Form No. 3414-730 Rev A 2226 Directional Drill Model No. 23803—Serial No. 400000000 and Up Register at www.Toro.com.
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.
Contents 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 ..................................
Safety Storage ................................................................... 99 Troubleshooting .................................................... 100 Index ..................................................................... 103 Important: This machine was manufactured according to the appropriate regulatory standards. 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.
Tramming Safety • Move slowly when using the pendant for tramming. • Use care when loading or unloading the machine You move the machine to and from the work site with the use of a travel pendant. When tramming (moving the machine with the pendant), observe the following safety precautions: 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.
Drilling Safety Drilling Danger Zone • Always lower the pipe loading guard before drilling The danger zone is the area within and around the machine where a person is exposed to the risk of injury. (Figure 4). • Always engage the exit side lockout before operating. The danger zone defines the amount of space needed for safe drilling operation, including movement of the carriage. • Keep bystanders and pets a safe distance away from the machine.
• The alarm will sound if the drill contacts an Utility Line Color electrical power source. Refer to the following table for the proper utility line and the corresponding utility line color (USA and Canada). Utility Line • Do not attempt to leave the machine. Note: You will be safe as long as you do not leave the seat of the machine. Utility Line Color Electric Red • Touching any part of the machine may ground you.
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 missing. decalbatterysymbols g228534 Battery Symbols Some or all of these symbols are on your battery Figure 5 1. 137-7160 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.
g228521 Figure 6 1. 125-6130 2. 125-6128 3. 125-6115 decal125-6130 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. decal125-6128 decal125-6115 125-6128 125-6115 1. High pressure fluid hazard, injection into the body—read the Operator’s Manual before performing maintenance. 1. Crushing hazard—deploy cylinder locks before performing maintenance.
g228523 Figure 8 1. 137-7167 g228522 Figure 7 1. 137-7166 decal137-7167 137-7167 1. Thrown object hazard—keep bystanders away from the machine. decal137-7166 137-7166 1. Crushing hazard—do not stand under the machine.
g228524 Figure 9 1. 137-7168 g228525 Figure 10 1. 137-7172 decal137-7168 137-7168 1. Electrocution hazard—do not touch the machine when the alarm is sounding. decal137-7172 137-7172 1. Runover/backover hazard—read the Operator’s Manual.
g228526 Figure 11 1. 125-6127 2. 125-6129 decal137-7164 137-7164 3. 137-7164 4. 137-7174 1. Read the Operator’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. decal125-6127 125-6127 1. Cutting/dismemberment hazard, fan—keep away from moving parts. decal137-7174 137-7174 8. 1. Read the Operator’s Manual for information on fuses. 2.
decal137-7175 137-7175 1. Rotate the operator platform. g231766 Figure 12 1. 125-6152 2. 137-7171 3. 137-7175 g228528 Figure 13 decal125-6152 125-6152 1. 125-6694 1. Move seat forward and backward. decal125-6694 125-6694 1. Tie-down location decal137-7171 137-7171 1. Falling hazard—do not ride on the machine while it is moving.
g228532 Figure 14 1. 137-7179 2. 137-7178 g228533 Figure 15 1. 125-6197 2. 125-4967 decal137-7179 137-7179 decal125-6197 125-6197 1. Warning—hazardous area; keep at least 3 m (10 ft) away from the machine during operation. 1. Max weight limit—1342 kb (2,958 lb) decal137-7178 137-7178 1. Entanglement hazard—keep away from moving parts. decal125-4967 125-4967 1.
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. g228531 Figure 16 1. 137-7180 2. 125-8473 3. 125-6119 decal125-6119 125-6119 1. Entanglement hazard—keep away from moving objects. decal137-7180 137-7180 1. Impact hazard—do not use a pipe wrench; refer to the Operator’s Manual.
decal117-2718 117-2718 g228960 Figure 17 1. 117-2718 2. 137-7161 decal137-7161 137-7161 1. Engine—stop 5. Headlights 2. Engine—run 6. On 3. Engine—start 7. Off 4.
decal125-6140 125-6140 1. Rotate the chair. g228527 Figure 18 1. 125-6140 2. 137-7183 3. 137-7182 4. 125-6124 decal137-7183 137-7183 1. Read the Operator’s Manual.
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.
decal137-7165 137-7165 1. Antifreeze g228530 Figure 19 1. 137-7165 2. 125-8483 3. 137-7169 4. 137-7170 5. 127-1829 decal125-8483 125–8483 1. Hydraulic fluid; read the Operator’s Manual. 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. 3. Warning—keep bystanders away from the machine. 5. Warning—hearing protection must be worn. 6.
decal137-7170 137-7170 g228520 Figure 20 1. Falling hazard—do not climb on the machine while it is moving. 1. 125-6107 decal127-1829 127-1829 1. Oil drain decal125-6107 125-6107 1. Crushing hazard of hand and foot—keep hands and feet away.
g231767 Figure 21 1. 137-7177 2. 137-7176 3. 125-6193 4. 125-6194 decal137-7177 137-7177 1. Mud—On/Off 8. Carriage thrust speed—high 2. Upper wrench—open/close 9. Mud flow—high 3. Lower wrench—open/close 10. Thrust the carriage forward (drill mode I and II); lower 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.
decal137-7176 137-7176 1. Engine—start 10. Rotate the cam assembly. 2. Engine speed—increase 11. Move to the next or previous step in SmartTouch™ mode. 3. Engine speed—decrease 12. Cam override function to rotate the cam assembly. 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.
decal125-6193 125-6193 1. Exit-side lockout—reset 5. Tramming and setup 2. Exit-side lockout switch 6. 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.
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.
g218959 Figure 24 Right Side View 1. Carriage 6. Thrust frame 2. Zap-alert strobe 7. Stabilizer foot 3. Front hood 4. Front control panel 8. Rear hood 9. Tracks 5.
g218960 Figure 25 Top view 1. Carriage 5. Lower wrench 2. Drill spindle 6. Pipe wiper 3. Thrust frame 4. Upper wrench 7.
Controls Operator-Platform Latch Refer to the following sections for the appropriate machine controls: The operator platform swings out away from the machine, making room for you to sit. It has 5 positions: travel (swung all the way into the machine), full-out, and 3 intermediate positions. Return the platform to the TRAVEL position before moving the machine.
Adjusting the Operator 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.
Front Control Panel Emergency Engine Stop Button Push this button (Figure 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.
Joysticks in Setup Mode The machine must be in setup mode (Figure 29) and you must be in the seat to use these functions. g225942 Figure 30 Joysticks – Setup Mode 5. Lower the right stake down 1. Lower the left stake down 2. Rotate the left stake clockwise 6. Rotate the right stake clockwise 3. Raise the left stake up 7. Raise the right stake up 4. Rotate the left stake counter clockwise 8.
Left Joystick g226145 Figure 31 Left Joystick in DRILL mode 1. Raise the elevator 6. Go to the next step in SmartTouch™ mode 2. Lower the elevator 7. Retract the pipe gripper arm 3. Open / Close the pipe gripper 8. Extend the pipe gripper arm 4. Rotate the cam assembly 9. Apply tread-joint compound 5. Go to the previous step in SmartTouch™ mode g226143 Figure 32 Left Joystick — Directional Controls 1. Rotate the drill spindle counter clockwise (Drill Mode II) 3.
Right Joystick The joystick controls vary depending on the control mode you select when powering up the machine. There are 2 control modes: Drill Mode I and Drill Mode II; refer to the Control-Select Screen in the Software Guide for information on setting the control modes. g226146 Figure 33 Right Joystick 1. Turn the mud on or off 4. Open and Close the rear wrench 7. Set the auto drill on or off 2. Increase the mud flow momentarily 5. Open and close the front wrench 8.
Exit Side Lockout • Engine-off position—turn the key to this position to shut off the engine. The engine cannot be started from the operator platform when the key is in this position. The exit-side-lockout system provides the individuals working around the machine with a means to disable the drill pipe from rotating and thrusting. • Engine-run position—turn the key to this position For more information and instructions, refer to the Operator’s Manual for the Exit-side-lockout system.
Battery-Disconnect Switch If you release the operator presence switch while operating, you will need to release all of the controls before resuming operation. Open the front hood to access the BATTERY -DISCONNECT switch; refer to Opening the Front and Rear Hoods (page 67). Operator Presence Switch The BATTERY -DISCONNECT switch is located to the right of the engine; it is used to electrically disconnect the battery from the machine.
Understanding Horizontal Directional Drilling Operation Determine the left and right sides of the machine from the normal operating position. 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, pull back the utility lines or pipes through the bore and connect them as needed.
Gathering Site Information Refer to Preparing the Job Site and the Machine (page 44) for instructions on preparing the job site and the machine. 4. Drill the bore. Planning the Initial Path Drill the bore in 3 stages: Before drilling, plan the path you will bore and prepare as follows: A. Entry • Create a basic plan for the bore, mapping out the In the entry phase of the bore, push the drill bit and head into the ground at an angle of up to 16 degrees.
– Crystalline silica and other dust DANGER 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. 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. ◊ Control dust, mist, and fumes at the source where possible. Water should be used for dust suppression when feasible.
Planning the Bore Path Before setting up the job site, you need to plan the bore path, including the following: g218955 Figure 40 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 you will need to determine the distance from the end-of-bore-at-depth location 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.
g021765 Figure 41 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 31 m (101 ft). g218953 Figure 43 • Entry pitch The entry pitch is the angle at which the drill bit enters the ground.
Note: The depths given in the following table are for 3 m (10 ft) of combined drill head and pipe. As you steer up, the pitch of the steered section changes 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.
The following example illustrates the process given an installation using the maximum entry pitch of the machine (26%) on level ground: g218954 Figure 44 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 insert the first 3 m (10 ft) of drill bit/pipe into the ground with no steering. The end of the drill bit is 76 cm (30 inches) deep (Figure 44).
The following example illustrates the process given an installation using the machine at an 18% pitch on level ground: g218952 Figure 45 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 Path • You insert the first 3 m (10 ft) of drill bit/pipe into the ground with no steering. The end of the drill bit is 53 cm (21 inches) deep (Figure 45).
Preparing the Job Site and the Machine Checking the Safety-Interlock Switches Before drilling, prepare the job site and machine as follows: Checking the Operator Presence Safety-Interlock Functions on the Operator Platform • Marking and Preparing the Bore Path (page 44) • Testing the Zap-Alert System (page 45) • Loading the Drill Pipes (page 46) 1. Start the engine. • Filling the Fuel Tank (page 46) 2.
Checking the Pipe Load Guard Safety Interlock Functions 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 becomes energized, setting off the alarm. You will need 2 people for this procedure. 1. Start the engine. 2. Lower the pipe load guard. 3. With the engine running, have 1 person sit in the seat and begin the drilling process. 1.
Mounting a Fire Extinguisher Mount your fire extinguisher below the operator seat (Figure 50). 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. g230009 Figure 48 Operate and maintain the fire extinguisher per the instructions on the fire extinguisher. 7. Push the ZAP-ALERT RESET button to stop the alarm (Figure 29). 8.
• Never keep fuel in containers with zinc plating on • Fuel filter plugging may be expected for a time the inside. after converting to biodiesel blends. Contact your Authorized Service Dealer for more information on biodiesel. • • Do not use fuel additives. Petroleum Diesel Adding Fuel Cetane rating: 45 or higher Sulfur content: Ultra-low sulfur (<15 ppm) 1. Move the machine to a level surface. 2. Position the thrust frame in the horizontal position. 3. Shut off the engine. 4.
Loading and Unloading the Machine emergency-engine-stop buttons are released (Figure 29 and Figure 38). 6. Turn the key to the START position until the engine starts, then release it. WARNING To shut off the engine, turn the key to the OFF position. 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.
3. Place a block at the front and rear of the trailer and/or truck tires. 7. Lower the stabilizers until the stabilizer feet contact the trailer floor. 4. Using the travel pendant, set the engine and the tram speed to slow. 8. Turn off the engine. 9. 5. Using the travel pendant, carefully tram the machine forward or rearward up the ramp and into position on the trailer.
Setting Up the Drill Head and Tracking System The drill head consists of 2 parts, the drill bit and the sonde housing (Figure 54). g023073 Figure 55 g023076 Figure 54 1. Sonde housing 2. Drill bit 1. Sonde housing 4. Housing cover 2. Screws 5. Housing 3. 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: 3.
Deploying the Zap-Alert System Setting up the Machine for Drilling 1. Using the travel pendant, tram 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. Remove the console covers.
g218964 Figure 60 1. Thrust frame 3. 2. Stake-down plate 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 ground. g218966 Figure 59 Note: If the ground is soft, place timber below 2. 3. the stabilizers and lower the stabilizers.
refer to your mixing system Operator’s Manual for details. Setting Up the Pump to Use a Natural Water Source 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 instead of mixed drilling fluid. To set up a pump to use a natural water source, ensure that you use the Y-screen to filter all materials other than water. 1.
Slope Safety During Operation 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.
Diesel Particulate Filter Regeneration • When enough soot accumulates, the computer The diesel particulate filter (DPF) is part of the exhaust system. The diesel-oxidation catalyst of the DPF reduces harmful gasses and the soot filter removes soot from the engine exhaust. • DPF regeneration is a process that heats the DPF informs you that it is time to regenerate the diesel particulate filter. to convert the soot to ash.
Types of Diesel Particulate Filter Regeneration Types of diesel particulate filter regeneration that are performed while the machine is operating: Type of Regeneration Conditions for DPF regeneration DPF description of operation Passive Occurs during normal operation of the machine at high-engine speed or high-engine load The display does not display an icon indicating passive regeneration.
Drilling the Bore Passive DPF Regeneration • Passive regeneration occurs as part of normal engine operation. Starting the First Pipe • While operating the machine, run the engine at The Software Guide is used in this procedure. full-engine speed when possible to promote DPF regeneration. Assist DPF Regeneration 1. Ensure that all bystanders are away from the machine and that the exit-side lockout is ON. 2.
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 drill pipe and lead bar back through the pipe guide and into the wrenches, aligning the shoulder of the upper joint of the lead bar with the upper wrench (Figure 66).
Boring the Entry Shaft 9. The first step is to create the entry shaft. Push and bore the drill bit and the 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. Note: Tighten the joint until the pipe is rotating with the spindle. Important: Drill and ream in a clockwise rotation. 10.
Exiting the Ground ft) of forward travel. If you steer more than this, you will damage the drill pipes. 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.
2. Using breakout tools, remove the drill head from the lead bar. Important: Do not use pipe wrenches. 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 Service Dealer to acquire the appropriate puller to meet your requirements. Removing Drill Pipes 1.
16. Rotate the drill spindle counterclockwise moving rearward slowly until the spindle fully separates from the pipe. 17. Send the carriage to the rear stop on the thrust frame. 18. Retract the pipe gripper arms. 19. Rotate the pipe cam to the desired row. Release the pipe gripper and raise the pipe into the pipe box using the pipe elevators. 21. Rotate the pipe gripper past the third row of pipes. 23.
Finishing the Job Adjusting the TJC-spray Volume Complete the following after each day of use: To adjust the volume of thread-joint compound that is delivered by the applicator, complete the following: • Connect the hand spray gun to the pump and clean 1. the machine with clean water; refer to Cleaning with the Spray-Hose Attachment (page 97). • Flush the drilling fluid out of the drilling-fluid pump Loosen the jam nut on the adjustment bolt located on top of the TJC-applicator piston (Figure 71).
Moving a Disabled Machine Filling the TJC Applicator 1. Stop the machine and shut off the engine. 2. Loosen the wing nuts securing the cover straps to the machine (Box A of Figure 72). 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.
Maintenance WARNING Failure to properly maintain the machine could result in premature failure of machine systems, causing possible harm to you or bystanders. Keep the machine well maintained and in good working order as indicated in these instructions. Note: Determine the left and right sides of the machine from the normal operating position. Place a service tag on the machine when maintenance procedures are being performed. Replace all covers and guards after you service or clean the machine.
Maintenance Service Interval Every 800 hours Maintenance Procedure • • • • • • • • • • • Adjust the engine-valve clearance (if necessary). Drain and clean the fuel tank. Change the planetary oil (or yearly, whichever comes first). Check the rotary gearbox drive oil (or yearly, whichever comes first). Change the gearbox-drive oil (or yearly, whichever comes first). Check the concentration of the coolant before the winter season. Clean the cooling system.
Pre-Maintenance Procedures Pre-Maintenance Safety – Allow machine components to cool before performing maintenance. • Before adjusting, cleaning, repairing, or leaving the machine, do the following: – Move the machine on a level surface. – Shut off the engine and remove the key. – Set the battery-disconnect switch to the OFF position. – Wait for all moving parts to stop. • If possible, do not perform maintenance while the engine is running. Keep away from moving parts.
Lubrication Using the Cylinder Lock WARNING Greasing the Machine The thrust frame may lower when it is in the raised position, causing serious injury or death. Service Interval: Before each use or daily (Grease immediately after every washing). Grease type: General-purpose grease. Install the cylinder lock before performing maintenance that requires the thrust frame to be raised. Total number of grease fittings: 51 Installing the Cylinder Lock 1. Start the engine. 2.
g220078 Figure 78 Cam Assembly (Operator Side)—2 fittings g222835 Figure 79 Left Side, Front Cam Assembly—4 fittings 69
g222836 Figure 80 Left Side, Rear Cam Assembly—4 fittings g222837 Figure 81 Tracks—12 fittings (6 on each side) 70
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
Engine Maintenance Engine Safety • Shut off the engine before checking the oil or adding oil to the crankcase. • Do not change the governor speed or overspeed the engine. g223045 Figure 85 Lift Cylinder (Drill/Carriage Side; lower grease fitting is behind the track roller)—3 fittings Servicing the Air Cleaner Check the air-cleaner body for damage that could cause an air leak and replace it if it is damaged. Check the entire intake system for leaks, damage, or loose hose clamps.
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 help remove large accumulations of debris packed between the outside of the primary filter and the canister. Note: Avoid using high-pressure air that could force dirt through the filter into the intake. This cleaning process prevents debris from migrating into the intake when the primary filter is removed.
Servicing the Engine Oil Crankcase Oil Capacity 11.2 L (11.8 US qt) with the filter Oil Specification Use high-quality, low-ash engine oil that meets or exceeds the following specifications: g034926 Figure 90 • API service category CJ-4 or higher 1. Secondary filter • ACEA service category E6 5. • JASO service category DH-2 Inspect the new filter for shipping damage, checking the sealing end of the filter and the body.
g220795 g220852 g031256 Figure 91 g220851 Figure 92 Changing the Engine Oil and Engine-Oil Filter 4. Note: Ensure that the oil-filter gasket touches Service Interval: After the first 50 hours—Change the engine oil and engine-oil filter. the engine, and then an extra 3/4 turn is completed. Every 400 hours—Change the engine oil and engine-oil filter. Note: Change the engine oil and filter more frequently when the operating conditions are extremely dusty or sandy. 1.
Adjusting the Engine-Valve Clearance Service Interval: Every 800 hours Refer to your engine owner’s manual for the adjustment procedure. Cleaning the Engine EGR Cooler Service Interval: Every 1,500 hours For information on cleaning the engine EGR cooler, refer to your engine owner’s manual. g220797 Figure 93 1. Engine-oil filter Inspecting the Engine Crankcase-Breather System 2.
Inspecting and Cleaning Engine-Emission-Control Components and Turbocharger Fuel System Maintenance Servicing the Fuel System Service Interval: Every 3,000 hours Draining the Fuel Tank For information on inspecting and cleaning the engine-emission-control components, refer to your engine owner’s manual. Service Interval: Every 800 hours—Drain 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.
Replacing the Water-Separator Element 1. Place a clean container under the water separator. 2. Drain some fuel by loosening the vent plug and opening the drain valve (Figure 95). 3. Clean the area where the filter element mounts to the head. 4. Remove the filter element. 5. Apply a coating of clean fuel or engine oil to the new O-ring and element seal. 6. Install the new filter canister by hand until the gasket contacts the filter head, then tighten it an additional 1/2 turn.
Electrical System Maintenance WARNING A battery contains sulfuric acid, which can cause serious burns; and they can produce explosive gases. Battery Safety • Avoid contact with skin, eyes, or clothing; flush affected areas with water. • Disconnect the battery before repairing the machine. Disconnect the negative terminal first and the positive last. Connect the positive terminal first and the negative last. • If taken internally, drink large quantities of water or milk. Do not induce vomiting.
Charging the Battery Battery-Charger Table Charger setting Charging time 10 A 8 to 10 hours Charging the battery produces gasses that can explode. 20 A 4 to 6 hours (do not exceed 6 hours) Do not smoke near the battery and keep sparks and flames away from battery. 8. WARNING Important: Keep the battery fully charged. This is especially important to prevent battery damage when the temperature is below 32° F (0° C). 1. Move the machine to a level surface, shut off the engine, and remove the key.
Drive System Maintenance Checking the Planetary Drive 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 g234645 Figure 98 1. Jumper-cable post (negative) 2. Jumper-cable post (positive) 7. Connect the positive (+) jumper cable to the jump post (Figure 98). 8.
7. Checking the Rotary Gearbox Drive Oil Repeat steps 1 through 6 to check the planetary-drive oil level on the other side of the machine. Service Interval: Before each use or daily—Check the rotary gearbox drive oil. Changing the Planetary Drive Oil Every 800 hours—Check the rotary gearbox drive oil (or yearly, whichever comes first). Service Interval: After the first 250 hours—Change the planetary oil.
Changing the Rotary Gearbox Drive Oil Service Interval: After the first 100 hours—Change the gearbox-drive oil. Every 800 hours—Change the gearbox-drive oil (or yearly, whichever comes first). Note: Change the oil when it is warm, if possible. 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). g235824 Figure 102 g235823 Figure 101 4. Install the drain plug.
Servicing the Tracks Loosening the Track Tension Service Interval: Before each use or daily—Check 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 frame and stabilizers so that the tracks are raised. 2. Shut off the engine and remove the key. 3. Remove dirt and debris found around the track-tension grease valve (Figure 103).
Cooling System Maintenance Checking the Coolant Level in the Reservoir Coolant specification: 50/50 solution of ethylene-glycol antifreeze and water or equivalent Service Interval: Before each use or daily Engine and Radiator coolant capacity: 16.77 L (17.7 US qt) during this procedure. Important: Do not remove the radiator filler cap WARNING If you remove the radiator cap from a hot engine, hot coolant could spray, causing scalding. 1.
Checking the Coolant Level in the Radiator 5. If the coolant level is low, add coolant until the level is up to the bottom of the filler neck (Figure 105). Important: Do not overfill the radiator. Service Interval: Every 50 hours Note: If the radiator coolant level is low and the WARNING coolant reservoir level is at the Full mark, check for air leaks in the hose between the radiator and the coolant reservoir.
Flushing the Cooling System Cleaning the Cooling System Engine and radiator coolant capacity: 16.8 L (17.7 US qt) Service Interval: Every 800 hours/Yearly (whichever comes first) (Clean the cooling system if the coolant becomes dirty or rust colored.) 1. Move the machine to a level surface, shut off the engine, and remove the key. 2. Condition the cooling system as follows: A.
3. F. Clean the threads on the drain plug and apply 3 layers of PTFE sealing tape. G. Close the drain plug. Filling the System with Coolant Important: You must fill the cooling system properly to prevent air pockets in the cooling passages. Failing to vent the cooling system properly can severely damage the cooling system and engine. Flush the cooling system as follows: A. Open the filler-neck cap. B. Fill the radiator with clean water (Figure 108).
Belt Maintenance Checking the Belt Tension Service Interval: Every 800 hours Servicing the Engine-Drive Belt WARNING 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). Contacting a rotating belt can cause serious injury or death. Shut off the engine and remove the key before working near belts.
Adjusting the Tension of the Belt 1. Move the machine to a level surface, shut off the engine, and remove the key. 2. Open the front hood. 3. Loosen the nut and bolt at the pivot point for the alternator (Figure 111). Hydraulic System Maintenance Hydraulic System Safety • Seek immediate medical attention if fluid is injected into skin. Injected fluid must be surgically removed within a few hours by a doctor.
High Viscosity Index/Low Pour Point Anti-wear Hydraulic Fluid, ISO VG 46 (cont'd.) Pour Point, ASTM D97 Industry Specifications: -6° C (-42° F) Vickers I-286-S (Quality Level), Vickers M-2950-S (Quality Level), Denison HF-0 Note: Many hydraulic fluids are almost colorless, making it difficult to spot leaks. A red dye additive for the hydraulic fluid is available in 20 mL (2/3 oz) bottles. One bottle is sufficient for 15-22 L (4-6 gallons) of hydraulic fluid.
Changing the Hydraulic-Fluid Return Filter Changing the Hydraulic-Charge Filter Service Interval: Every 800 hours/Every 6 months (whichever comes first) Service Interval: 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. 1. Move the machine to a level surface, shut off the engine, and remove the key. 2. Discard the old hydraulic-fluid return filter. 2. Open the front hood. 3.
Changing the Hydraulic Fluid Service Interval: Every 800 hours/Yearly (whichever comes first) Important: If the fluid becomes contaminated, contact your Authorized Service 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. Move the machine to a level surface, shut off the engine, and remove the key. 2. Open the front hood. 3.
Drilling-fluid Pump Maintenance the system. Check for leaks; then shut off the engine. 16. Check the fluid level and add enough to raise the level to the Full mark on the dipstick. Do not overfill. Servicing the Drilling-Fluid-Pump Oil Checking the Hydraulic Lines and Hoses 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 2 years—Replace moving hoses. The crankcase capacity is 1.
Preparing the Drilling-Fluid System for Cold Weather Oil (page 95) and add the necessary amount of oil. Changing the Drilling-Fluid Pump Oil Prepare the machine as follows after drilling if the temperature will be below 0° C (32° F). Service Interval: Every 400 hours—Change the drilling-fluid pump oil. 1. Move the machine to a level surface, shut off the engine, and remove the key. 2. Open the rear hood. 3. Allow the engine to cool. 4.
g220260 Figure 119 D. Remove the cap from the antifreeze tank for the drilling-fluid pump (Figure 120). g220258 Figure 120 1. Antifreeze tank 3. Antifreeze valve (shown in the ON position) 2. Drilling-fluid valve (shown in the ON position) E. 3. Ensure that the tank is full of antifreeze (Figure 120). Circulate the antifreeze as follows: 96 A. Open the antifreeze valve on the front side of the drilling-fluid pump as shown in Figure 120. B.
Controls Maintenance Cleaning Calibrating the Joysticks and the Travel Pendant Cleaning with the Spray-Hose Attachment Service Interval: Every 400 hours Service Interval: Before each use or daily Refer to the joystick section of the Software Guide for this procedure. The machine comes with a spray-hose attachment that you can use to clean the machine and pipes.
7. Turn the drilling-fluid 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.
Storage 1. Shut off the engine and remove the key. 2. Remove dirt and grime from the entire machine. Important: You can wash the machine with mild detergent and water. Avoid excessive use of water, especially near the control panel, engine, hydraulic pumps, and motors. 3. Service the air cleaner; refer to Servicing the Air Cleaner (page 72). 4. Grease the machine; refer to Greasing the Machine (page 68). 5. Charge the battery; refer to Charging the Battery (page 80). 6.
Troubleshooting Problem Possible Cause Corrective Action The machine is not responding to the controls properly. 1. The joysticks need to be calibrated. 1. Calibrate the joysticks. 2. The cam assembly needs to be calibrated. 3. One of the sensors is not responding. 2. Calibrate the cam assembly; refer to the Software Guide. 3. Check the machine can information screen; refer to the Software Guide. The starter does not crank. 1. The BATTERY -DISCONNECT switch is in the OFF position. 1.
Problem The engine starts, but does not keep running. Possible Cause 1. The fuel tank vent is restricted. 1. Loosen the cap. If the engine runs with the cap loosened, replace the cap. 2. Dirt or water is in the fuel system. 2. Drain and flush the fuel system; add fresh fuel. 3. Replace the fuel filter. 4. Bleed the nozzles and check for air leaks at fuel hose connections and fittings between the fuel tank and engine. 5. Drain the fuel system and replace the fuel filter.
Problem The engine overheats. Possible Cause 1. More coolant is needed. 1. Check and add coolant. 2. There is restricted air flow to the radiator. 3. The crankcase oil level is incorrect. 4. There is excessive loading. 2. Inspect and clean the side panel screens with every use. 3. Fill or drain to the full mark. 4. Reduce the load and use a lower ground speed. 5. Drain and flush the fuel system; add fresh fuel. 6. Contact your Authorized Service Dealer. 7. Contact your Authorized Service Dealer. 8.
Index Engine-stop . . . . . . . . . . . . . . . . 29, 33–34, 81 811 ............................. 4, 35–36 A Accessing internal components Access. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adding drill pipes . . . . . . . . . . . . . . . . . . . . . . . . . . After Operation Safety . . . . . . . . . . . . . . . . . . . . Air cleaner Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Boring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Error indicator light . . . . . . . . . . . . . . . . . . . . . . . . Exit-side lockout Drill-enabled light . . . . . . . . . . . . . . . . . . . . . . . Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reset light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reset switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exiting the ground . . . . . . . . . . . . . . . . . . . .
Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Pipe load guard Lowering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Pipes Loading into the pipe holder . . . . . . . . . . . 46 Pitch Setting the thrust frame . . . . . . . . . . . . . . . . 52 Planetary drive Changing the oil . . . . . . . . . . . . . . . . . . . . . . . . 82 Checking the oil level. . . . . . . . . . . . . . . . . . . 81 Oil specification and capacity . . . . . . . . . .
Deploying. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ground-strike-reset switch . . . . . . . . . . . . . Grounding stake Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Notes:
