
  • Page 35 Drilling-fluid-information Screen Track-drive-information Screen Press the down arrow on the Auxiliary-activations Press the down arrow on the Drilling-fluid-information Screen (page 34) to access this screen. Screen (page 35) to access this screen. The drilling-fluid-information screen (Figure 36) provides the The track-drive-information screen (Figure 37) provides the following information:...

  • Page 36: Control Panel

    Control Panel Transmitter-battery-status Light This light (Figure 38) illuminates red when the battery on the exit-side-lockout transmitter is too low to transmit. Stop drilling operations and fix the problem with the transmitter before continuing. Engine-start Button Press this button (Figure 38) to start the engine.

  • Page 37: Left Joystick-Mode I

    Operate in this mode only when 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 39 Joystick—Forward...

  • Page 38: Left Joystick-Mode Ii

    Operate in this mode only when 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 40 Joystick—Forward...

  • Page 39: Right Joystick-Mode I

    Right Joystick—Mode I Lower Button Note: The joystick controls vary depending on the control Press this button to turn the drilling-fluid pump on or off. mode you select when powering up the machine. There are 2 control modes: Mode I and Mode II; refer to the Trigger Control-select Screen (page 25) for information on setting...

  • Page 40: Right Joystick-Mode Ii

    Right Joystick—Mode II Lower Button Note: The joystick controls vary depending on the control Press this button to turn the drilling-fluid pump on or off. mode you select when powering up the machine. There are 2 control modes: Mode I and Mode II; refer to the Trigger Control-select Screen (page 25) for information on setting...

  • Page 41: Rear Control Panel

    Exit-side-lockout System Rear Control Panel The exit-side-lockout system provides the individuals working around the machine with a means to disable the drill pipe from rotating and thrusting. This system consists of a receiver mounted on the machine and a transmitter (Figure 43) that must be held by a designated individual working around the machine.

  • Page 42: Drill Frame And Stabilizer Controls

    Drill Frame and Stabilizer Controls Engine Key Switch The key switch has 3 positions as follows (Figure 45): G0221 15 Figure 45 1. Engine-off position 3. Engine-start position 2. Engine-run position Figure 46 1. Drill-frame tilt lever 3. Right-stabilizer lever •...

  • Page 43: Drive Pendant

    Drive Pendant Operator-presence Switch Refer to Figure 44 for the location of the drive pendant. Press and hold this button to enable the other controls on the drive pendant. The machine will stop moving if you release this button. g021855 Figure 47 1.

  • Page 44: Drill Pendant

    Drill Pendant Left-track-control Switch/Rotary-control Switch When this switch is connected to the drive-pendant WARNING receptacle, move it to control the movement of the left track. Only an authorized person(s) should operate the drill pendant. Personal injury, harm to others, or •...

  • Page 45: Stake-Down Levers

    Stake-down Levers Drill-spindle-control Switch When this switch is connected to the front drill-pendant receptacle, move it to control the movement of the drill spindle. • Move the switch forward to rotate the drill spindle backward toward the pipe holder. • Move the switch backward to rotate the drill spindle forward toward the operator.

  • Page 46: Specifications

    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.

  • Page 47: Operation

    Operation Important: Use only Toro approved attachments. Other attachments may create an unsafe operating environment or damage the traction unit. Note: Determine the left and right sides of the machine from the normal operating position. Understanding Horizontal Directional Drilling 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.

  • Page 48: Gathering Site Information

    Gathering Site Information 4. Drill the bore. You drill the bore in 3 stages: Planning the Initial Route A. Entry In the entry phase of the bore, you push the drill Before you can begin boring, you need to plan the route that bit and head into the ground at an angle of up to you will bore and prepare as follows: 16 degrees.
  • Page 49 – Electrical power lines DANGER Contacting underground hazards with the DANGER machine while drilling or reaming can cause Drilling into an electric power line will cause explosion, electrocution, breathing problems, the machine to become electrified and may severe trauma, and death to you or bystanders. electrocute you or any bystanders.
  • Page 50 – 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.

  • Page 51: Planning The Bore Path

    Planning the Bore Path Before setting up the job site, you need to plan the bore path, including the following: Figure 51 1. Bore entry 4. Obstacle 2. Beginning-of-bore-at-depth point 5. End-of-bore-at-depth point and bore exit 3. Bore depth • Bore entry needed for steering the drill to the surface, typically 9 to 15 m (30 to 50 ft) from the end-of-the-bore-at-depth point.
  • Page 52 g021765 Figure 52 1. 20 cm (8 inches) This flexibility is often rated in materials as a minimum bend radius, which is the radius of the circle formed if the material or pipes, connected together, were bent to form a giant circle. The minimum radius of a circle made with the pipe used with this machine is 36.6 m (102 ft).
  • Page 53 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.
  • Page 54 Toro recommends that you start the entry point the (26%) on level ground: same distance back from your beginning-at-depth point as •...
  • Page 55 • The following example illustrates the process given an Insert the first 3 m (10 ft) of drill bit/pipe into the ground installation using the machine at an 18% pitch on level with no steering. The end of the drill bit will be 53 cm ground: (21 inches) deep (Figure...

  • Page 56: Understanding And Using The Exit-Side-Lockout System

    Understanding and Using the Indicator Light Meaning Exit-side-lockout System Unmarked indicator light Input power polarity reverse when lit +V1 to +V3 OK and active when solid Understanding the Base-unit Blinking when transmitting Transmitter Indicator Lights Active when receiving The following table lists the various states of the indicator Over temp/voltage Lights up when the lights on the base-unit transmitter...
  • Page 57 Understanding and Using the Handheld Indicator Light State Meaning Transmitter Indicator Lights The green transmit (TX) light The handheld is transmitting is blinking rapidly and is dim. to the base unit. The individual holding the transmitter can push the Lock Drill (Off) button to stop the drill rotation and thrust.

  • Page 58: Preparing The Job Site And The Machine

    Preparing the Job Site and the Important: Ensure that you install the batteries in the correct polarity orientation or you could Machine damage the transmitter. Before drilling, prepare the job site and the machine as follows: • Mark and prepare the bore path Marking and Preparing the Bore Path (page 58).
  • Page 59 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.
  • Page 60 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 g021838 Figure 63 1. Grounding stake If either the audible alarm or the strobe light fail to trigger when you pressed the test button, have them repaired before drilling with the machine.
  • Page 61 Loading Drill Pipes into the Pipe Holder Before using the machine, fill the pipe holder with up to 40 drill pipes. Figure 65 1. Pipe 2. Male end 3. Clevis pins Adding Fuel 1. Remove the clevis pins from the pipe holder (Figure 65).
  • Page 62 • cold flow characteristics which will ease starting and reduce If this is not possible, then refuel such equipment on fuel filter plugging. a truck or trailer from a portable container rather than from a fuel dispenser nozzle. Using summer grade fuel above -7° C (20° F) will contribute •...
  • Page 63 Checking the Engine-oil Level Note: Be sure to keep this safe distance whenever moving the machine. Before you start the engine and use the machine, check the oil 6. Press and hold the operator presence button on the level in the engine crankcase; refer to Checking the Engine-oil drive pendant.
  • Page 64 11. Remove the block from the trailer tires, and stow them with the machine for use when unloading it. 12. After driving a few miles, pull over and check to ensure that all chains are still tight and that the machine has not moved.
  • Page 65 Figure 70 1. Pedestrian safety bar (lowered position shown) Figure 72 5. Push down on the rear platform latch securing the 1. Front pin 2. Rear pin operator platform, and swing it out to the desired position, ensuring that it locks in place (Figure 71).
  • Page 66 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: •...
  • Page 67 Deploying the Zap-alert System 2. Insert the hose from the mixing system over the pump inlet, and secure it with the cam-lock levers. The Zap-alert system is an electric strike-sensing device on the machine that triggers a strobe light and an audible Setting up the Pump to Use a Natural Water Source alarm whenever the drill bit, reamer, or stake breaks into an energized power line.

  • Page 68: Drilling The Bore

    4. Lower the elevators to load a pipe into the cam. 5. Rotate the cam with the pipe facing toward the operator until the cam stops. 6. Rotate the pipe-gripper cam forward until the pipe is in the grippers. 7. Grip the pipe with the pipe grippers. 8.
  • Page 69 All of the above bits come in varying widths. A wider blade increases your ability to steer in soft soils. A narrower blade Figure 83 moves through hard soils better. Contact your Authorized Toro Dealer for a complete list of available blades. 1. Sonde housing 3. Drill bit 2. Sonde beacon The sondes and receivers are essential to track the position of the drill head throughout the drilling operation.
  • Page 70 Installing the Drill Head 5. Using the lower wrench (stationary wrench), clamp the lead bar, and tighten the drill spindle to full-seat threads. 1. Using the exit-side-lockout transmitter, activate the exit-side lockout to disable the thrust and rotation of 6. Double check the drill head and bit to ensure that the the carriage.
  • Page 71 Adding Drill Pipes Steering the Drill Head 1. Align the pipe joint in the wrench assembly. The drill bit is shaped like a wedge, angled from one side of the bit to the other. When you push the bit through the soil 2.

  • Page 72: Backreaming And Pullback

    Exit Side Lockout The following reamers are available from your Authorized and dig down to the obstruction to identify it and Toro Dealer in various sizes to meet your needs and soil remove it if possible. conditions: •...
  • Page 73 Contact your Authorized Toro Dealer to purchase drill-pipe wipers. 15. Release the upper wrench (makeup/breakout wrench). 16. Move the drill carriage back until the pipe is lined up with the pipe holder.

  • Page 74: Finishing The Job

    Removing the Last Pipe and the Reamer Using the TJC Applicator Important: Do not pull the drill head into the pipe Adjusting the Applicator Nozzle guide, or you may damage the machine or the drill head. 1. Using the exit-side-lockout transmitter, enable the exit You can adjust the applicator nozzle to spray thread-joint side lockout.
  • Page 75 Adjusting the TJC-spray Volume Filling the TJC Applicator 1. Loosen the jam nut on the adjustment bolt located on 1. Stop the machine and stop the engine. top of the TJC-applicator piston (Figure 88). 2. Open the stake-down-guard door. 3. Loosen the wing nuts securing the cover straps to the machine (Figure 89).

  • Page 76: Moving A Disabled Machine

    Moving a Disabled Machine Replacing the Pipe Holder 1. Ensure that the 2 upper pins and the 2 lower pins Whenever the machine is stopped and the engine is not are installed to secure the pipe inside the pipe holder running, the hydrostatic brakes automatically engage.

  • Page 77: Positioning The Cab (Model With Cab Only)

    Positioning the Cab (Model Opening the Door (Model with with Cab only) Cab only) Open the door from the outside by pulling on the handle, and Positioning the Cab for Drilling swing the door to the left (Figure 94). Operation 1.

  • Page 78: Operating The Air Conditioning And Heating (Model With Cab Only)

    Operating the Air Conditioning Operating the Windshield and Heating (Model with Cab Wipers (Model with Cab only) only) Changing the Windshield-wiper Speed Air Conditioning the Cab Turn the windshield-wiper knob (Figure 97) to the right increase the speed of the windshield wipers, or turn the knob 1.

  • Page 79: Maintenance

    Maintenance Note: Determine the left and right sides of the machine from the normal operating position. Recommended Maintenance Schedule(s) Maintenance Service Maintenance Procedure Interval • Check the stakedown planetary-drive oil level (Also, check if external leakage is observed). • Check the rotary motor planetary-drive oil level (Also, check if external leakage is observed).
  • Page 80 Maintenance Service Maintenance Procedure Interval • 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.) Every 1,000 hours •...

  • Page 81: Premaintenance Procedures

    Premaintenance Procedures Opening the Front Hood 1. Park the machine on a level surface, stop the engine, and remove the ignition key. 2. Lift up on the latch as shown in Figure Note: Ensure that the key is in the open (horizontal) position as shown in Figure Figure 100...

  • Page 82: Using The Cylinder Lock

    Using the Cylinder Lock Removing and Storing the Cylinder Lock WARNING 1. Start the engine. The thrust frame may lower when it is in the raised 2. Lower the thrust frame to the fully lowered position. position, causing serious injury or death. 3.

  • Page 83: Lubrication

    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.
  • Page 84 Figure 109 Figure 112 Rear pipe-loader cam area (6 fittings) Carriage-roller bearings (operator’s side shown; repeat on other side) Figure 113 Figure 110 Gearbox float (operator’s side shown; repeat on other side) Hydraulic cylinder and wrench assembly Figure 114 Stakedown shaft (left side shown; repeat on right side) Figure 111 Stabilizer cylinder and foot (repeat on other side)

  • Page 85: Engine Maintenance

    Engine Maintenance it is necessary only increases the chance of dirt entering the engine when the filter is removed. • Be sure that the cover is seated correctly and seals with Cleaning the Crankcase-vent the air-cleaner body. Tube Checking the Air-cleaner Indicator Service Interval: Before each use or daily—Check the crankcase-vent tube and clean it if Service Interval: Before each use or daily...
  • Page 86 Cleaning the Dust Valve Service Interval: Every 50 hours 1. Park the machine on a level surface, stop the engine, and remove the ignition key. 2. Open the rear-access door. 3. Squeeze the sides of the dust valve on the air-cleaner cover to release any collected water, dust, or dirt from the valve.

  • Page 87: Servicing The Engine Oil And Filter

    (Figure 120). Toro Premium Engine Oil is available from an Authorized Toro Service Dealer in either 15W-40 or 10W-30 viscosity with API classification CJ-4 (ACEA E9) or higher. See the parts catalog for part numbers.
  • Page 88 Checking the Engine-oil Level B. Install the oil-fill cap and the dipstick. Service Interval: Before each use or daily—Check the engine Changing the Engine-oil Filter oil level. 1. Park the machine on a level surface, stop the engine, Service Interval: Every 250 hours and remove the ignition key.

  • Page 89: Adjusting The Valve Clearance

    If you cannot adjust the valve clearance, contact your 5. When the oil stops, close the drain valve (Figure 124). Authorized Toro Service Dealer. 6. Place the drain hose back into the original position (Figure 124). 7. Change the engine oil filter; refer to...

  • Page 90: Fuel System Maintenance

    Fuel System Note: If the fuel-water separator has any water or sediment, also drain the water and sediment from Maintenance the fuel tank; refer to Draining Water from the Fuel Tank (page 90). 5. When clean fuel appears, rotate the drain valve DANGER clockwise until it is closed.

  • Page 91: Priming The Fuel System

    (Figure 128). 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.

  • Page 92: Checking The Fuel Lines And Connections

    Replacing the Secondary Fuel Filter Checking the Fuel Lines and Connections 1. Park the machine on a level surface, stop the engine, and remove the ignition key. Service Interval: Every 500 hours/Yearly (whichever 2. Open the front hood; refer to Opening the Front comes first)—Inspect the fuel lines and Hood (page...

  • Page 93: Electrical System Maintenance

    Rinse with clear water. Coat the battery posts and keep the battery fully charged. cable connectors with Grafo 112X (skin-over) grease (Toro Part No. 505-47) or petroleum jelly to prevent corrosion. WARNING WARNING •...

  • Page 94: Charging The Battery

    Charging the Battery Battery-charger Table Charger setting Charging time WARNING 4 to 6 amperes 30 minutes Charging the battery produces gasses that can 25 to 30 amperes 10 to 15 minutes explode. 8. When the battery is fully charged, unplug the charger Do not smoke near the battery, and keep sparks and from the electrical source, then disconnect the charger flames away from the battery.

  • Page 95: Drive System Maintenance

    (negative) (positive) 3. Jump post Toro Premium Gear Oil is available from an Authorized Toro Service Dealer. See the parts catalog for part numbers. 7. Connect the positive (+) jumper cable to the jump post 1. Check the oil level on the sight-glass on each stakedown (Figure 131).

  • Page 96: Checking The Oil Level For The Tracks Planetary Drive

    Note: Change the oil when it is warm, if possible. Planetary-drive oil capacity: approximately 1.4 L (1.5 US 1. Park the machine on a level surface. Toro Premium Gear Oil is available from an Authorized Toro 2. Clean the area around the oil-level plug (Figure 133).

  • Page 97: Checking The Oil Level For The Rotary Motor Planetary Drive

    1. Park the machine on a level surface, stop the engine, and remove the ignition key. Toro Premium Gear Oil is available from an Authorized Toro 2. Check the oil level on the sight-glass on each thrust Service Dealer. See the parts catalog for part numbers.

  • Page 98: Checking The Oil For The Gearbox Drive

    Checking the Oil for the Changing the Oil for the Gearbox Drive Gearbox Drive Service Interval: After the first 100 hours—Check the Service Interval: After the first 100 hours—Change the gearbox drive oil. gearbox-drive oil. Every 500 hours—Check the gearbox drive oil (or Every 500 hours—Change the gearbox-drive oil (or yearly, whichever comes first).

  • Page 99: Servicing The Tracks

    Servicing the Tracks 3. Remove the 2 bolts and nuts on the carriage guard (Box B of ). Service Interval: Before each use or daily—Check the track 4. Remove the 2 bolts and nuts on the side of the carriage tension.

  • Page 100: Cooling System Maintenance

    Loosening the Track Tension Cooling System If the track seems tight, loosen the track tension as follows: Maintenance 1. Park the machine on a level surface, stop the engine, and remove the ignition key. Coolant specification: 50/50 solution of ethylene-glycol antifreeze and water or equivalent 2.

  • Page 101: Checking The Coolant Level In The Radiator

    Checking the Coolant Level in Checking the Condition of the Radiator Cooling-system Components Service Interval: Before each use or daily Service Interval: Every 300 hours/Yearly (whichever comes first) WARNING Check the condition of the cooling system for leaks, damage, dirt, and loose hoses and clamps. Clean, repair, tighten, and If the engine has been running, the radiator will be replace the components as necessary.
  • Page 102 Draining the Coolant from the System Flushing the Cooling System Engine and radiator coolant capacity: 16.8 L (17.7 US qt) Important: Do not pour coolant onto the ground or into an unapproved container that can leak. 1. Park the machine on a level surface, stop the engine, and remove the ignition key.
  • Page 103 Filling the System with Coolant A. Open the filler-neck cap. Important: You must fill the cooling system properly to B. Fill the radiator with clean water (Figure 143). prevent air locks in the cooling passages. Failing to vent the cooling system properly can severely damage the cooling system and engine.

  • Page 104: Belt Maintenance

    Belt Maintenance Servicing the Engine-drive Belt WARNING Contacting a rotating belt can cause serious injury or death. Stop the engine and remove the ignition key before working near belts. G022028 Figure 146 Checking the Condition of the Belt 1. Coolant level (at the 3.
  • Page 105 Checking the Tension of the Belt Adjusting the Tension of the Belt 1. Park the machine on a level surface, stop the engine, Service Interval: Every 1,000 hours and remove the ignition key. 1. Park the machine on a level surface, stop the engine, 2.

  • Page 106: Hydraulic System Maintenance

    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.
  • Page 107 Important: If the fluid becomes contaminated, contact Service Interval: Every 500 hours/Every 6 months your Authorized Toro Dealer, because the system must (whichever comes first) be flushed. Contaminated fluid looks milky or black 1. Park the machine on a level surface, stop the engine, when compared to clean oil.
  • Page 108 Changing the High-pressure Hydraulic Changing the Hydraulic-return Filter Filter Service Interval: Every 1,000 hours Service Interval: Every 1,000 hours 1. Park the machine on a level surface, stop the engine, and remove the ignition key. WARNING 2. Open the rear-access door. Ensure that the engine is in the Off position before 3.

  • Page 109: Drilling-Fluid Pump Maintenance

    • Oil:SAE 80W-90, non-detergent oil above 0° C (32° F) hole leaks or nozzles that eject high-pressure Toro Premium Engine Oil is available from your dealer. See hydraulic fluid. the parts catalog for part numbers. Also, refer to the Engine •...
  • Page 110 Checking the Drilling-fluid-pump Oil Changing the Drilling-fluid-pump Oil Level Service Interval: Every 500 hours—Change the drilling-fluid pump oil. Service Interval: Before each use or daily—Check the drilling-fluid pump oil level. 1. Park the machine on a level surface, stop the engine, and remove the ignition key.

  • Page 111: Preparing The Drilling-Fluid System For Cold Weather

    Changing the Drilling-fluid-pump, Preparing the Drilling-fluid Charge Filter System for Cold Weather 1. Park the machine on a level surface, stop the engine, Prepare the machine as follows after drilling if the temperature and remove the ignition key. will be below 0° C (32° F). 2.
  • Page 112 Figure 161 1. Valve (open position) Figure 159 1. Antifreeze-tank cap 2. Antifreeze tank C. Start the machine and turn On the drilling-fluid pump. D. Ensure that the tank is full of antifreeze (Figure D. Add antifreeze to the tank as needed (Figure 159).

  • Page 113: Cab Maintenance

    Cab Maintenance Changing the Cab Air Filter 1. Open the cab door. 2. Park the machine on a level surface, stop the engine, and remove the ignition key. 3. Remove the screw and the cover that house the air filter (Figure 162).

  • Page 114: Cleaning

    Cleaning Cleaning with the Spray-hose Attachment Service Interval: Before each use or daily The machine comes with a spray-hose attachment that you can use to clean the machine and pipes. Important: Do not spray any electronic component of the machine and ensure that the hood is down before Figure 166 cleaning the machine with the spray-hose attachment.

  • Page 115: Storage

    Storage 1. Stop the engine and remove the key. 2. Remove dirt and grime from the entire machine. Important: You can wash the machine with mild detergent and water. Avoid excessive use of water, especially near the control panel, engine, hydraulic pumps, and motors.

  • Page 116: Troubleshooting

    Troubleshooting Problem Possible Cause Corrective Action The starter does not crank. 1. The battery-disconnect switch is in the 1. Turn the battery-disconnect switch to Off position. the On position. 2. The electrical connections are 2. Check the electrical connections for corroded or loose.
  • Page 117 Problem Possible Cause Corrective Action The engine starts, but does not keep 1. The fuel tank vent is restricted. 1. Loosen the cap. If the engine runs with running. the cap loosened, replace the cap. 2. Dirt or water is in the fuel system. 2.
  • Page 118 Problem Possible Cause Corrective Action The engine overheats. 1. More coolant is needed. 1. Check and add coolant. 2. There is restricted air flow to the 2. Inspect and clean the side panel radiator. screens with every use. 3. The crankcase oil level is incorrect. 3.

  • Page 119: Index

    Index Mapping ....... . . 55 Right joystick—Mode I ....114 Marking and preparing .
  • Page 120 Adding ........71 Changing ......89 Priming .
  • Page 121 ( See Pipe holder ) Location......2, 30 Main Operating Screen ....34 Job site Main-selection screen.
  • Page 122 Pipe-clamp-control switch ....45 Replacing the fuel filters ....91 Start-up .
  • Page 123 Safety Alert......2, 4 Valve clearance ......89 Vent tube Cleaning .
  • Page 124 Notes:...
  • Page 125 Notes:...
  • Page 126 Notes:...
  • Page 127 The Way Toro Uses Information Toro may use your personal information to process warranty claims, to contact you in the event of a product recall and for any other purpose which we tell you about. Toro may share your information with Toro's affiliates, dealers or other business partners in connection with any of these activities. We will not sell your personal information to any other company.
  • Page 128 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.

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