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Toro 4045 - User Manual

Toro 4045
128 pages
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FormNo.3401-924RevA
4045DirectionalDrill
ModelNo.23825—SerialNo.313000501andUp
ModelNo.23825—SerialNo.314000501andUp
Registeratwww.Toro.com.
OriginalInstructions(EN)
*3401-924*A

Table of Contents

Other manuals for Toro 4045

Questions and Answers:

Toro 4045 Specifications

General IconGeneral
TypeHammer Drill
Voltage120V
Power SourceCorded Electric
No Load Speed0-2800 RPM
Impact Rate0-44, 800 IPM
Max Drill Capacity (Concrete)5/8 inch
Max Drill Capacity (Steel)1/2 inch

Summary

Introduction to Directional Drilling

Safety Guidelines

Operator Training

Read the Operator's Manual and become familiar with safe operation and controls.

Job Site Preparation

Evaluate terrain, use approved attachments, wear appropriate clothing, and inspect the area.

General Operation Rules

Do not run the engine in enclosed areas, operate with guards in place, and keep away from moving parts.

Driving Safety Procedures

Drilling Safety Precautions

Drilling Danger Zone Identification

Area within and around the machine where a person is exposed to injury by operational movement.

Utility Line Awareness During Drilling

Before operating near high-voltage lines, contact a 'One-Call System Directory' service.

Utility Line Electrical Safety

Gas Line Safety Guidelines

WARNING: Damaging a gas line causes explosion/fire hazard. Ensure safety precautions.

Water Line Safety Guidelines

Potential flood hazard if water line is damaged. Follow safety procedures.

Communication Line Safety Guidelines

CAUTION: Damage to fiber-optic cable can harm eyes. Follow safety procedures.

Maintenance and Storage Procedures

Noise and Vibration Level Information

Information on sound pressure, sound power, and vibration levels for operator safety.

Safety and Instructional Decals

Battery Symbol Explanations

Explanation of various battery symbols found on the machine for safety.

Product Overview

Machine Controls

Operator Platform Details

Description of the operator platform location and its controls.

Operator Controls Protective Covers

Information on covers that protect operator controls from weather conditions.

Operator Platform Adjustment Latch

Instructions for releasing and adjusting the operator platform position.

Monitor Screens

Machine Start-up Screen

The initial screen displayed when the machine powers up.

Control Layout Selection Screen

Screen for choosing between control layout modes (Mode I or Mode II).

Drill Function Display Screens

Pressure Measurement Display Screen

Displays pressure measurements and indicators for rotary, drilling fluid, and carriage.

Torque Measurement Display Screen

Displays torque, pressure, force, and flow rate measurements for drilling operations.

Drill Operation Control Screens

Drill Rotation Speed Adjustment Screen

Screen for increasing or decreasing the drill rotation speed.

Thrust Output Control Screen

Screen for increasing or decreasing the machine's thrust output.

Engine Performance Control Screens

Horsepower Control Adjustment Screen

Screen for adjusting engine speed settings to control horsepower.

Pipe Row Selection Screen

Screen for selecting the row of pipe(s) to be used.

Main Selection and Maintenance Screens

Main Selection Menu Screen

Main menu screen for selecting various operational and maintenance functions.

Lubrication and Maintenance Schedule Access

Accesses screens for maintenance schedules at various hour increments.

Diagnostic and Calibration Screens

Error Codes Display Screen

Displays the number of drill errors and engine errors that have occurred.

Parameter Diagnosis and Adjustment Screen

Screen for diagnosing and adjusting machine parameters, requires PIN.

Loader and Calibration Screens

Loader Cam Calibration Screen

Screen for calibrating the loader cam or loader arm and adjusting cam-stop positions.

Loader Cam Position Setting Screen

Screen for setting row positions for the pipe holder.

Loader Arm and Service Reminder Screens

Loader Arm Position Setting Screen

Screen for setting the loader arm to the In or Home position.

Clear Service Reminder Screen

Screen to clear a service reminder by entering an 8-digit PIN.

Drill System Service Screens

Rotary and Carriage Service Information

Provides information on rotary and carriage joystick output and indicators.

Auxiliary Activations Status Screen

Shows On and Off indicators for various auxiliary functions.

Drilling Fluid and Track System Screens

Drilling Fluid Information Screen

Provides On/Off indicators for drilling fluid, flow, and mud output.

Track Drive System Information Screen

Shows output for track drive movements and joystick control.

Control Panel Layout

Engine Start and Stop Buttons

Buttons to start and immediately stop the engine and drilling operations.

Drive;Drill Mode Selection Switch

Switch to enable drive/setup controls or drill/pipe-loader functions.

Engine Speed Adjustment Switch

Switch to increase or decrease engine speed.

Left Joystick Controls - Mode I

Joystick Trigger Function

Changes joystick controls from pipe-loader to wrench-operation.

Joystick Toggle Switch Function

Controls upper wrench rotation or pipe cam movement.

Left Joystick Front Button Function

Resumes auto-drill speed or opens pipe gripper.

Left Joystick Rear Button Function

Sets auto-drill speed or closes pipe gripper.

Left Joystick Lower Button Function

Overrides pipe cam presets for manual movement.

Left Joystick Forward Movement

Spin drill spindle counterclockwise.

Left Joystick Rearward Movement

Spin drill spindle clockwise.

Left Joystick Left Movement

Opens upper wrench or lowers pipe elevator.

Left Joystick Right Movement

Closes upper wrench or raises pipe elevator.

Left Joystick Controls - Mode II

Right Joystick Controls - Mode I

Right Joystick Toggle Switch Function

Increases or decreases drilling fluid flow rate.

Right Joystick Front Button Function

Applies thread-joint compound.

Right Joystick Rear Button Function

Sets maximum drilling fluid pressure.

Right Joystick Lower Button Function

Turns the drilling-fluid pump on or off.

Right Joystick Trigger Function

Moves drill carriage at high speed up or down the drill frame.

Right Joystick Forward Movement

Thrusts the drill carriage forward.

Right Joystick Rearward Movement

Pulls the drill carriage rearward.

Right Joystick Left Movement

Spins the drill spindle clockwise.

Right Joystick Right Movement

Spins the drill spindle counterclockwise.

Right Joystick Controls - Mode II

Exit-Side Lockout System

Base Unit Transmitter Indicator Lights

Lists states of indicator lights on the base-unit transmitter and their meanings.

Rear Control Panel Components

Engine Heating Indicator Light

Indicator light for the intake air heater when the engine is cold.

Machine Frame and Stabilizer Controls

Stabilizer Lever Operation

Levers to raise and lower the stabilizers.

Drill Frame Tilt Lever Operation

Lever to tilt the drill frame for stake-down or travel.

Drive Pendant Operation

Engine Stop Button Function

Button to immediately stop the engine and all operations.

Engine Speed Adjustment Switch

Switch to increase or decrease engine speed.

Drive Direction Control Joystick

Joystick to control the direction of machine movement.

Drive Speed Selection Switch

Switch to set the machine travel speed.

Operator Presence Safety Switch

Button to enable other controls; machine stops if released.

Drill Pendant Control Functions

Left Track and Rotary Control Switch

Controls left track movement or pipe rotation.

Drilling Fluid and Wrench Control Switch

Controls drilling fluid flow or wrench operation.

Right Track and Carriage Control Switch

Controls right track movement or carriage movement.

Breakout Wrench Control Switch

Controls wrench breakout and makeup for the upper wrench.

Drill Pendant Specific Switch Functions

Drill Spindle Control Switch

Controls the movement of the drill spindle.

Pipe Grip Control Switch

Controls the pipe grip.

Pipe Clamp Control Switch

Controls the pipe clamp.

Cam Rotation Control Switch

Controls the movement of the cam.

Pipe Elevator Control Switch

Controls the pipe elevator.

Stationary Pipe Clamp Control Switch

Controls the stationary-pipe clamp for the lower wrench.

Stake-Down Lever Operations

Stake Raise;Lower Lever Function

Levers to lower stakes into ground or raise them out.

Stake Spin Lever Function

Levers to spin stakes clockwise or counterclockwise.

Machine Specifications

Machine Physical Specifications

Specifications for the machine's dimensions and weight.

Exit-Side Lockout System Handheld Unit Specs

Specifications for the handheld transmitter unit.

Exit-Side Lockout System Base Unit Specs

Specifications for the machine's base unit for the lockout system.

Available Attachments and Accessories

Information on approved attachments and accessories available for the machine.

Operation Procedures

Understanding Horizontal Directional Drilling Process

Explanation of the directional drilling process and its benefits.

Gathering Essential Site Information

Steps to gather necessary site information before drilling operations.

Planning the Bore Path Strategy

Process of planning the bore path based on gathered site information.

Job Site and Machine Preparation

Steps to prepare the job site and the machine for drilling operations.

Bore Path Planning Details

Defining Bore Entry Point

Location where the machine and drill bit enter the ground.

Identifying Beginning-of-Bore-at-Depth Point

Point where the utility line or pipe ends after installation.

Determining Required Bore Depth

The desired depth for installing the utility line or pipe.

Identifying and Navigating Path Obstacles

Identifying and planning around known obstacles affecting the bore path.

Defining End-of-Bore-at-Depth Point

Point where the utility line or pipe begins after installation.

Defining the Bore Exit Location

Location where the drill head exits the ground.

Bore Entry Point Determination Factors

Factors to consider when determining the bore entry point location.

Utility Line Installation Depth Requirements

Depth for utility line installation, typically 1-3 meters.

Pipe and Material Flexibility Considerations

Information on pipe flexibility and bend radius to avoid damage.

Entry Pitch Calculation

Bore Path Mapping Procedure

Exit-Side Lockout System Operation

Base Unit Transmitter Indicator Lights Meaning

Lists states of indicator lights on the base-unit transmitter and their meanings.

Handheld Transmitter Operation and Maintenance

Handheld Transmitter Indicator Lights Meaning

Lists indicator light states on handheld transmitter and their meanings.

Replacing Handheld Transmitter Batteries

Step-by-step guide to replacing the batteries in the handheld transmitter.

Job Site and Machine Pre-Drilling Preparation

Marking and Preparing the Bore Path

Marking the bore path on the ground for alignment.

Testing the Zap-Alert System

Procedures for testing the Zap-Alert system before drilling operations.

Loading Drill Pipes into Holder

Instructions for loading drill pipes into the pipe holder.

Adding Fuel to the Machine

Instructions for adding fuel to the machine.

Checking Engine Oil Level

Procedure to check the engine oil level.

Checking Cooling System Coolant Level

Procedure to check the engine coolant level.

Checking Hydraulic Fluid Level

Procedure to check the hydraulic fluid level.

Checking Drilling Fluid Pump Oil Level

Procedure to check the drilling-fluid pump oil level.

Loading and Unloading Machine Procedures

Steps for safely loading and unloading the machine from a trailer.

Driving Machine to Entry Point

Procedures for safely driving the machine to the entry point.

Connecting to Drilling Fluid Source

Steps to connect the machine to a drilling-fluid source.

Drill Bit and Tracking Electronics Setup

Procedures for setting up the drill head and tracking system.

Machine Setup for Drilling

Final steps to set up the machine for drilling operations.

Deploying the Zap-Alert Safety System

Procedure for deploying the Zap-Alert system before drilling.

Zap-Alert System Testing Procedure

Actions When Zap-Alert System is Triggered

Actions to take if the Zap-alert system is triggered during operation.

Fire Extinguisher Mounting Instructions

Drill Pipe Loading Procedure

Fueling the Machine

Biodiesel Fuel Usage Guidelines

Information and precautions for using biodiesel blended fuels.

Engine and Machine Operation Checks

Checking Engine Oil Level

Procedure to check the engine oil level before starting the engine.

Checking Cooling System Coolant Level

Procedure to check the engine coolant level.

Checking Hydraulic Fluid Level

Procedure to check the hydraulic fluid level.

Engine Starting and Stopping Procedures

Steps for starting and stopping the engine, including emergency procedures.

Machine Driving Procedures

Procedures for starting and driving the machine safely.

Machine Loading and Unloading

Safety warnings and procedures for loading/unloading the machine onto a trailer.

Machine Setup for Drilling Operations

Connecting to Drilling Fluid Sources

Setting Up the Drilling Fluid Mixing System

Steps to set up and use the mixing system for drilling fluid.

Setting Up Pump for Natural Water Source

Steps to set up the pump to use a natural water source for drilling.

Zap-Alert System Deployment Procedure

Drilling the Bore Process

Starting the First Pipe Installation

Procedure for installing and starting the first pipe in the drilling operation.

Drill Head and Tracking System Setup

Drill Head Installation Procedure

Entry Shaft Boring Procedure

Drill Pipe Addition Procedure

Drill Head Steering Techniques

Horizontal Shaft Boring Procedure

Last Pipe and Reamer Removal

Connecting Reamer and Product

Steps to connect the product to the reamer for pulling.

Exiting the Ground Procedure

Backreaming and Pullback Process

Drill Pipe Removal Procedure

Job Completion Procedures

TJC Applicator Usage Guide

Instructions for using the thread-joint compound applicator.

Adjusting the Applicator Nozzle

How to adjust the applicator nozzle for fan-shaped spray or stream.

TJC Spray Volume Adjustment

TJC Applicator Filling Procedure

Moving a Disabled Machine

Pipe Holder Replacement Procedure

Cab Positioning (Cab Model Only)

Positioning Cab for Drilling Operation

Steps to swing and rotate the cab to the drill position.

Positioning Cab for Transport Mode

Steps to rotate and swing the cab into transport position.

Cab Door Opening Procedure

Cab Air Conditioning and Heating Operation

Air Conditioning Cab System

Steps to turn on and adjust the air conditioning system.

Heating Cab System

Steps to turn on and adjust the heating system.

Windshield Wiper Operation

Changing Windshield Wiper Speed

How to change the speed of the windshield wipers.

Dispersing Windshield Washer Fluid

How to disperse windshield washer fluid.

Machine Maintenance Overview

Recommended Maintenance Schedules

Schedules for routine maintenance tasks based on operating hours.

Premaintenance Safety Procedures

Front Hood Opening Procedure

Instructions for opening the machine's front hood.

Rear Access Door Opening Procedure

Instructions for opening the machine's rear-access door.

Cylinder Lock Safety and Usage

Installing the Cylinder Lock

Steps to install the cylinder lock to secure the thrust frame.

Removing and Storing the Cylinder Lock

Steps to remove and store the cylinder lock.

Machine Lubrication Procedures

Daily Machine Greasing Procedure

Daily lubrication steps for grease fittings on various machine parts.

Engine Maintenance Procedures

Crankcase Vent Tube Cleaning

Procedure to clean the crankcase-vent tube.

Air Cleaning System Servicing

Instructions for checking and servicing the air-cleaning system.

Air Cleaner Indicator Check

How to check the air-cleaner indicator on the display screen.

Air Cleaner Component Servicing

Dust Valve Cleaning Procedure

Procedure to clean the dust valve on the air-cleaner cover.

Air Cleaner Cover Removal and Installation

Instructions for removing and installing the air-cleaner cover.

Air Cleaner Filter Servicing

Primary Air Cleaner Filter Replacement

Procedure for replacing the primary air-cleaner filter.

Engine Oil and Filter Servicing

Checking Engine Oil Level

Procedure to check the engine oil level using the dipstick.

Changing Engine Oil Filter

Steps to replace the engine oil filter.

Engine Oil Change Procedure

Valve Clearance Adjustment

Fuel System Maintenance

Draining Water from Fuel Filter

Procedure to drain water and sediment from the fuel filter.

Draining Water from Fuel Tank

Procedure to drain water and sediment from the fuel tank.

Fuel System Priming Procedure

Primary Fuel Filter Replacement

Steps to replace the primary fuel filter.

Fuel Filter Replacement Procedures

Secondary Fuel Filter Replacement

Steps to replace the secondary fuel filter.

Fuel Line and Tank Checks

Checking Fuel Lines and Connections

Inspection of fuel lines and connections for wear or damage.

Draining and Cleaning Fuel Tank

Procedure to drain and clean the fuel tank for storage or contamination.

Electrical System Maintenance

Battery Servicing Guidelines

Instructions for checking battery condition and maintenance.

Battery Charging and Jump-Starting

Battery Charging Procedure

Procedure for charging the machine's battery.

Machine Jump-Starting Procedure

Procedure for jump-starting the machine's battery.

Drive System Maintenance

Stakedown Planetary Drive Oil Level Check

Procedure to check the oil level in the stakedown planetary drives.

Tracks Planetary Drive Maintenance

Tracks Planetary Drive Oil Level Check

Procedure to check the oil level in the tracks planetary drives.

Tracks Planetary Drive Oil Change

Procedure to change the oil in the tracks planetary drives.

Rotary Motor Planetary Drive Oil Check

Thrust Motor Planetary Drive Oil Check

Gearbox Drive Oil Level and Change

Checking Gearbox Drive Oil Level

Procedure to check the oil level in the gearbox drive.

Changing Gearbox Drive Oil

Procedure to change the oil in the gearbox drive.

Track Servicing Procedures

Tightening Track Tension

Procedure to tighten the track tension if it seems loose.

Track Tension Loosening Procedure

Cooling System Maintenance

Checking Coolant Level in Radiator

Procedure to check the coolant level in the radiator.

Checking Cooling System Components Condition

Inspect cooling system components for leaks, damage, and dirt.

Checking Coolant Concentration

Test coolant concentration to ensure 50% ethylene glycol and 50% water mixture.

Cleaning the Cooling System

Procedure to clean the cooling system if coolant is dirty or rust-colored.

Coolant System Draining and Flushing

Draining Coolant from the System

Procedure to drain the coolant from the system.

Flushing the Cooling System

Procedure to flush the cooling system using cleaning solution and water.

Filling the Cooling System with Coolant

Belt Maintenance Procedures

Servicing the Engine Drive Belt

Instructions for servicing the engine-drive belt.

Checking Engine Drive Belt Condition

Inspect the belt for cuts, cracks, and signs of wear.

Engine Drive Belt Tension Checks and Adjustments

Checking Engine Drive Belt Tension

Procedure to check the drive belt tension.

Adjusting Engine Drive Belt Tension

Procedure to adjust the drive belt tension.

Hydraulic System Maintenance

Servicing the Hydraulic Fluid

Information on hydraulic fluid and its servicing.

Checking the Hydraulic Fluid Level

Procedure to check the hydraulic fluid level.

Hydraulic Fluid and Filter Change Procedures

Changing the Hydraulic Fluid

Steps to change the hydraulic fluid.

Changing Hydrostatic-Charge Filter

Procedure to change the hydrostatic-charge filter.

Hydraulic Filter Replacement Procedures

High-Pressure Hydraulic Filter Change

Procedure to change the high-pressure hydraulic filter.

Hydraulic-Return Filter Change

Procedure to change the hydraulic-return filter.

Hydraulic System Line and Port Checks

Checking Hydraulic Lines and Hoses

Inspect hydraulic lines and hoses for leaks, wear, and damage.

Checking Hydraulic System Test Ports

Information on using test ports to check hydraulic circuits.

Drilling Fluid Pump Maintenance

Servicing Drilling Fluid Pump Oil

Information on drilling-fluid pump oil and its specifications.

Drilling Fluid Pump Oil Level Check

Drilling Fluid Pump Oil Change Procedure

Drilling Fluid Pump Charge Filter Change

Drilling Fluid System Cold Weather Preparation

Cab Maintenance Procedures

Changing the Cab Air Filter

Instructions for changing the cab air filter.

Filling Windshield Washer Fluid Tank

Procedure to fill the windshield-washer fluid tank.

Machine Cleaning Procedures

Cleaning with Spray-Hose Attachment

Instructions for cleaning the machine using the spray-hose attachment.

Cleaning Plastic and Resin Parts

Guidelines for cleaning plastic and resin parts to avoid damage.

Machine Storage Guidelines

Troubleshooting Common Problems

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