Diesel-Powered FM 330 Fluid Mixer

Model No. 23897-Serial No. 400000000 and Up

Introduction

This machine is designed to mix drilling-fluid products with clean water. You can mount the machine onto a suitable transport vehicle and connect the machine to a suitable horizontal directional drill. Read and understand the directional drill Operator’s Manual.

Read this information carefully to learn how to operate and maintain your product properly and to avoid injury and product damage. You are responsible for operating the product properly and safely.

You may contact Toro directly at www.Toro.com product safety and operation training materials, accessory information, help finding a dealer, or to register your product.

To ensure optimum performance and continued safety certification of the machine, use only genuine Toro replacement parts and accessories. Replacement parts and accessories made by other manufacturers could be dangerous, and such use could void the product warranty.

g038405

Figure 1

  1. Model and serial-number location

This manual identifies potential hazards and has safety messages identified by the safety-alert symbol (Figure 2), which signals a hazard that may cause serious injury or death if you do not follow the recommended precautions.

g000502

Figure 2

  1. Safety-alert symbol

This manual uses 2 words to highlight information. Important calls attention to special mechanical information and Note emphasizes general information worthy of special attention.

This product complies with all relevant European directives; for details, please see the separate product-specific Declaration of Conformity (DOC) sheet.

Warning

CALIFORNIA

Proposition 65 Warning

Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

Use of this product may cause exposure to chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

It is a violation of California Public Resource Code Section 4442 or 4443 to use or operate the engine on any forest-covered, brush-covered, or grass-covered land unless the engine is equipped with a spark arrester, as defined in Section 4442, maintained in effective working order or the engine is constructed, equipped, and maintained for the prevention of fire.

The enclosed Engine Owner's Manual is supplied for information regarding the US Environmental Protection Agency (EPA) and the California Emission Control Regulation of emission systems, maintenance, and warranty. Replacements may be ordered through the engine manufacturer.

Safety

General Safety

This product is capable of causing personal injury. Always follow all safety instructions to avoid serious personal injury.

Using this product for purposes other than its intended use could prove dangerous to you and bystanders.

  • Read and understand the contents of this Operator’s Manual before starting the engine.

  • Do not put your hands or feet near moving components of the machine.

  • Do not operate the machine without all guards and other safety protective devices in place and working on the machine.

  • Keep bystanders and pets a safe distance away from the machine.

  • Never allow children to operate the machine.

  • Stop the machine and shut off the engine before servicing or fueling the machine.

Improperly using or maintaining this machine can result in injury. To reduce the potential for injury, comply with these safety instructions and always pay attention to the safety-alert symbol, which means Caution, Warning, or Danger—personal safety instruction. Failure to comply with these instructions may result in personal injury or death.

You can find additional safety information where needed throughout this Operator’s Manual.

Safety and Instructional Decals

Graphic

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.
decal117-2718

117-2718

decal119-0217

119–0217

  1. Warning—shut off the engine; keep away from moving parts; keep all guards and shields in place.
decal125-6155

125–6155

  1. Warning—read the Operator’s Manual.
  2. Electrical shock hazard—ensure the equipment is grounded before starting drill operation.
  3. Explosion hazard; electrical shock hazard—Call local utilities before digging underground.
decal125-6171

125-6171

  1. Piercing hazard—wear hand protection.
decal125-6156

125–6156

  1. Tank drain—read the Operator’s Manual.
decal130-2845

130–2845

decal125-6185

125-6185

  1. Engine stop
  2. Engine run
  3. Engine start
decal125-6186

125-6186

  1. Engine stop
  2. Slow
  3. Fast

Setup

Connecting the Battery

Parts needed for this procedure:

Bolt (5/16 x 3/4 inch)2
Washer (5/16 inch)2
Nut (5/16 inch)2

Warning

CALIFORNIA

Proposition 65 Warning

Use of this product may cause exposure to chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

  1. Remove the red plastic cover from the positive battery terminal (Figure 3).

    g024037

    Figure 3

    1. Red cover
    2. Positive cable
    3. Black cover
    4. Negative cable

  2. Use a bolt (5/16 x 3/4 inch), a washer, and a nut (5/16 inch) to mount the positive cable to the positive battery terminal.

  3. Remove the black plastic cover from the negative battery terminal.

  4. Use a bolt (5/16 x 3/4 inch), a washer, and a nut (5/16 inch) to mount the negative cable to the negative battery terminal.

Connecting the Pump to the Tank

Parts needed for this procedure:

Circulation hose1
Hose clamp2

Ensure that the frame of the fluid mixer and the frame of the tank are secured to a strong surface, with an adequate fastener through each mounting hole (Figure 4).

Note: Ensure that the mixer and the tank are in a position that allows the hoses to connect them without stretching or kinking.

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Figure 4

Underside shown

  1. Mounting holes in tank frame
  2. Mounting holes in mixer frame

  1. Locate the suction hose connected to the bottom of the tank, and pull the loose end out from under the tank.

  2. Use a hose clamp (provided with the transfer hose) to connect the loose end of the suction hose to the pump inlet on the mixer as shown in Figure 5, Figure 6, and Figure 7.

    g024043

    Figure 5

    1. Circulation hose
    2. Suction hose
    g025173

    Figure 6

    1. Fitting
    2. Hose clamp
    3. Hose
    g024041

    Figure 7

    1. Locknut

  3. Tighten the hose clamp by tightening the locknut.

  4. Use 2 hose clamps (provided) to connect the circulation hose to the top of the tank and the top of the mixer as shown in Figure 5, Figure 6, and Figure 7.

  5. Tighten the hose clamps by tightening the locknuts.

Product Overview

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Figure 8

Tank sold separately

  1. Access hatch
  2. Circulation hose
  3. Tank drain plug
  4. Forklift pockets
  5. Suction hose
  6. Engine
  7. Hopper
  8. Grate

Become familiar with all the controls before you start the engine and operate the machine.

g023834

Figure 9

  1. Circulation valve
  2. Transfer valve
  3. Hopper valve
  4. Suction valve

Circulation Valve

The circulation valve (Figure 9) controls the flow from the pump to the tank.

Suction Valve

The suction valve (Figure 9) controls the flow from the tank to the pump.

Hopper Valve

The hopper valve (Figure 9) controls the flow from the hopper into the mixing system. The hopper valve is most effective when it is just slightly open, as the fluid then creates a vacuum effect and draws the bentonite and other components into the flow.

Transfer Valve

The transfer valve (Figure 9) controls the flow from the mixing system to the drill.

Engine Controls

g038406

Figure 10

  1. Dipstick
  2. Oil-drain plug
  3. Decompression lever
  4. Oil filter
g038407

Figure 11

  1. Fuel-shutoff lever
  2. Fuel-injection pump
  3. Speed-control handle
  4. Dipstick
  5. Ignition switch
  6. Air cleaner
  7. Recoil-Start handle
  8. Fuel-drain plug

Ignition Switch

The ignition switch (Figure 11) allows the operator of the machine to start the engine; refer to Starting and Shutting Off the Engine.

Recoil-Start Handle

If the battery is not charged, you can start the engine with the recoil-start handle; refer to Starting and Shutting Off the Engine.

Speed-Control Handle

The speed-control handle (Figure 11) controls the engine speed and also shuts off the engine. Moving it all the way to the left (counterclockwise) shuts off the engine. Moving it to the right (clockwise) increases the engine speed.

Mixer

Flow rateLengthWidthHeightWeight
Up to 1249 L/minute (330 gallons/minute)141 cm (55 inches)90 cm (35 inches)116.2 cm (46 inches)204 kg (450 lb)

Tanks

CapacityLengthWidthHeightDry weight
1893 L (500 US gallons)203.2 cm (80 inches)78.7 cm (31 inches)177.8 cm (70 inches)241 kg (532 lb)
3785 L (1000 US gallons)257.2 cm (101 inches)108.6 cm (43 inches)191.1 cm (75 inches)397 kg (876 lb)

Operation

Before Operation

Before Operation Safety

General Safety

  • The owner must ensure that all operators are well trained and competent to safely operate the machine.

  • Never allow children or untrained people to operate or service the machine. Local regulations may restrict the age of the operator.

  • Become familiar with the safe operation of the equipment, operator controls, and safety signs.

  • Know how to stop the machine and shut off the engine quickly.

  • Check that safety switches and shields are attached and functioning properly. Do not operate the machine unless they are functioning properly.

  • Inspect the area where you will use the machine and remove all objects that the machine could throw.

  • Keep the manual(s) with the machine. Go to www.Toro.com for a replacement manual.

Fuel Safety

  • Use extreme care in handling fuel. It is flammable and its vapors are explosive.

  • Extinguish all cigarettes, cigars, pipes, and other sources of ignition.

  • Use only an approved fuel container.

  • Do not remove the fuel cap or fill the fuel tank while the engine is running or hot.

  • Do not add or drain fuel in an enclosed space.

  • Do not store the machine or fuel container where there is an open flame, spark, or pilot light, such as on a water heater or other appliance.

  • If you spill fuel, do not attempt to start the engine; avoid creating any source of ignition until the fuel vapors have dissipated.

Grounding the Mixer and the Tank

Ground the mixing system.

Connect a braided grounding strap or a jumper cable (sold separately) from the mixer frame to the ground.

Adjusting the Valves

Warning

If you run the engine when the mixing valves are not adjusted as directed, the pump can direct fluid out through the hopper and push the grate into the air.

Ensure that the mixing valves are adjusted appropriately and that the grate is tethered to the hopper, before starting the engine.

To open a valve, turn the handle so that it is in line with the pipe. To close a valve, turn the handle so that it is perpendicular to the pipe (Figure 12).

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Figure 12

  1. Closed position
  2. Open position

Before starting the engine, ensure that the hopper valve and the transfer valve are both closed, and the suction valve and the circulation valve are both open (Figure 9).

Adding Fuel

  • The engine runs on clean, fresh, ultra-low-sulfur diesel fuel with a minimum cetane rating of 40.

  • Purchase fuel in quantities that can be used within 30 days to ensure fuel freshness.

  • Use summer-grade diesel fuel (Number 2-D) at temperatures above -7°C (20°F) and winter-grade diesel fuel (Number 1-D or Number 1-D/2-D blend) below -7°C (20°F ).

  • Never mix kerosene, used engine oil, or residual fuels with the diesel fuel.

  • Do not store fuel either in the fuel tank or fuel containers over the winter.

  • Fuel additives are not recommended. Some fuel additives may cause poor engine performance.

Important: Do not mix oil with diesel.

Diesel fuel should comply with the following specification. The table lists 7 worldwide specifications for diesel fuels.

Diesel Fuel SpecificationsLocation
Number 2-D, Number 1-D, ASTM D975-94USA
EN590:96European Union
ISO 8217 DMXInternational
BS 2869-A1 or A2United Kingdom
JIS K2204 Grade Number 2Japan
KSM-2610Korea
GB252China

Using Fuel Stabilizer/Conditioner

Use a diesel fuel stabilizer/conditioner in the machine to keep the fuel fresh during storage of 90 days or less. If you are storing the machine for longer, drain the fuel tank; refer to Draining the Tank.

Important: Do not use fuel additives containing methanol or ethanol.

Add the correct amount of fuel stabilizer/conditioner to the fuel, and follow the directions of the manufacturer.

Note: Fuel stabilizer/conditioner is most effective when mixed with fresh fuel.

Filling the Fuel Tank

Capacity: 5.4 L (5.7 US qt)

  1. Park the machine on a level surface, shut off the engine, and allow the engine to cool.

  2. Clean around the fuel-tank cap and remove it (Figure 13).

    g038408

    Figure 13

    1. Fuel-tank cap
    2. Inlet fuel screen
    3. Red ring

    Important: Keep the inlet fuel screen and the red ring in the fuel tank while pouring the fuel.

  3. Add fuel to the fuel tank until the level is up to the red ring (Figure 13 and Figure 14).

    Important: This space in the tank allows the fuel to expand. Do not fill the fuel tank completely full.

    g038409

    Figure 14

  4. Install the fuel-tank cap securely.

  5. Wipe up any fuel that may have spilled.

During Operation

During Operation Safety

General Safety

  • The owner/operator can prevent and is responsible for accidents that may cause personal injury or property damage.

  • Wear appropriate clothing, including long pants; eye and hearing protection; slip-resistant, substantial foot protection; and hard hats. Tie back long hair and do not wear jewelry.

  • Do not operate the machine while ill, tired, or under the influence of alcohol or drugs.

  • Operate the machine only in good visibility to avoid holes or hidden hazards.

  • Keep your hands and feet away from moving parts.

  • Do not operate near drop-offs, ditches, or embankments.

  • Stop the machine whenever you are not operating it.

  • Never run an engine in an area where exhaust gasses are enclosed.

  • Never leave a running machine unattended.

  • Before leaving the operating position, do the following:

    • Move the machine to level ground.

    • Shut off the engine and remove the key.

    • Wait for all moving parts to stop.

  • Do not operate the machine when there is the risk of lightning.

  • Use accessories, attachments, and replacement parts approved by The Toro® Company only.

Starting and Shutting Off the Engine

Warning

If you run the engine when the mixing valves are not adjusted as directed, the pump can direct fluid out through the hopper and push the grate into the air.

Ensure that the mixing valves are adjusted appropriately and that the grate is tethered to the hopper, before starting the engine.

Starting the Engine

Important: Because the fluid cools the pump seal, the pump may overheat if you run the engine without fluid in the mixer. Do not run the engine without fluid in the mixer.

Starting the Engine using the Key Switch

  1. Move the fuel-shutoff lever to the ON position.

  2. Move the speed-control handle to the right (Figure 11); refer to Controls.

    Note: If smoke comes from the exhaust, move the speed-control handle to the left.

  3. Rotate the ignition switch to the RUN position (Figure 11); refer to Ignition Switch.

    g024065

    Figure 15

    1. Stop position
    2. Run position
    3. Start position

  4. Turn the ignition switch to the START position, and hold it there until the engine starts (Figure 15).

    Important: If the engine does not start within 15 seconds, release the key, and wait at least 10 seconds before operating the starter again. Using the electric starter for too long will overheat the starter motor and can damage it.

    Note: If after several attempts of starting the exhaust begins to emit white smoke, move the speed adjustment lever all the way to the left, and pull the recoil-start handle out slowly 5 times. Repeat the starting procedure.

Starting the Engine using the Recoil Handle

  1. Move the fuel-shutoff lever to the ON position.

  2. Move the speed-control handle to the right (Figure 11); refer to Controls.

    Note: If smoke comes from the exhaust, move the speed-control handle to the left.

  3. Push the decompression lever to the left (Figure 10).

    Note: The decompression lever will stay cocked to the left and will automatically return to the original position when the recoil starter handle is pulled again.

  4. Grasp the recoil-start handle, pull it out slowly until you feel resistance, then pull it all the way out with a strong and even motion (Figure 16).

    Note: Use 2 hands if necessary.

    g022414

    Figure 16

  5. Slowly return the recoil-start handle to the initial position.

  6. If the engine does not start, repeat steps 1 to 5.

Shutting Off the Engine

Warning

In an emergency situation, shut off the engine immediately.

  1. Move the speed-control handle to the STOP position (Figure 11); refer to Ignition Switch.

  2. Rotate the ignition switch to the OFF position; refer to Ignition Switch.

  3. Move the fuel-shutoff lever to the OFF position.

Important: Keep the ignition switch in the OFF position. Leaving the ignition switch in the RUN position while the engine is off will discharge the battery.

Mixing the Fluid

Warning

If you run the engine when the mixing valves are not adjusted as directed, the pump can direct fluid out through the hopper and push the grate into the air.

Ensure that the mixing valves are adjusted appropriately and that the grate is tethered to the hopper, before starting the engine.

Warning

Drilling fluid can be very slippery. If there are drilling-fluid components on the ground or other surfaces, someone could slip and fall, resulting in serious personal injury.

Wear slip-resistant footwear and use caution while working in areas with drilling-fluid components.

There is a variety of materials available for creating different types of drilling fluid. Match the drilling fluid to suit the needs of the soil conditions, and follow the manufacturer’s instructions that are printed on the packaging of the product.

Note: The order in which you add the components of the fluid is important. Follow the instructions of the manufacturers.

  1. Ensure that the grate is tethered to the hopper and that the valves are adjusted appropriately; refer to Adjusting the Valves.

  2. Add the appropriate amount of water to the tank through the hatch (Figure 8).

    If you are using water from a ditch or a pond, place a very fine screen over the inlet of the hose to prevent unwanted material from entering the mixing system.

    Ensure that there is enough room for additives in the mixing system.

  3. Start the engine; refer to Starting the Engine.

  4. Test the pH of the water. If it is below 8, add soda ash until the pH is 8 or higher.

    Note: Supplies for testing pH are available where swimming-pool supplies are sold.

  5. Slightly open the valve at the bottom of the hopper.

    Note: The valve works more effectively when it is open only slightly; it creates a vacuum effect that allows the dry components to enter the mixer at a faster rate.

  6. Add the appropriate amount of bentonite to the hopper.

    Note: Add the bentonite slowly to avoid clumping—1 bag in approximately 3 to 5 minutes. Open the tank cover and look to ensure that the fluid components are mixing correctly. If you see any clumps, add the components at a slower rate.

  7. After you have added the appropriate amount of bentonite, add any polymers that the particular soil conditions require.

  8. Lastly, add any other liquids that the soil conditions require.

  9. Close the hopper valve.

  10. Allow the machine to thoroughly mix the fluid for several minutes.

Pumping the Fluid to the Drill

Danger

The fluid mixer will be electrified if the hose is attached to the drill and the drill strikes an electrical line. Contacting the fluid mixer during an electrical strike may cause bodily harm.

  • Ensure that the fluid-mixer frame and the tank frame are bonded to the ground rod.

  • If a strike occurs, stay away from the fluid mixer and the drill. Do not contact the mixer until the electrical strike has been corrected.

  1. Use the transfer hose (provided) to connect the mixer and the drill.

    Note: The mixer has a male camlock fitting (Figure 17) located after the transfer valve.

    g234696

    Figure 17

  2. Open the transfer valve to allow the fluid to flow to the drill.

    Note: Keep the circulation valve open so that the fluid continues to circulate in the mixer.

Important: Unless you are using additional equipment to thoroughly clean the drilling fluid, do not circulate the used fluid through the mixer. Doing so may damage the pump.

Dispose of the used drilling fluid, as well as the unused fluid left in the tank, according to environmental regulations.

After Operation

After Operation Safety

General Safety

  • Clean up any oil or fuel spills.

  • Allow the engine to cool before storing the machine in any enclosure.

  • Never store the machine or fuel container where there is an open flame, spark, or pilot light, such as on a water heater or on other appliances.

Draining the Tank

To drain the tank, remove the drain plug from the side of the tank frame (Figure 8).

Dispose of the used drilling fluid, as well as the unused fluid left in the tank, according to environmental regulations.

Protecting the Machine from Freezing

  1. Ensure that all the valves are open.

  2. Rinse the tank with clean clear water and then pump it through the system, removing as much of the slurry mix in the system as possible.

  3. Drain the tank; refer to Draining the Tank.

  4. Drain any remaining fluid from the pump by removing the drain plug in the bottom of the pump (Figure 18).

    g023837

    Figure 18

    1. Drain plug

  5. To prevent the valve at the base of the hopper from freezing around the edges, either leave the valve open half way, or close the valve and pour an environmentally friendly antifreeze into the hopper until about 51 mm (2 inches) of fluid covers the valve.

Maintenance

Important: Before performing any maintenance procedures, first shut off the engine and wait 5 minutes to allow all moving parts to come to a complete stop and cool.

Recommended Maintenance Schedule(s)

Maintenance Service IntervalMaintenance Procedure
After the first 25 hours
  • Change the engine oil.
    		•
    After the first 50 hours
  • Inspect and clean the engine-oil filter.
    		•
    Before each use or daily
  • Inspect the air-cleaner element.
  • Check the engine-oil level.
    		•
    After each use
  • Clean the machine.
    		•
    Every 50 hours
  • Clean the air-cleaner element.Clean it more frequently in dusty operating conditions.
  • Clean the inlet fuel screen.
    		•
    Every 100 hours
  • Lubricate the pump.
  • Change the engine oil.
  • Check the battery cable connections.
    		•
    Every 200 hours
  • Replace the air-cleaner element.Replace it more frequently in dusty operating conditions.
  • Replace the outlet fuel filter.
    		•
    Every 400 hours
  • Inspect and clean the engine-oil filter.
    		•

    Important: Refer to your engine owner's manual for additional maintenance procedures.

    Pre-Maintenance Procedures

    Pre-Maintenance Safety

    • 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.

      • Wait for all moving parts to stop.

      • Allow machine components to cool before performing maintenance.

    • If possible, do not perform maintenance while the engine is running. Keep away from moving parts.

    • Use adequate support to support the machine or components when required.

    • Carefully release pressure from components with stored energy.

    Preparing the Machine for Maintenance

    1. Park the transport vehicle on a level surface and chock the tires, or remove the machine from the transport vehicle.

    2. Ensure that the engine and muffler are cool.

    3. Turn the electric-start switch to the OFF position.

    Lubrication

    Lubricating the Pump

    Maintenance Service IntervalMaintenance Procedure
    Every 100 hours
  • Lubricate the pump.
    		•

    Grease Type: NLGI #1 heavy-duty EP grease

    Use a grease gun to pump grease into the grease fitting on the side of the pump (Figure 19).

    g023836

    Figure 19

    Engine Maintenance

    Servicing the Air Cleaner

    Maintenance Service IntervalMaintenance Procedure
    Before each use or daily
  • Inspect the air-cleaner element.
    		•
    Every 50 hours
  • Clean the air-cleaner element.Clean it more frequently in dusty operating conditions.
    		•
    Every 200 hours
  • Replace the air-cleaner element.Replace it more frequently in dusty operating conditions.
    		•

    Important: Do not operate the engine without the air filter assembly; extreme engine damage will occur.

    1. Set the throttle to slow, shut off the engine, and wait for all moving parts to stop.

    2. Turn the fuel shutoff lever to the OFF position.

    3. Remove the wing nut that secures the air-cleaner cover (Figure 20).

      g038411

      Figure 20

      1. Wing nut
      2. Air-cleaner cover
      3. Paper element
      4. Foam element

    4. Remove the air-cleaner cover.

    5. Remove the internal wing nut.

    6. Remove the foam and paper elements from the base (Figure 20).

    7. Remove the foam element from the paper element (Figure 20).

    8. Inspect the foam and paper elements, and replace them if they are damaged or excessively dirty.

      Note: Never try to brush dirt off the paper element; brushing forces the dirt into the fibers.

    9. Wipe dirt from the base and the cover with a moist rag.

      Note: Be careful to prevent dirt and debris from entering the air duct inside the air-cleaner housing.

    10. Slide the outer foam element over the paper element.

    11. Install the air cleaner elements and ensure that they are properly positioned.

    12. Install the internal wing nut

    13. Securely install the cover with the other wing nut.

    Servicing the Engine Oil

    Maintenance Service IntervalMaintenance Procedure
    After the first 25 hours
  • Change the engine oil.
    		•
    Every 100 hours
  • Change the engine oil.
    		•

    Checking the Engine-Oil Level

    Maintenance Service IntervalMaintenance Procedure
    Before each use or daily
  • Check the engine-oil level.
    		•

    Important: Use 4-cycle engine oil that meets or exceeds the following guidelines and classifications:

    • API Service Categories CJ-4 or higher

    • ACEA Service Categories E-3, E-4, and E-5

    Note: Toro Premium Engine Oil is available from your Authorized Toro Dealer.

    Crankcase Capacity: 1.6 L (1.7 US qt)

    Important: If the oil level in the crankcase is too low or too high and you run the engine, you may damage the engine. This type of damage is not covered by the warranty.

    Viscosity: SAE 5W-30

    Note: If the ambient temperature is above 35°C (95°F), use SAE 5W-40 or SAE 10W-40.

    1. Place the machine on a flat, level surface.

    2. Run the engine for a few minutes to warm the oil.

      Note: Warm oil flows better and carries more contaminants.

    3. Shut off the engine and wait for all moving parts to stop.

    4. Clean around the dipstick (Figure 21) so that dirt cannot fall into the filler hole and damage the engine.

      g038410

      Figure 21

      1. Dipstick upper limit
      2. Dipstick lower limit
      3. Fill port

    5. Remove the dipstick and wipe the end clean (Figure 21).

    6. Slide the dipstick fully into the fill port without threading it into the port.

    7. Remove the dipstick and look at the end.

      Note: If the engine oil level is below the halfway point on the hatchmarks, slowly pour only enough oil into the fill port to raise the level to the halfway point on the dipstick.

    8. Install the dipstick.

    Changing the Engine Oil

    1. Ensure that the machine is on a level surface.

    2. Run the engine for a few minutes to warm the oil.

      Note: Warm oil flows better and carries more contaminants.

    3. Shut off the engine and wait for all moving parts to stop.

    4. Place a suitable receptacle under the oil drain plug (Figure 22).

      g038412

      Figure 22

    5. Remove the drain plug.

    6. Allow the oil to drain and replace the drain plug.

    7. Remove the dipstick (Figure 21) and slowly pour oil into the fill hole until the oil is between the upper and lower limit on the dipstick; refer to Checking the Engine-Oil Level.

    8. Install and secure the dipstick.

    9. Wipe up any spilled oil.

    Inspecting and Cleaning the Engine-Oil Filter

    Maintenance Service IntervalMaintenance Procedure
    After the first 50 hours
  • Inspect and clean the engine-oil filter.
    		•
    Every 400 hours
  • Inspect and clean the engine-oil filter.
    		•

    1. Remove the oil-filter retaining bolt.

    2. Pull the oil-filter cap out and remove the oil filter.

      g038413

      Figure 23

    3. Clean the oil filter or replace it if it is damaged.

    4. Install the oil filter.

    5. Make sure that the oil-filter cap is fully seated.

    6. Install and tighten the oil-filter retaining bolt.

    7. Add new engine oil; refer toServicing the Engine Oil.

    8. Warm up the engine by running it for 5 minutes, and check for any engine oil leaks.

    9. After the engine is warm, turn it off and let it sit for 10 minutes.

    10. Check the engine oil level by fully inserting, but not screwing in, the dipstick.

    11. Add engine oil as needed; refer to Servicing the Engine Oil.

    Fuel System Maintenance

    Servicing the Fuel System

    Cleaning the Inlet Fuel Screen

    Maintenance Service IntervalMaintenance Procedure
    Every 50 hours
  • Clean the inlet fuel screen.
    		•

    1. Clean the area around the fuel cap.

    2. Remove the fuel cap.

    3. Lift the inlet fuel screen out of the fuel tank.

      g019997

      Figure 24

      1. Fuel cap
      2. Inlet fuel screen
      3. Fuel tank

    4. Clean the inlet fuel screen or replace it if it is damaged.

    5. Install the inlet fuel screen.

    6. Install the fuel cap and hand tighten it.

      Note: Overtightening the fuel cap will damage it.

    Draining the Fuel Tank and Replacing the Outlet Fuel Filter

    Maintenance Service IntervalMaintenance Procedure
    Every 200 hours
  • Replace the outlet fuel filter.
    		•

    1. Shut off the engine and wait for all moving parts to stop.

    2. Place an approved container under the fuel tank to collect the fuel.

    3. Remove the fuel cap (Figure 25).

      g235178

      Figure 25

      1. Fuel cap
      2. Gasket
      3. Drain plug

    4. Remove the drain plug and gasket to drain the fuel (Figure 25).

    5. Loosen the nuts under the fuel-shutoff lever (Figure 26).

      g021307

      Figure 26

      1. Outlet fuel filter
      2. Gasket
      3. Filler port
      4. O-ring
      5. Fuel-shutoff lever
      6. Nut (2)

    6. Remove and discard the O-ring (Figure 26).

    7. Pull the outlet fuel filter and gasket out of the filler port (Figure 26).

    8. Install a new outlet fuel filter and gasket through the filler port, and seat them in the fuel tank (Figure 26).

    9. Install a new O-ring on the fuel shutoff lever, and install the assembly to the fuel tank using the nuts under the fuel shutoff lever (Figure 26).

    10. Install the drain plug with a new gasket (Figure 25).

    11. Install the fuel cap and hand tighten it.

      Note: Overtightening the fuel cap will damage it.

    Electrical System Maintenance

    Replacing the Battery

    1. Remove the cover of the battery box.

    2. Disconnect the negative (black) ground cable from the battery post.

      Warning

      Incorrect battery cable routing could damage the machine and cables, causing sparks. Sparks can cause the battery gases to explode, resulting in personal injury.

      • Always disconnect the negative (black) battery cable before disconnecting the positive (red) cable.

      • Always connect the positive (red) battery cable before connecting the negative (black) cable.

      Warning

      Battery terminals or metal tools could short against metal machine components, causing sparks. Sparks can cause the battery gases to explode, resulting in personal injury.

      • When removing or installing the battery, do not allow the battery terminals to touch any metal parts of the machine.

      • Do not allow metal tools to short between the battery terminals and metal parts of the machine.

    3. Remove the positive (red) battery cable.

    4. Remove the battery.

    5. Place the new battery in the tray.

    6. Install the positive (red) battery cable to the positive (+) battery terminal, and tighten the nut onto the bolt.

    7. Install the negative (black) ground cable to the negative (-) battery terminal, and tighten the nut onto the bolt.

    8. Install the cover of the battery box, and secure it with the strap.

    9. Recycle the old battery at an authorized facility.

    Charging the Battery

    Warning

    Charging the battery produces gases that can explode, seriously injuring you or bystanders.

    Never smoke near the battery, and keep sparks and flames away from the battery.

    Important: Always keep the battery fully charged. This is especially important to prevent battery damage when the temperature is below 0°C (32°F).

    1. Charge the battery for 10 to 15 minutes at 25 to 30 A, or 30 minutes at 10 A.

    2. When the battery is fully charged, unplug the charger from the electrical outlet, and disconnect the charger leads from the battery posts (Figure 27).

    3. Install the battery in the machine and connect the battery cables; refer to Connecting the Battery.

      Important: Do not run the machine with the battery disconnected; electrical damage may occur.

      g000960

      Figure 27

      1. Positive battery post
      2. Negative battery post
      3. Red (+) charger lead
      4. Black (-) charger lead

    If the battery no longer holds a charge, replace it; refer to Checking and Cleaning the Battery.

    Checking and Cleaning the Battery

    Maintenance Service IntervalMaintenance Procedure
    Every 100 hours
  • Check the battery cable connections.
    		•

    Keep the top of the battery clean. If the machine is stored in a location where temperatures are extremely high, the battery discharges more rapidly than if the machine is stored in a cooler location.

    Keep the top of the battery clean by washing it with a brush dipped in ammonia or a solution of sodium bicarbonate. Flush the top surface with water after cleaning. Do not remove the fill cap while cleaning the battery.

    The battery cables must be tight on the terminals to provide good electrical contact.

    If corrosion occurs at the battery terminals, disconnect the cables, negative (-) cable first, and scrape the clamps and terminals separately. Connect the cables, positive (+) cable first, and coat the terminals with petroleum jelly.

    Cleaning

    Cleaning the Machine

    Maintenance Service IntervalMaintenance Procedure
    After each use
  • Clean the machine.
    		•

    Regular cleaning and washing increases the life span of the machine. Clean the machine after each use, before the dirt hardens.

    Ensure that the fuel-tank cap and oil cap/dipstick are secure to avoid getting water in the engine.

    Use care when using a high-pressure sprayer, because it can damage warning decals, instruction signs, and the engine.

    Storage

    Storing the Machine

    For storage over 30 days, prepare the machine as follows:

    1. Remove dirt and grime from the external parts of the entire machine, especially the engine. Clean dirt and debris from the outside of the engine cylinder-head fins and blower housing.

      Important: You can wash the machine with mild detergent and water.

    2. Condition the fuel system as follows:

      1. Add a petroleum-based stabilizer/conditioner to fuel in the tank. Follow the mixing instructions from the stabilizer manufacturer. Do not use an alcohol-based stabilizer (ethanol or methanol).

        Important: Do not store stabilizer/conditioned fuel over 90 days.

        Note: Fuel stabilizer/conditioner is most effective when mixed with fresh fuel and used at all times.

      2. Run the engine for 5 minutes to distribute the conditioned fuel through the fuel system.

        Important: Running the engine without water in the tank will damage the pump.

      3. Shut off the engine, allow it to cool, and drain the fuel tank using a pump-type siphon. Dispose of fuel properly; recycle it according to local codes.

      4. Start the engine and run it until it shuts off.

      5. Choke the engine.

      6. Start and run the engine until it does not start again.

    3. Service the air cleaner; refer to Servicing the Air Cleaner.

    4. Change the engine crankcase oil; refer to Changing the Engine Oil.

    5. Grease the machine; refer to Lubricating the Pump.

    6. Check and tighten all bolts, nuts, and screws. Repair or replace any part that is damaged.

    7. Paint all scratched or bare metal surfaces. Paint is available from your Authorized Toro Dealer.

    8. Store the machine in a clean, dry garage or storage area.

    9. Cover the machine to protect it and keep it clean.

    Troubleshooting

    ProblemPossible CauseCorrective Action
    The engine does not start.
    1. The engine On/Off switch is in the Off position.
    2. The fuel tank is empty.
    3. The engine contains bad or old fuel.
    1. Rotate the switch to the On position.
    2. Fill the fuel tank with fresh fuel.
    3. Drain the fuel tank. Fill the fuel tank with fresh fuel.
    The engine lacks power or runs rough.
    1. The air filter is restricted.
    2. The engine contains bad or old fuel.
    3. There is water or contamination in the fuel.
    4. The fuel line is restricted.
    5. There is too much oil in the engine crankcase.
    1. Clean or replace the air-filter element(s).
    2. Drain the fuel tank. Fill the fuel tank with fresh fuel.
    3. Drain the fuel tank. Fill the fuel tank with fresh fuel.
    4. Clean the fuel filter.
    5. Drain the oil to the proper level.
    The fluid does not circulate at full efficiency.
    1. The pump inlet is clogged.
    1. Contact an Authorized Service Dealer.