NOTICE

The information contained is for DEALER REFERENCE PURPOSES ONLY.

MANUALS ARE MODEL AND SERIAL NUMBER SPECIFIC.

If additional printed manuals are required for your shop/office location, order by
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If a retail customer needs replacement manual(s) for a specific unit, contact the
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D20x22 Series II Navigator®
Horizontal Directional Drill

Service
Manual

D20x22 Series II_S2_00

Serial No. 166 -
Order No. 105400AU2
This manual contains service requirements and
procedures needed by an experienced service person
to complete necessary service and repairs on the
machine. Study and understand these requirements
and procedures thoroughly before servicing or
repairing the machine. There are also many
components which are not user-serviceable. Do not
attempt any service which you do not fully understand,
nor any service that you cannot do adequately and
safely with the tools and equipment available to you.
Failure to do so could result in personal injury or
equipment damage. If you encounter a problem that
you do not understand or cannot solve, contact your
Vermeer service representative.
The instructions, illustrations and specifications in this
manual are based on the latest information available at
the time of publication. Your machine may have
product improvements and options not yet contained in
this manual.
This document may contain portions of technical
materials of various suppliers. Such component
suppliers shall not be responsible for the direct results
of their technical materials being presented out of
context.
Designations used by component suppliers to
distinguish their products which appear in this manual
are the property of the respective trademark owner(s).
Vermeer Corporation is aware of the following
component suppliers trademarks.
KUBOTA is the trademark of the Kubota Corporation.
CANalyzer is a trademark of Vector Cantech, Inc.
FLUKE is a trademark of Fluke Corporation.
TEFLON is a trademark of E.I. DuPont de Nemours
and Company.

Vermeer Corporation reserves the right to make SUNDSTRAND is a trademark of Sauer-Sundstrand

changes at any time without notice or obligation. Corp.

Additional copies of this manual are available. When EATON and CHAR-LYNN are trademarks of Eaton
ordering, use the part number on the front cover. Corporation.

VERMEER, VERMEER Logo and NAVIGATOR are

trademarks of Vermeer Manufacturing Company in the
U.S. and/or other countries.

No part of this manual may be reproduced in any form or by any means, electronic or
mechanical, including photocopying, recording, or by any information storage and retrieval
systems, without the express written consent of Vermeer Corporation.

Copyright 2008 All rights reserved.

Vermeer Corporation
1210 Vermeer Road East, P.O. Box 200
Pella, Iowa 50219-0200, USA
D20x22 Series II Navigator HDD Service Table of Contents

General Information ........................................................................................................... 1-1

Using the Manual ........................................................................................................................................... 1-1

Reference Publications ............................................................................................................................................ 1-1
Vermeer Publications ......................................................................................................................................... 1-1
Vendor Publications ........................................................................................................................................... 1-2
Warranty Considerations .............................................................................................................................. 1-2
Vermeer Warranty ..................................................................................................................................................... 1-2
Kubota Warranty ....................................................................................................................................................... 1-2
Safety .............................................................................................................................................................. 1-3
Do Not Modify Machine ............................................................................................................................................ 1-3
Replace Shields ........................................................................................................................................................ 1-3
Safety Symbol Explanation ...................................................................................................................................... 1-3
Terminology ................................................................................................................................................... 1-6
Function ..................................................................................................................................................................... 1-6
Circuit......................................................................................................................................................................... 1-6
Inputs and Outputs ................................................................................................................................................... 1-6
Reference Designators ............................................................................................................................................. 1-7
Diagrams and Schematics ....................................................................................................................................... 1-7
Chapter Organization................................................................................................................................................ 1-7
Overview .............................................................................................................................................................. 1-7
Function Theory.................................................................................................................................................. 1-7
Troubleshooting/Testing.................................................................................................................................... 1-7
Repair................................................................................................................................................................... 1-8
Troubleshooting Guidelines ......................................................................................................................... 1-8
Problem-Solving Analysis........................................................................................................................................ 1-8
Rule Out Operator Error ..................................................................................................................................... 1-8
Define the Problem ............................................................................................................................................. 1-8
Research the System ......................................................................................................................................... 1-9
Electrical Troubleshooting..................................................................................................................................... 1-10
Common Electrical Problems .......................................................................................................................... 1-10
Basic Hydraulic Troubleshooting.......................................................................................................................... 1-11
Mechanical Component Inspection....................................................................................................................... 1-12
Hydraulic Troubleshooting .................................................................................................................................... 1-12
Leakage Path Analysis ..................................................................................................................................... 1-12
Pumps and Motors ........................................................................................................................................... 1-13
Directional Control Valves ............................................................................................................................... 1-14
Sequence Valves .............................................................................................................................................. 1-14
Lock Valves ....................................................................................................................................................... 1-14
Cylinders ........................................................................................................................................................... 1-14
Required Tools ........................................................................................................................................................ 1-15
Hydraulic Connections ........................................................................................................................................... 1-15
Avoid Trapped Pressure .................................................................................................................................. 1-15
Avoid Oil Contamination .................................................................................................................................. 1-16
Connecting Flow Meters .................................................................................................................................. 1-16
Connecting a Needle Valve .............................................................................................................................. 1-16
Connecting Pressure Gauges.......................................................................................................................... 1-17
Thermometer or Pyrometer.................................................................................................................................... 1-17
Digital Multimeter .................................................................................................................................................... 1-17
Measuring Voltage ............................................................................................................................................ 1-17
Measuring Resistance ...................................................................................................................................... 1-18
Testing for Continuity....................................................................................................................................... 1-18
Table of Contents D20x22 Series II Navigator HDD Service

Measuring Current ............................................................................................................................................1-19

Repair Guidelines ........................................................................................................................................ 1-19
Shop Requirements................................................................................................................................................. 1-19
Special Tools & Test Equipment......................................................................................................................1-19
Personnel and Lifting Requirements..................................................................................................................... 1-19
Replacement Parts .................................................................................................................................................. 1-19
Part Numbers/Hose Lengths/Fitting Orientation............................................................................................1-19
Parts Ordering ...................................................................................................................................................1-19
Torque Values.......................................................................................................................................................... 1-20

Machine Information........................................................................................................................ 2-1

Shutdown Procedure .................................................................................................................................... 2-1

Stopping the Machine ............................................................................................................................................... 2-1
Remote Lockout System - Shut Down..................................................................................................................... 2-1
Starting Procedure ........................................................................................................................................ 2-2
Starting the Engine.................................................................................................................................................... 2-2
Cold Weather Starting............................................................................................................................................... 2-2
Engine ..................................................................................................................................................................2-2
Hydraulic Fluid ....................................................................................................................................................2-2
Operation Overview .................................................................................................................................................. 2-3
Legend for Reference Designators.......................................................................................................................... 2-3
Chapter 2 - Machine ............................................................................................................................................2-3
Chapter 3 - Power................................................................................................................................................2-4
Chapter 4 - Hydraulic Fluid Distribution ...........................................................................................................2-5
Chapter 5 - Stakedown .......................................................................................................................................2-5
Chapter 6 - Stabilizer ..........................................................................................................................................2-6
Chapter 7 - Rack Angle .......................................................................................................................................2-6
Chapter 8 - Ground Drive....................................................................................................................................2-6
Chapter 9 - Rotation ............................................................................................................................................2-7
Chapter 10 - Thrust/Pullback..............................................................................................................................2-7
Chapter 11 - Rod Loader.....................................................................................................................................2-8
Chapter 12 - Vises ...............................................................................................................................................2-8
Chapter 13 - Rod Greaser ...................................................................................................................................2-8
Chapter 14 - Drilling Fluid...................................................................................................................................2-9
Chapter 15 - Remote Lockout ............................................................................................................................2-9
Chapter 16 - Strike Alert .....................................................................................................................................2-9
Specifications .............................................................................................................................................. 2-10
Machine Reference and Orientation ...................................................................................................................... 2-10
General Machine Specifications ............................................................................................................................ 2-10
Hydraulic Specifications......................................................................................................................................... 2-10
Electrical Specifications ......................................................................................................................................... 2-11
Engine Specifications ............................................................................................................................................. 2-11
Fuel and Lubricants ............................................................................................................................................... 2-12
Machine Interlocks ...................................................................................................................................... 2-13
Engine Start Interlocks ........................................................................................................................................... 2-13
Engine Protection Interlock.................................................................................................................................... 2-13
Operator Presence Interlock .................................................................................................................................. 2-13
Remote Lockout Interlock ...................................................................................................................................... 2-14
D20x22 Series II Navigator HDD Service Table of Contents

Controller A5 ................................................................................................................................................ 2-14

Controller Faceplates ............................................................................................................................................ 2-15
Troubleshooting at the Controller ......................................................................................................................... 2-16
Key to LEDs ............................................................................................................................................................. 2-17
Controller A5 Assignments.............................................................................................................................. 2-17
Display DP-10 E7 ......................................................................................................................................... 2-19
Display DP-10 E7 Assignments ....................................................................................................................... 2-20
Key to Fault Codes.................................................................................................................................................. 2-21
Controller A5 ..................................................................................................................................................... 2-21
CAN Bus Connector and Resistors ........................................................................................................... 2-22
Thrust/Pullback Joystick A1 ....................................................................................................................... 2-23
P90 Pin Identification (12-Pin Connector)............................................................................................................. 2-23
P85 Pin Identification (6-Pin Connector)............................................................................................................... 2-23
Rotation Joystick A2 ................................................................................................................................... 2-24
P80 Pin Identification (12-Pin Connector)............................................................................................................. 2-24
P82 Pin Identification (6-Pin Connector)............................................................................................................... 2-24
Testing Joysticks .................................................................................................................................................... 2-25
Hydraulic Valves .......................................................................................................................................... 2-25
Solenoids ................................................................................................................................................................. 2-25
Valves....................................................................................................................................................................... 2-26

Power ................................................................................................................................................ 3-1

Overview......................................................................................................................................................... 3-1
Theory............................................................................................................................................................. 3-1
Functions/Circuits..................................................................................................................................................... 3-1
Components .............................................................................................................................................................. 3-2
Component Locations .............................................................................................................................................. 3-3
Engine ........................................................................................................................................................................ 3-6
Engine Service .......................................................................................................................................................... 3-6
Engine Maintenance ................................................................................................................................................. 3-6
Engine Start Circuit................................................................................................................................................... 3-7
Operation ............................................................................................................................................................. 3-7
Engine OFF Circuit.................................................................................................................................................... 3-8
Operation ............................................................................................................................................................. 3-8
Engine Heat Circuit ................................................................................................................................................... 3-9
Operation ............................................................................................................................................................. 3-9
Engine RUN or ACC Circuit.................................................................................................................................... 3-10
Operation ........................................................................................................................................................... 3-10
Battery Charging Circuit......................................................................................................................................... 3-11
Operation ........................................................................................................................................................... 3-11
Table of Contents D20x22 Series II Navigator HDD Service

Troubleshooting .......................................................................................................................................... 3-12

Pretest Inspection ................................................................................................................................................... 3-12
Test Equipment Needed.......................................................................................................................................... 3-13
Testing the Circuits ................................................................................................................................................. 3-13
Measure Battery Voltage......................................................................................................................................... 3-13
Check for Power at Controller and Remote Lockout Charger ............................................................................ 3-13
Troubleshooting the Battery Charging Circuit ..................................................................................................... 3-14
Testing Fuses .......................................................................................................................................................... 3-15
Troubleshooting the Circuit Breakers ................................................................................................................... 3-16
Testing Circuit Breakers ......................................................................................................................................... 3-17
Testing the Emergency Stop Switch ..................................................................................................................... 3-17
Testing the Ignition Switch..................................................................................................................................... 3-17
Specifications .......................................................................................................................................................... 3-18
Electrical System ..............................................................................................................................................3-18
Battery ................................................................................................................................................................3-18
Circuit Breaker ..................................................................................................................................................3-18
Fuse Ratings......................................................................................................................................................3-18
Engine ................................................................................................................................................................3-18
Component Repair/Replace.................................................................................................................................... 3-18
Component Repair ...................................................................................................................................... 3-19
Fuse Panel ............................................................................................................................................................... 3-19
Remove ..............................................................................................................................................................3-19
Install ..................................................................................................................................................................3-19
Circuit Breakers CB1 and CB2 ............................................................................................................................... 3-19
Relays ....................................................................................................................................................................... 3-20
Emergency Stop Switch S39 .................................................................................................................................. 3-20
Replace ..............................................................................................................................................................3-20
Ignition Switch S2 ................................................................................................................................................... 3-21
Battery Disconnect Switch S1................................................................................................................................ 3-21
Replace ..............................................................................................................................................................3-21

Hydraulic Fluid Distribution............................................................................................................ 4-1

Overview......................................................................................................................................................... 4-1
Theory............................................................................................................................................................. 4-1
Functions ................................................................................................................................................................... 4-1
Components .............................................................................................................................................................. 4-2
Component Locations............................................................................................................................................... 4-3
Hose Connections — Fluid Supply.......................................................................................................................... 4-4
Hose Connections — Fluid Return .......................................................................................................................... 4-5
Hydraulic Schematic ................................................................................................................................................. 4-5
Oil Supply Function................................................................................................................................................... 4-6
PFC Pump PMP2 ....................................................................................................................................................... 4-6
Operation .............................................................................................................................................................4-6
Rotation and Thrust Closed-Loop Pump PMP1...................................................................................................... 4-8
Operation - Charge Pressure Mode ...................................................................................................................4-8
Operation - High Pressure Mode .......................................................................................................................4-9
Pump PMP1 Ports ................................................................................................................................................... 4-10
Oil Filtering Function .............................................................................................................................................. 4-11
With Functions Operating or At Rest ..............................................................................................................4-11
Oil Cooling Function ............................................................................................................................................... 4-12
D20x22 Series II Navigator HDD Service Table of Contents

Operation ........................................................................................................................................................... 4-12

Specifications.......................................................................................................................................................... 4-13
Troubleshooting .......................................................................................................................................... 4-14
Excessive Noise/Vibration ............................................................................................................................... 4-14
Pretest Inspection ................................................................................................................................................... 4-16
Test Equipment Needed ......................................................................................................................................... 4-16
Troubleshooting/Testing Pump PMP1 .................................................................................................................. 4-17
Troubleshooting/Testing PFC Pump PMP2 .......................................................................................................... 4-17
Troubleshooting/Testing the Oil Cooling Function ............................................................................................. 4-20
Flow Test for PFC Pump......................................................................................................................................... 4-21
Set Up ................................................................................................................................................................ 4-21
Case Drain Flow Test ....................................................................................................................................... 4-21
Case Drain Flow Analysis ................................................................................................................................ 4-22
Case Pressure Test .......................................................................................................................................... 4-23
Outlet Flow Test ................................................................................................................................................ 4-24
Understanding the Results of Flow Test ........................................................................................................ 4-25
Calculating Theoretical Flow and Acceptable Flow ...................................................................................... 4-25
Hydraulic Fluid Sampling............................................................................................................................ 4-26
Preventive Maintenance ......................................................................................................................................... 4-26
Hydraulic Fluid Sampling ....................................................................................................................................... 4-26
Fluid Sample Collection Points ....................................................................................................................... 4-28
Flushing the Implement and Transport System................................................................................................... 4-29
General Guidelines for Hydraulic Circuits...................................................................................................... 4-29
Component Repair....................................................................................................................................... 4-29
Diverter/Fluid Valve Assembly A9 ......................................................................................................................... 4-30
Remove .............................................................................................................................................................. 4-30
Directional Valve DV16–DV18 and DV24 and Relief Valve PV4 .......................................................................... 4-31
Disassembly ...................................................................................................................................................... 4-31
Assembly ........................................................................................................................................................... 4-31
PFC Pump PMP2 ..................................................................................................................................................... 4-32
Remove .............................................................................................................................................................. 4-32
Install ................................................................................................................................................................. 4-32
Disassembly – Shaft Seal Replacement ......................................................................................................... 4-33
Assembly – Shaft Seal Replacement .............................................................................................................. 4-33
Disassembly – Auxiliary Pads ......................................................................................................................... 4-34
Assembly – Auxiliary Pads .............................................................................................................................. 4-34
Disassembly – Pump Control .......................................................................................................................... 4-35
Assembly – Pump Control ............................................................................................................................... 4-36
Rotation/Thrust Pump PMP1.................................................................................................................................. 4-36
Charge Pump PMP4 ................................................................................................................................................ 4-37
Oil Cooler/Radiator HE1 ......................................................................................................................................... 4-37

Stakedown ........................................................................................................................................ 5-1

Overview......................................................................................................................................................... 5-1
Table of Contents D20x22 Series II Navigator HDD Service

Theory............................................................................................................................................................. 5-1
Functions/Circuits ..................................................................................................................................................... 5-1
Components .............................................................................................................................................................. 5-1
Component Locations............................................................................................................................................... 5-2
Hose Connections ..................................................................................................................................................... 5-3
Hydraulic Schematic ................................................................................................................................................. 5-4
Electrical Schematic ................................................................................................................................................. 5-5
Shared Components ................................................................................................................................................. 5-6
Stakedown Valve Assembly A12.............................................................................................................................. 5-6
Stakedown Cylinder Left Stake Down Mode........................................................................................................... 5-7
Operation .............................................................................................................................................................5-7
Stakedown Cylinder Right Stake Down Mode ........................................................................................................ 5-9
Operation .............................................................................................................................................................5-9
Stakedown Cylinder Stake Up Mode ..................................................................................................................... 5-11
Operation ...........................................................................................................................................................5-11
Stakedown Motor Left Stake In Mode.................................................................................................................... 5-12
Operation ...........................................................................................................................................................5-12
Stakedown Motor Right Stake In Mode ................................................................................................................. 5-14
Operation ...........................................................................................................................................................5-14
Stakedown Motor Stake Out Mode ........................................................................................................................ 5-16
Operation ...........................................................................................................................................................5-16
Troubleshooting .......................................................................................................................................... 5-17
Pretest Inspection ................................................................................................................................................... 5-17
Troubleshooting Machine Performance................................................................................................................ 5-19
Possible Results ...............................................................................................................................................5-19
Testing Stakedown Performance........................................................................................................................... 5-20
Troubleshooting/Testing Stakedown Function .................................................................................................... 5-21
Test Equipment Needed.......................................................................................................................................... 5-23
Specifications .......................................................................................................................................................... 5-24
Component Repair/Replace.................................................................................................................................... 5-24
Component Repair ...................................................................................................................................... 5-25
Stakedown Valve Assembly A7.............................................................................................................................. 5-25
Remove ..............................................................................................................................................................5-25
Directional Valves DV25–DV28 .............................................................................................................................. 5-26
Disassemble ......................................................................................................................................................5-26
Assembly ...........................................................................................................................................................5-26
Stakedown Motors MH7 and MH8 .......................................................................................................................... 5-27
Remove ..............................................................................................................................................................5-27
Motor Breakdown ..............................................................................................................................................5-28
Install ..................................................................................................................................................................5-29
Stakedown Cylinders CY4 and CY5....................................................................................................................... 5-30
Remove ..............................................................................................................................................................5-30

Stabilizer .......................................................................................................................................... 6-1

Overview......................................................................................................................................................... 6-1
D20x22 Series II Navigator HDD Service Table of Contents

Theory............................................................................................................................................................. 6-1
Components .............................................................................................................................................................. 6-1
Component Locations .............................................................................................................................................. 6-2
Hydraulic Schematic................................................................................................................................................. 6-3
Hose Connections..................................................................................................................................................... 6-4
Shared Components ................................................................................................................................................. 6-4
Transport Valve Assembly A11 ............................................................................................................................... 6-5
Stabilizer Function – Stabilizer LOWER Mode ....................................................................................................... 6-6
Operation ............................................................................................................................................................. 6-6
Stabilizer Function – Stabilizer RAISE Mode.......................................................................................................... 6-7
Operation ............................................................................................................................................................. 6-7
Troubleshooting ............................................................................................................................................ 6-8
Pretest Inspection ..................................................................................................................................................... 6-8
Test Equipment Needed ........................................................................................................................................... 6-9
Troubleshooting Machine Performance ............................................................................................................... 6-10
Possible Results ............................................................................................................................................... 6-10
Testing Stabilizer Performance ............................................................................................................................. 6-11
Troubleshooting Stabilizer Function..................................................................................................................... 6-11
Troubleshooting Transport Valve A11 .................................................................................................................. 6-12
Component Repair/Replace ................................................................................................................................... 6-12
Specifications.......................................................................................................................................................... 6-12
Component Repair....................................................................................................................................... 6-13
Transport/Rack Valve Manifold A11 ...................................................................................................................... 6-14
Remove .............................................................................................................................................................. 6-14
Install ................................................................................................................................................................. 6-14
Disassembly ...................................................................................................................................................... 6-15
Stabilizer Cylinders CY2 and CY3 ......................................................................................................................... 6-16
Remove .............................................................................................................................................................. 6-16
Disassembly ...................................................................................................................................................... 6-18
Assembly ........................................................................................................................................................... 6-19
Stabilizer .................................................................................................................................................................. 6-20

Rack Angle ....................................................................................................................................... 7-1

Overview......................................................................................................................................................... 7-1
Theory............................................................................................................................................................. 7-1
Components .............................................................................................................................................................. 7-1
Component Locations .............................................................................................................................................. 7-2
Hose Connections..................................................................................................................................................... 7-3
Hydraulic Schematic................................................................................................................................................. 7-4
Shared Components ................................................................................................................................................. 7-5
Rack Angle RAISE Mode .......................................................................................................................................... 7-6
Operation ............................................................................................................................................................. 7-6
Rack Angle LOWER Mode........................................................................................................................................ 7-7
Operation ............................................................................................................................................................. 7-7
Troubleshooting ............................................................................................................................................ 7-8
Pretest Inspection ..................................................................................................................................................... 7-8
Troubleshooting Machine Performance ................................................................................................................. 7-9
Table of Contents D20x22 Series II Navigator HDD Service

Possible Results ...............................................................................................................................................7-10

Testing Rack Angle Performance .......................................................................................................................... 7-10
Troubleshooting Rack Angle Function ................................................................................................................. 7-11
Component Repair/Replace.................................................................................................................................... 7-11
Test Equipment Needed.......................................................................................................................................... 7-11
Specifications .......................................................................................................................................................... 7-12
Component Repair ...................................................................................................................................... 7-12
Rack Angle Cylinder CY1........................................................................................................................................ 7-13
Remove ..............................................................................................................................................................7-13
Disassembly ......................................................................................................................................................7-15
Rack Angle Cylinder Lock Check Valve FV1 ........................................................................................................ 7-16

Ground Drive .................................................................................................................................... 8-1

Overview......................................................................................................................................................... 8-1
Theory............................................................................................................................................................. 8-1
Components .............................................................................................................................................................. 8-1
Component Locations............................................................................................................................................... 8-2
Hydraulic Schematic ................................................................................................................................................. 8-3
Electrical Schematic ................................................................................................................................................. 8-4
Electrical Schematic – Optional Tether ................................................................................................................... 8-5
Hose Connections ..................................................................................................................................................... 8-6
Ground Drive Function – Left Track FORWARD Mode .......................................................................................... 8-7
Operation .............................................................................................................................................................8-7
Ground Drive Function – Right Track FORWARD Mode ....................................................................................... 8-8
Operation .............................................................................................................................................................8-8
Ground Drive Function – Left Track REVERSE Mode............................................................................................ 8-9
Operation .............................................................................................................................................................8-9
Ground Drive Function – Right Track REVERSE Mode ....................................................................................... 8-10
Operation ...........................................................................................................................................................8-10
Troubleshooting .......................................................................................................................................... 8-11
Pretest Inspection ................................................................................................................................................... 8-11
Test Equipment Needed.......................................................................................................................................... 8-12
Troubleshooting Machine Performance................................................................................................................ 8-13
Possible Results ...............................................................................................................................................8-13
Testing Ground Drive Performance....................................................................................................................... 8-14
Troubleshooting/Testing Ground Drive Function ................................................................................................ 8-15
Towing the Machine ................................................................................................................................................ 8-16
Conditions .........................................................................................................................................................8-16
Procedure ..........................................................................................................................................................8-16
Specifications .......................................................................................................................................................... 8-17
Component Repair/Replace.................................................................................................................................... 8-17
Component Repair ...................................................................................................................................... 8-18
Planetary Gears ....................................................................................................................................................... 8-18
Remove ..............................................................................................................................................................8-18
Install ..................................................................................................................................................................8-18
Gearbox and Track Motors MH5 and MH6 ............................................................................................................ 8-19
Repair .................................................................................................................................................................8-19
Install ..................................................................................................................................................................8-20
Tracks ....................................................................................................................................................................... 8-20
Remove ..............................................................................................................................................................8-20
D20x22 Series II Navigator HDD Service Table of Contents

Install ................................................................................................................................................................. 8-21

Track Tension Tightener ........................................................................................................................................ 8-21
Remove .............................................................................................................................................................. 8-21
Install ................................................................................................................................................................. 8-22
Track Tension Adjustment............................................................................................................................... 8-23

Rotation ............................................................................................................................................ 9-1

Overview......................................................................................................................................................... 9-1
Theory............................................................................................................................................................. 9-1
Components .............................................................................................................................................................. 9-1
Component Locations .............................................................................................................................................. 9-2
Hydraulic Schematic................................................................................................................................................. 9-3
Electrical Schematic ................................................................................................................................................. 9-4
Hose Connections..................................................................................................................................................... 9-5
Rotation and Thrust Pump PMP1 Ports .................................................................................................................. 9-6
Operation Overview .................................................................................................................................................. 9-7
Rotation Motor .................................................................................................................................................... 9-7
Rotation Pump .................................................................................................................................................... 9-7
Charge Pump ...................................................................................................................................................... 9-7
Torque Limiter/Loop Flush Valve ...................................................................................................................... 9-7
Operation ............................................................................................................................................................. 9-7
Shared Components ................................................................................................................................................. 9-7
Charge Pump............................................................................................................................................................. 9-8
Operation ............................................................................................................................................................. 9-8
Pump PMP1 – High Pressure Relief Valves............................................................................................................ 9-9
Operation ............................................................................................................................................................. 9-9
Pump PMP1 – Electric Displacement Control (EDC) ........................................................................................... 9-10
Operation ........................................................................................................................................................... 9-10
Torque Limiter/Loop Flush Valve A7..................................................................................................................... 9-11
Torque Limiter................................................................................................................................................... 9-11
Loop Flush ........................................................................................................................................................ 9-11
Low Speed Function......................................................................................................................................... 9-11
High Speed Function ........................................................................................................................................ 9-11
Rotation Motor MH1 ................................................................................................................................................ 9-12
Drill Rotation Function – Drilling/Backreaming Mode ......................................................................................... 9-13
Operation ........................................................................................................................................................... 9-13
Drill Rotation Function – Rod Uncoupling Mode ................................................................................................. 9-15
Operation ........................................................................................................................................................... 9-15
Troubleshooting .......................................................................................................................................... 9-16
Pretest Inspection ................................................................................................................................................... 9-17
Hydrostatic Closed-Loop Troubleshooting .......................................................................................................... 9-18
Indicators Used For Troubleshooting Closed Loops .......................................................................................... 9-20
Pump Noise ....................................................................................................................................................... 9-20
Fluid Temperature ............................................................................................................................................ 9-21
Required Test Equipment....................................................................................................................................... 9-21
Pressure Check ....................................................................................................................................................... 9-22
Oil Sampling ............................................................................................................................................................ 9-22
Troubleshooting Machine Performance ............................................................................................................... 9-24
Table of Contents D20x22 Series II Navigator HDD Service

Possible Results ...............................................................................................................................................9-24

Testing Drill Rotation Performance ....................................................................................................................... 9-25
Troubleshooting/Testing Rotation and Thrust Pump PMP1 ............................................................................... 9-25
Pump Test Procedure ............................................................................................................................................. 9-30
Case Drain Pressure Test.................................................................................................................................9-31
Analyzing Case Pressure Test Results ...........................................................................................................9-32
Pump Case Pressure Test ................................................................................................................................9-33
Test Objective....................................................................................................................................................9-33
Special Tools and Materials .............................................................................................................................9-33
Conditions .........................................................................................................................................................9-33
Procedure ..........................................................................................................................................................9-33
Inspect Electric Displacement Control (EDC).................................................................................................9-34
Inspect Charge Check/High Pressure Relief Valves ......................................................................................9-34
Adjusting Pump Neutral Setting ............................................................................................................................ 9-35
Charge Pressure Relief Valve Check and Adjustment......................................................................................... 9-37
Rotation Motor Case Drain Flow Test.................................................................................................................... 9-39
Analyzing Motor Test Results ................................................................................................................................ 9-40
Flushing the Rotation System................................................................................................................................ 9-40
General Guidelines When Servicing Hydrostatic Circuits ............................................................................9-40
Special Tools .....................................................................................................................................................9-41
Procedure ..........................................................................................................................................................9-41
Filter Components ............................................................................................................................................9-43
Specifications .......................................................................................................................................................... 9-44
Returning System to Service.................................................................................................................................. 9-45
Component Repair ...................................................................................................................................... 9-46
Rotation and Thrust Pump PMP1........................................................................................................................... 9-47
Removal .............................................................................................................................................................9-47
Install ..................................................................................................................................................................9-48
EDC Module Removal .......................................................................................................................................9-49
EDC Module Assembly .....................................................................................................................................9-50
Shaft, Seal and Bearing Removal ....................................................................................................................9-51
Shaft, Seal and Bearing Assembly ..................................................................................................................9-52
High Pressure Relief/Charge Check Valves....................................................................................................9-53
Charge Pressure Relief Valve ..........................................................................................................................9-54
Charge Pump PMP3 ................................................................................................................................................ 9-55
Torque Limiter/Loop Flush Valve Assembly A7 ................................................................................................... 9-56
Removal .............................................................................................................................................................9-56
Directional Valves DV4–DV7 and Relief Valves PV2 and PV3 ............................................................................. 9-57
Disassembly ......................................................................................................................................................9-57
Assembly ...........................................................................................................................................................9-57
Replace Drive Chuck............................................................................................................................................... 9-58
Special Tools and Materials .............................................................................................................................9-58
Drive Chuck Sub-Saver Installation/Removal....................................................................................................... 9-58
Special Tools and Materials .............................................................................................................................9-58
Thread Locking Compound Considerations ..................................................................................................9-58
Install Sub-Saver ..................................................................................................................................................... 9-59
Remove Sub-Saver.................................................................................................................................................. 9-59
Gearbox Removal/Installation ................................................................................................................................ 9-60
Special Tools and Materials .............................................................................................................................9-60
Rotation Gearbox .................................................................................................................................................... 9-61
Replace ..............................................................................................................................................................9-61
Gearbox Disassembly.......................................................................................................................................9-62
Gearbox Assembly............................................................................................................................................9-64
Motor Replacement ................................................................................................................................................. 9-66
D20x22 Series II Navigator HDD Service Table of Contents

Special Tools and Materials............................................................................................................................. 9-66

Rotation Motor MH1 ................................................................................................................................................ 9-66
Removal ............................................................................................................................................................. 9-66
Disassembly ...................................................................................................................................................... 9-67
Assembly ........................................................................................................................................................... 9-68

Thrust/Pullback.............................................................................................................................. 10-1

Overview....................................................................................................................................................... 10-1
Theory........................................................................................................................................................... 10-1
Components ............................................................................................................................................................ 10-1
Component Locations ............................................................................................................................................ 10-2
Hydraulic Schematic............................................................................................................................................... 10-4
Electrical Schematic ............................................................................................................................................... 10-5
Hose Connections................................................................................................................................................... 10-6
Operation Overview ................................................................................................................................................ 10-7
Rotation and Thrust Pump............................................................................................................................... 10-7
Thrust Limiter.................................................................................................................................................... 10-7
Anti-Crash and Slowdown Switches............................................................................................................... 10-7
2-Speed Solenoid.............................................................................................................................................. 10-7
Shared Components ............................................................................................................................................... 10-7
Thrust Function....................................................................................................................................................... 10-8
Operation ........................................................................................................................................................... 10-8
Pullback Function ................................................................................................................................................. 10-10
Operation ......................................................................................................................................................... 10-10
Troubleshooting ........................................................................................................................................ 10-11
Pretest Inspection ................................................................................................................................................. 10-12
Troubleshooting Machine Performance ............................................................................................................. 10-13
Possible Results ............................................................................................................................................. 10-13
Testing AutoDrill Mode......................................................................................................................................... 10-14
Testing Pressure Limit Selector in R.A.T.T. Manual Mode................................................................................ 10-15
Troubleshooting the Thrust/Pullback Function ................................................................................................. 10-16
Movement—One Direction Only .................................................................................................................... 10-17
Movement—Neither Direction........................................................................................................................ 10-18
Movement—Gearbox Creeps in Stop............................................................................................................ 10-18
Control—Response is Sluggish .................................................................................................................... 10-19
Motor Torque ......................................................................................................................................................... 10-19
Charge Pressure Measurement ........................................................................................................................... 10-20
Function Pressure Measurement ........................................................................................................................ 10-21
Testing Proximity Switches ................................................................................................................................. 10-22
Adjusting Proximity Switch ........................................................................................................................... 10-22
Specifications........................................................................................................................................................ 10-23
Component Repair..................................................................................................................................... 10-23
Thrust Valve Assembly A8 ................................................................................................................................... 10-24
Remove ............................................................................................................................................................ 10-24
Directional Valves DV12–DV14 ............................................................................................................................ 10-25
Disassembly .................................................................................................................................................... 10-25
Thrust Motors MH2, MH3, and MH4..................................................................................................................... 10-26
Removal ........................................................................................................................................................... 10-26
Disassembly .................................................................................................................................................... 10-27
Table of Contents D20x22 Series II Navigator HDD Service

Assembly .........................................................................................................................................................10-30
Returning System to Service................................................................................................................................ 10-35
Carriage .................................................................................................................................................................. 10-35
Special Tools ...................................................................................................................................................10-35
Remove ............................................................................................................................................................10-35
Install ................................................................................................................................................................10-37
Stop and Slowdown Switches.............................................................................................................................. 10-38

Rod Loader ..................................................................................................................................... 11-1

Overview....................................................................................................................................................... 11-1
Theory........................................................................................................................................................... 11-1
Components ............................................................................................................................................................ 11-1
Component Locations............................................................................................................................................. 11-2
Hose Connections ................................................................................................................................................... 11-3
Electrical Schematic ............................................................................................................................................... 11-4
Hydraulic Diagram................................................................................................................................................... 11-5
Shared Components ............................................................................................................................................... 11-6
Rod Loader Valve Assembly A14........................................................................................................................... 11-6
Rod Loader Function – Rod Lifter Lower Mode ................................................................................................... 11-7
Operation ...........................................................................................................................................................11-7
Rod Loader Function – Rod Lifter Raise Mode .................................................................................................... 11-8
Operation ...........................................................................................................................................................11-8
Rod Loader Function – Rod Selector Retract Mode ............................................................................................ 11-9
Operation ...........................................................................................................................................................11-9
Rod Loader Function – Rod Selector Extend Mode........................................................................................... 11-10
Operation .........................................................................................................................................................11-10
Troubleshooting ........................................................................................................................................ 11-11
Pretest Inspection ................................................................................................................................................. 11-11
Test Equipment Needed........................................................................................................................................ 11-12
Troubleshooting Machine Performance.............................................................................................................. 11-13
Possible Results .............................................................................................................................................11-13
Testing Rod Loader Performance........................................................................................................................ 11-14
Troubleshooting the Rod Loader Load Function ............................................................................................... 11-15
Troubleshooting Rod Loader Lift Function ........................................................................................................ 11-17
Specifications ........................................................................................................................................................ 11-18
Component Repair/Replace.................................................................................................................................. 11-18
Component Repair .................................................................................................................................... 11-18
Rod Loader Valve Assembly A14......................................................................................................................... 11-19
Removal ...........................................................................................................................................................11-19
Directional Valves DV34 and DV35 ...................................................................................................................... 11-20
Check Valve CV8 ................................................................................................................................................... 11-21
Check Valves CV9–CV12 ...................................................................................................................................... 11-21
Rod Lift Cylinders CY10 and CY11 ...................................................................................................................... 11-22
Removal ...........................................................................................................................................................11-22
Disassembly ....................................................................................................................................................11-23
Assembly .........................................................................................................................................................11-23
Rod Loader Motor MH9 ......................................................................................................................................... 11-24
Rod Box.................................................................................................................................................................. 11-25
Remove ............................................................................................................................................................11-25
Install ................................................................................................................................................................11-26
D20x22 Series II Navigator HDD Service Table of Contents

Rod Arm Extend and Lift Limit Switches ................................................................................................ 11-27

Replacement ................................................................................................................................................... 11-27

Vises .............................................................................................................................................. 12-1

Overview....................................................................................................................................................... 12-1
Theory........................................................................................................................................................... 12-1
Functions ................................................................................................................................................................. 12-1
Components ............................................................................................................................................................ 12-1
Component Locations ............................................................................................................................................ 12-2
Hose Connections................................................................................................................................................... 12-3
Hydraulic Schematic............................................................................................................................................... 12-4
Electrical Schematic ............................................................................................................................................... 12-5
Shared Components ............................................................................................................................................... 12-6
Vise Valve Assembly A13....................................................................................................................................... 12-7
Operation ........................................................................................................................................................... 12-7
Front Vise CLAMP Mode ........................................................................................................................................ 12-8
Operation ........................................................................................................................................................... 12-8
Front Vise UNCLAMP Mode ................................................................................................................................... 12-9
Operation ........................................................................................................................................................... 12-9
Torque Limiter Function....................................................................................................................................... 12-10
Rear Vise CLAMP Mode........................................................................................................................................ 12-10
Operation ......................................................................................................................................................... 12-10
Rear Vise UNCLAMP Mode .................................................................................................................................. 12-11
Operation ......................................................................................................................................................... 12-11
Rear Vise Rotation EXTEND Mode ...................................................................................................................... 12-13
Operation ......................................................................................................................................................... 12-13
Rear Vise Rotation RETRACT Mode.................................................................................................................... 12-15
Operation ......................................................................................................................................................... 12-15
Troubleshooting ........................................................................................................................................ 12-16
Pretest Inspection ................................................................................................................................................. 12-16
Test Equipment Needed ....................................................................................................................................... 12-17
Troubleshooting Machine Performance ............................................................................................................. 12-18
Possible Results ............................................................................................................................................. 12-18
Troubleshooting/Testing the Front Vise ............................................................................................................. 12-19
Troubleshooting/Testing the Rear Vise .............................................................................................................. 12-20
Troubleshooting/Testing the Rear Rotation Vise............................................................................................... 12-21
Specifications........................................................................................................................................................ 12-22
Component Repair/Replace ................................................................................................................................. 12-23
Component Repair..................................................................................................................................... 12-24
Vise Valve Assembly A13..................................................................................................................................... 12-24
Remove ............................................................................................................................................................ 12-24
Directional Valve DV29–DV33 and Relief Valve PV6.......................................................................................... 12-25
Disassembly .................................................................................................................................................... 12-25
Vise Cylinders CY7, CY8 and CY9 ....................................................................................................................... 12-26
Remove ............................................................................................................................................................ 12-26
Vise Rotation Cylinder CY9.................................................................................................................................. 12-28
Disassembly .................................................................................................................................................... 12-28
Front and Rear Vise Clamp Cylinders CY7 and CY8 ......................................................................................... 12-29
Disassembly and Assembly .......................................................................................................................... 12-29
Table of Contents D20x22 Series II Navigator HDD Service

Rod Greaser .................................................................................................................................. 13-1

Overview....................................................................................................................................................... 13-1
Theory........................................................................................................................................................... 13-1
Components ............................................................................................................................................................ 13-1
Component Locations............................................................................................................................................. 13-2
Hose Connections ................................................................................................................................................... 13-3
Schematics .............................................................................................................................................................. 13-3
Auto Greaser Function – Greasing Mode.............................................................................................................. 13-4
Operation ...........................................................................................................................................................13-4
Troubleshooting .......................................................................................................................................... 13-5
Pretest Inspection ................................................................................................................................................... 13-5
Troubleshooting/Testing the Auto Greaser Function .......................................................................................... 13-7
Test Equipment Needed.......................................................................................................................................... 13-7
Specifications .......................................................................................................................................................... 13-8
Component Repair/Replace.................................................................................................................................... 13-8
Component Repair ...................................................................................................................................... 13-9
Auto Greaser Cylinder CY12 .................................................................................................................................. 13-9
Remove ..............................................................................................................................................................13-9
Cylinder Disassembly .....................................................................................................................................13-10
Auto Greaser Valve A16........................................................................................................................................ 13-11

Drilling Fluid ................................................................................................................................... 14-1

Overview....................................................................................................................................................... 14-1
Theory........................................................................................................................................................... 14-1
Components ............................................................................................................................................................ 14-1
Component Locations............................................................................................................................................. 14-2
Hose Connections ................................................................................................................................................... 14-4
Hydraulic Schematic ............................................................................................................................................... 14-5
Electrical Schematic ............................................................................................................................................... 14-6
Drilling Fluid Function – Fluid On Mode ............................................................................................................... 14-7
Operation ...........................................................................................................................................................14-7
Drilling Fluid Function – Shutoff Mode ................................................................................................................. 14-8
Operation ...........................................................................................................................................................14-8
Wash Wand .............................................................................................................................................................. 14-9
Operation ...........................................................................................................................................................14-9
Troubleshooting .......................................................................................................................................... 14-9
Pretest Inspection ................................................................................................................................................. 14-10
Test Equipment Needed........................................................................................................................................ 14-11
Testing Machine Performance ............................................................................................................................. 14-12
Possible Results .............................................................................................................................................14-12
Testing Drilling Fluid Performance...................................................................................................................... 14-13
Troubleshooting/Testing the Drilling Fluid Function......................................................................................... 14-14
Check Controllers First......................................................................................................................................... 14-16
Ball Valve Not Turning On/Off .............................................................................................................................. 14-17
Fluid Pump Motor Does Not Turn at Regulated Speed...................................................................................... 14-19
Full Flow Switch Does Not Increase Speed of Fluid Pump ............................................................................... 14-21
Fluid Pump Motor Will Not Reach Full Speed..................................................................................................... 14-22
D20x22 Series II Navigator HDD Service Table of Contents

Flow Test of Motor MH10 ............................................................................................................................... 14-22

Worksheet for Flow Test of Motor MH10 ...................................................................................................... 14-23
Interpreting the Results.................................................................................................................................. 14-23
Troubleshooting the Fluid On/Off Switch ........................................................................................................... 14-24
Specifications........................................................................................................................................................ 14-24
Component Repair/Replace ................................................................................................................................. 14-25
Component Repair..................................................................................................................................... 14-26
Fluid Shutoff Valve Assembly A19 ...................................................................................................................... 14-26
Remove ............................................................................................................................................................ 14-26
Disassembly .................................................................................................................................................... 14-26
Drilling Fluid Shutoff Cylinder CY6 and Ball Valve A20 .................................................................................... 14-27
Remove ............................................................................................................................................................ 14-27
Cylinder Disassembly .................................................................................................................................... 14-28
Ball Valve Disassembly .................................................................................................................................. 14-29
Ball Valve Assembly ....................................................................................................................................... 14-30
Drilling Fluid Pump PMP3 and Motor MH10 ....................................................................................................... 14-31
Remove ............................................................................................................................................................ 14-31
Fluid Pump PMP3.................................................................................................................................................. 14-32
Replacing Suction and Discharge Valves .................................................................................................... 14-32
Replacing Piston Cup Seals .......................................................................................................................... 14-34
Replacing Power End Bearings..................................................................................................................... 14-36
Servicing Wrist Pin Bearings......................................................................................................................... 14-38
Drilling Fluid Motor MH10..................................................................................................................................... 14-39
Disassembly .................................................................................................................................................... 14-39
Assembly ......................................................................................................................................................... 14-42

Remote Lockout............................................................................................................................ 15-1

Overview....................................................................................................................................................... 15-1
Hydraulic Lockout or Engine Shutdown Option .................................................................................................. 15-1
Hydraulic Lockout Backup Engine Shutdown ..................................................................................................... 15-1
Theory........................................................................................................................................................... 15-2
Functions ................................................................................................................................................................. 15-2
Components ............................................................................................................................................................ 15-2
Component Locations ............................................................................................................................................ 15-3
Electrical Schematic ............................................................................................................................................... 15-4
Hydraulic Lockout Function................................................................................................................................... 15-5
Operation ........................................................................................................................................................... 15-5
Confirmation ..................................................................................................................................................... 15-5
Hydraulic Lockout with Backup Engine Shutdown Function....................................................................... 15-6
Engine Shutdown Lockout Function..................................................................................................................... 15-7
Option Procedure ............................................................................................................................................. 15-7
Operation ........................................................................................................................................................... 15-7
Confirmation ..................................................................................................................................................... 15-7
Troubleshooting .......................................................................................................................................... 15-8
General System Information .................................................................................................................................. 15-8
Base Module Indicators.......................................................................................................................................... 15-9
Power On ............................................................................................................................................................... 15-11
Remote Unit On............................................................................................................................................... 15-11
Table of Contents D20x22 Series II Navigator HDD Service

Base Module Run ............................................................................................................................................15-11

Lockout Mode ........................................................................................................................................................ 15-12
Power Off ............................................................................................................................................................... 15-12
Remote Registration ............................................................................................................................................. 15-13
Battery Condition .................................................................................................................................................. 15-15
Low Battery......................................................................................................................................................15-15
Discharged Battery .........................................................................................................................................15-15
Recharge Battery ............................................................................................................................................15-15
Troubleshooting/Testing the Remote Lockout Function................................................................................... 15-16
Remote Unit .....................................................................................................................................................15-16
Base Module ....................................................................................................................................................15-17
Verify Software ................................................................................................................................................15-17
Verify CAN Operation .....................................................................................................................................15-18
Hydraulic or Engine Shutdown Lockout Mode.............................................................................................15-18
Battery ..............................................................................................................................................................15-19
Battery Charger ...............................................................................................................................................15-19
Terminal Test ...................................................................................................................................................15-20

Strike Alert...................................................................................................................................... 16-1

Overview....................................................................................................................................................... 16-1
Theory........................................................................................................................................................... 16-1
Circuits ..................................................................................................................................................................... 16-1
Components ............................................................................................................................................................ 16-1
Component Locations............................................................................................................................................. 16-2
Strike Alert System Test ......................................................................................................................................... 16-3
Electrical Schematic ............................................................................................................................................... 16-4
Voltage Strike Circuit .............................................................................................................................................. 16-5
Operation ...........................................................................................................................................................16-5
Current Strike Circuit .............................................................................................................................................. 16-5
Operation ...........................................................................................................................................................16-5
Troubleshooting/Testing ............................................................................................................................ 16-6
Determining What to Troubleshoot .................................................................................................................16-6
Daily Test ...........................................................................................................................................................16-6
VCTool Software ...............................................................................................................................................16-7
Control Panel Light ................................................................................................................................................. 16-7
Strike Alert Module Lights ...................................................................................................................................... 16-8
Component Repair .................................................................................................................................... 16-10
Voltage Stake E3 ................................................................................................................................................... 16-10
Strike Alert Coil Assembly L6 .............................................................................................................................. 16-11

VCTool Software ............................................................................................................................ 17-1

Overview....................................................................................................................................................... 17-1
Installation.................................................................................................................................................... 17-1
Connection................................................................................................................................................... 17-2
Using the VCTool......................................................................................................................................... 17-2
Opening Definition Files ......................................................................................................................................... 17-2
Main Screen ............................................................................................................................................................. 17-3
D20x22 Series II Navigator HDD Service Table of Contents

Columns ............................................................................................................................................................ 17-3

Buttons .............................................................................................................................................................. 17-4
Formatting ......................................................................................................................................................... 17-5
Creating Graphs ...................................................................................................................................................... 17-6
Logging .................................................................................................................................................................... 17-7
This page intentionally left blank.
D20x22 Series II Navigator HDD Service Using the Manual

Chapter 1: General Information

USING THE MANUAL

This manual provides information and service procedures based upon current machine
knowledge and configuration at the time the manual was written. The instructions,
illustrations and specifications are based on the latest information available at the time
of publication. Due to ongoing efforts to continuously improve the equipment, there
may be changes on the machine not yet reflected in this manual.

Vermeer Corporation reserves the right to make changes at any time without notice or
obligation. Procedures given in this manual provide one method for completing a given
task. Additional information may be available through Vermeer Service Support
resources.

Additional copies of this manual are available through the Vermeer Parts Center. Use the
reorder number on the front cover to order additional manuals.

Operating instructions are found in the D16x20 Series II/D20x22 Series II Operator’s
Manual. Lubrication and maintenance procedures are found in the D16x20 Series II/

General Information
D20x22 Series II Maintenance Manual. Refer to Reference Publications for ordering
information.

Reference Publications
Vermeer The following Vermeer Manufacturing Publications are necessary for reference:
Publications
• D16x20 Series II/D20x22 Series II Navigator Horizontal Directional Drill
Operator’s Manual, order number 105400AD7.
• D16x20 Series II/D20x22 Series II Navigator Horizontal Directional Drill
Maintenance Manual, order number 105400AD9.
• D20x22 Series II Navigator Horizontal Directional Drill Parts Manual, order
number 105400ZKO.
• Vermeer Industrial Dealerships Technician’s Shop Manual, order number
105400V80
• Recommended Service Tools Users Guide, order number 105400T69 for special
tools and test equipment.
Continued on next page...

1-1
 Warranty Considerations D20x22 Series II Navigator HDD Service

Contact the Vermeer Parts Center to order these publications.

Vendor Publications The following vendor publications are optional reference materials:

• Kubota V3800 DI-T Engine Manual

Contact the appropriate local dealer for this information. Vermeer Corporation does not
verify the validity of vendor information within the context of the D20x22 Series II
machine configuration.

WARRANTY CONSIDERATIONS
Vermeer Warranty
Vermeer 1 year Limited Warranty is printed inside the front cover of the D16x20
Series II/D20x22 Series II Operator’s Manual. The warranty requires that all service
work be conducted by an authorized Vermeer representative or the warranty shall
become void.
General Information

Kubota Warranty
The engine is covered under Kubota’s Warranty.

Understand that only an authorized Kubota Service Facility may work on the engine
while the warranty is in effect. Unauthorized service on the engine will void the
warranty.

For the nearest Kubota authorized facility, consult the Yellow Pages of the phone
directory or contact Kubota’s Engine Warranty Service Dept.

1-2
D20x22 Series II Navigator HDD Service Safety

SAFETY
General safety messages appear in this Safety section of the manual. Specific safety
messages are located in the applicable sections of the manual where a potential hazard
may occur if the instructions or procedures are not followed.

A signal word “DANGER”, “WARNING”, or “CAUTION” is used with the safety

alert symbol.

Safety signs with signal word “DANGER”, “WARNING”, or “CAUTION” are located
near specific hazards.

DANGER: Imminent hazards which, if not avoided, will result in serious personal
injury or death.

WARNING: Potential hazards or unsafe practices which, if not avoided, could

result in serious personal injury or death.

CAUTION: Potential hazards or unsafe practices which, if not avoided, could result
in minor personal injury or product or property damage.

General Information
Do Not Modify Machine
Make no modifications to this equipment unless specifically recommended by Vermeer
Corporation.

Replace Shields
Be sure that all safety devices, including shields, are installed and functioning properly
after servicing the machine.

Safety Symbol Explanation

This is the safety alert symbol. This symbol is used in combination with
an exclamation mark or other symbols to alert you to the potential for
bodily injury or death.

Continued on next page...

1-3
 Safety D20x22 Series II Navigator HDD Service

WARNING: Read Operator’s Manual and safety signs before operating machine.
Allow only responsible, properly instructed individuals to operate and service the
machine.

WARNING: Check machine before operating. Machine must be in good operating

condition and all safety equipment installed and functioning properly.

WARNING: Wear personal protective equipment. Wear close-fitting clothing and confine
long hair. Avoid wearing jewelry such as rings, wristwatches, necklaces, or bracelets.
Always wear safety glasses, safety shoes, and hearing protection when the engine is
running, or when excessive noise is present.
General Information

WARNING: Keep spectators away.

WARNING: Exhaust fumes can be fatal.

If operating in an enclosed area, remove the exhaust fumes with an exhaust pipe
extension to the outside.

Continued on next page...

1-4
D20x22 Series II Navigator HDD Service Safety

WARNING: Pressurized fluid can penetrate body tissue and result in serious injury or
death. Leaks can be invisible. Keep away from any suspected leak. Relieve pressure in the
hydraulic system before searching for leaks, disconnecting hoses, or performing any other
work on the system. If you must pressurize the system to find a suspected leak, use an
object such as a piece of wood or cardboard rather than your hands. When loosening a
fitting where some residual pressure may exist, slowly loosen the fitting until oil begins to
leak. Wait for leaking to stop before disconnecting the fitting. Fluid injected under the skin
must be removed immediately by a surgeon familiar with this type of injury.

WARNING: Hot fluid under pressure can scald.

Allow engine to cool before opening radiator cap.

General Information
WARNING: Fuel and fumes can explode and burn.

Shut off engine before refueling. No flame. No smoking.

WARNING: Battery fumes are flammable and can explode. Keep all burning materials
away from battery. Battery explosion can blind. Acid can blind and burn. Tools and cable
clamps can make sparks.

Do not smoke. Shield eyes and face. Read instructions.

Pb WARNING: Battery post, terminals, and related accessories contain lead and lead
compounds, chemicals known to the state of California to cause cancer and reproductive
harm.

Wash hands after handling.

1-5
 Terminology D20x22 Series II Navigator HDD Service

DANGER: Entanglement with rotating drill string or drilling tools can kill.

Stay away from rotating drill rod and drilling tool.

WARNING: Use Shutdown Procedure before servicing, cleaning, repairing, or

transporting machine. Refer to "Shutdown Procedure," page 2-1 for instructions.

WARNING: Failure to follow any of the preceding safety instructions or those that
follow within this manual, could result in serious injury or death. This machine is to be
used only for those purposes for which it was intended as explained in the Operator’s
Manual.
General Information

TERMINOLOGY
Function
A function is an operation of the machine generally performed by a specific actuator or
actuators with different operating modes.
Circuit
An identifiable grouping of electrical or hydraulic components that fill a specific role
within a function.

Inputs and Outputs

Inputs and outputs are shown on the schematics and other functional diagrams by
different line styles classified as hydraulic, electrical, pneumatic, and mechanical.
Arrows on the end of the lines represent direction of electrical current flow, hydraulic oil
flow, and air flow.

1-6
D20x22 Series II Navigator HDD Service Terminology

Reference Designators
Reference designators are assigned to each component shown on the schematics and
other reference diagrams.

Each code-like designator identifies a specific component. The designator is comprised

of an uppercase letter or letters followed by a number. The letters identify the type of
component and the number specifies the exact component.

Diagrams and Schematics

Functional diagrams, including schematics, wire harness connections, and hydraulic
hose connections, are located throughout the chapters. The diagrams represent function
circuitry and components. Large format schematics and diagrams are located in the
addendum section in the back of manual.

General Information
Chapter Organization
Other than the general and the machine information (chapters 1 and 2), the manual is
divided up into chapters based on machine functions.

Overview Each chapter starts with an overview which consists of a list of functions and
components, along with graphics depicting component locations and hydraulic hose
connections. Some general information on troubleshooting, test equipment,
specifications and pretesting inspections is also given.

Function Theory Theory of operation for each function begins by listing the required operating conditions
that must be met before normal operation can occur. These would typically include any
safety interlocks that must be in a specific position and the position a switch, control
lever, or other control device must be in to actuate the function.

The normal operation will describe what happens when the controls are actuated, and
how components that comprise that function will operate together to achieve the desired
work. Illustrations, along with the text, will aid in understanding how these functions
work.

Troubleshooting/ The troubleshooting/testing that follows the normal operation will describe how to test
Testing suspected faulty circuits and positively determine which components have failed.

1-7
 Troubleshooting Guidelines D20x22 Series II Navigator HDD Service

Repair When it is determined through troubleshooting that components are malfunctioning, the
repair sections at the end of the chapters contain detailed instructions on how to repair or
replace each component and any special steps or procedures needed before returning the
machine to service.

TROUBLESHOOTING GUIDELINES
Problem-Solving Analysis
First, look at the overall condition of the machine functions and determine whether a
technical problem even exists.

Rule Out Operator The operator may not be familiar with machine interlocks that must be in the appropriate
Error position to allow a certain function to perform. In other words, the operator may not
thoroughly understand the theory of operation.

Ensure you are familiar with the interlocks and verify with the operator that all
interlocks are satisfied, that any E-stop switches are open and other simple items. Refer
to "Machine Interlocks," page 2-13 to see the list of interlocks used on this machine.
General Information

Define the Problem Once operator error is ruled out, analysis begins by asking questions and making
observations as follows:

• Discuss the defect with the operator. Learn what actuator or device is not working
and whether it is too slow, too fast or not working at all.
• Ask if the operator has recently used all the other actuators and whether they seemed
to be working normally. If not, ask the operator to try to use these actuators. If there
are multiple problems, there could be a common cause to all of them.
• If possible, inspect the machine. Verify that the problem is not something obvious,
like low hydraulic fluid, broken lines or wires. If you cannot personally inspect the
machine (such as when speaking over the phone), ask the operator to check for these
simple problems. Many problems are solved this way.

• Ask other questions to further define the problem, such as:

—Did the problem appear suddenly, or did machine performance deteriorate over
time?
—When was the problem first noticed, and had there been any changes made to the
machine or the working conditions prior to the problem’s appearance?
—Were any odd smells, sounds or machine actions noticed at the same time as the
problem?
Continued on next page...

1-8
D20x22 Series II Navigator HDD Service Troubleshooting Guidelines

• —Is the problem intermittent or continuous?

—If intermittent, does it occur when the machine is cold, or fully warmed up?
—Does it occur in cold weather, hot weather, dry weather, humid weather?
• Compare the problem with others from past experiences on this machine or
machines similar to this one.
• Make an overall observation of the situation, noting symptoms and relevant
changes.

Research the Familiarize yourself with the machine by reading the general and machine information
System chapters.

These chapters explain in detail how the machine is comprised of multiple separate
functions and circuits, as well as common functions and components that are shared by
all.

If you are not familiar with, or have limited knowledge of the machine’s functions, read
the theory of operation for all or selected functions.

General Information
Begin troubleshooting by doing the following:

• Describe and compare the problem situation with known operating

conditions prior to breakdown.
• Describe all known differences, such as symptoms, noises, and smells noticed when
the failure occurred.
• Note which functions or circuits appear to behave normally and which do not.
After doing the problem-solving analysis and noting the findings, use the observations
to decide how best to determine which circuits to investigate.

NOTE: The troubleshooting procedures in this manual cover the electrical and
hydraulic circuits. Ensure a mechanical problem is not the cause of the failure before
using the troubleshooting procedures.

All functions with hydraulic circuits share the fluid conditioning components. If all
those functions experience related problems, these components should be investigated.

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 Troubleshooting Guidelines D20x22 Series II Navigator HDD Service

Electrical Troubleshooting
Common Electrical Listed below are some common problems to consider when troubleshooting the
Problems electrical circuits:

• Ground
Characteristic of ground problems can be no circuit or component function or
intermittent function. Ground problems can be blamed for about 50% of all electrical
problems.

• High Resistance
A characteristic of high unwanted resistance is lower than normal circuit current. Higher
than normal resistance in a circuit will result in a lower circuit current. This can be
caused by loose, corroded, or oily terminals and connections on wire and cables, broken
strands in wire, or a poor ground connection.

Measurements taken with a multimeter can be used to troubleshoot for unwanted

resistance. Use the meter to test for lower than normal battery voltage (voltage drop)
while moving to accessible points in the circuit wiring.
General Information

• Open Circuit
Characteristics of an open circuit are zero current, infinite resistance, and higher than
normal voltage. An open circuit can be found either on the voltage side or the ground
side of a circuit. If there is an open anywhere in the circuit, the current path is broken
and current will cease to flow through the circuit.

An open circuit can occur when a component fails internally, a wire or cable is broken or
burned through or becomes detached, or when pins inside a connector do not make
contact.

In a normal working circuit, voltage is applied to the resistive load where it is dropped
proportionately over each resistor in the circuit. The amount of voltage drop is
dependent on the value of each resistor. Open circuits cannot drop voltage.

Although, troubleshooters may find full battery voltage all the way to the open part of
circuit. Full battery voltage can also be found on the ground side of the circuit if the
circuit is open near the battery negative terminal.

Measurements taken with a multimeter can be used to troubleshoot an open circuit. Use
the meter to test for voltage while moving to accessible points in the circuit to find the
open and isolate the failed component or wire harness section.
Continued on next page...

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D20x22 Series II Navigator HDD Service Troubleshooting Guidelines

• Short Circuit
Characteristics of a short circuit are higher than normal current and zero resistance. A
short circuit can be caused by a component being subjected to heat and vibration as it
ages. Over time this can cause abrasions in the insulation on insulated components.
Exposed wires can provide a short path for current, reducing the resistance that was
designed into the circuit(s).

The resistance lowers causing the current to increase to a level higher than the circuit
fuse was designed to handle, resulting in a blown fuse. The source of the short must be
fixed or the fuse will continue to trip.

Basic Hydraulic Troubleshooting

There are some basic hydraulic troubleshooting procedures that should be reviewed
when evaluating a machine with substandard performance. Many times machine
performance can be corrected by using the chart below to evaluate hydraulic
performance.

General Information
Possible Problem Possible Effect What to do

hydraulic oil level Low hydraulic oil level can cause Fill hydraulic oil to correct level.
low higher than normal oil temperatures, Look for leaks in hydraulic system.
slow or jerky actuator movement, or
pump cavitation.
plugged suction A plugged suction screen will cause Clean suction screen. The hydraulic
screen machine operation problems similar to tank may need to be cleaned and oil
the ones listed for low oil levels. If replaced.
allowed to continue, it will result in
damage to the pump which will
eventually cause extensive damage to
other hydraulic system components.
engine RPM too low Hydraulic functions that rely on Check engine RPM while operating
maximum pump flow like the ground under load. Engine air intake restriction
drive, or drill rotation circuit may have or fuel delivery problems are major
slow operation since maximum pump causes of poor engine performance.
output is reduced when RPM is
reduced.
hydraulic oil A dirty oil cooler or other conditions Check hydraulic oil cooler for
overheating causing overheating of the hydraulic oil blockage and clean if necessary.
can cause various problems.

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 Troubleshooting Guidelines D20x22 Series II Navigator HDD Service

Mechanical Component Inspection

Initial inspection of machine includes a check for mechanical malfunctions, such as
defective bearings, binding linkages, and loose fasteners.

Hydraulic Troubleshooting
Leakage Path The hydraulic troubleshooting procedures are based on leakage path analysis. Using
Analysis these methods, components are tested under no-load then full-load. The measurements
taken from the test equipment are compared to the standard specifications and tolerances
listed at the beginning of each subsystem troubleshooting chapter.

The specifications and tolerances give values indicating the nominal, minimum, and
maximum operating parameters.

High leakage will cause system overheating and/or a decline in actuator speed. The
amount of leakage is influenced by four factors:

• pressure difference across clearances

General Information

• oil viscosity
• temperature
• size of clearances
NOTE: Clearance-related problems are generally viscosity sensitive. Increased
leakage will be less obvious when the fluid temperature is low and will increase as the
fluid temperature increases.

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D20x22 Series II Navigator HDD Service Troubleshooting Guidelines

Pumps and Motors All pumps and motors have internal clearances (internal leakage), but some design types
have less leakage than others of the same displacement. Piston pumps or motors leak
less than gear or gerotor pumps and motors.

The general rule used for expected leakage is:

Theoretical flow is equal • Piston pumps and piston motors are expected to lose about 3% of theoretical flow at
to displacement times normal working pressures. This is a 97% volumetric efficiency.
input shaft speed; i.e.,
CID X RPM. • Gear pumps and motors are expected to lose about 20% of theoretical flow at
normal working pressures. This is an 80% volumetric efficiency. (This rises to 90%
Example: A pump with a if the gear pump has pressure-compensated wear plates.)
3.0 in3 displacement,
turned at 2500 rpm, has Through normal wear over time, the clearances between the moving parts in the pump
a theoretical flow of get larger, allowing more internal leakage. Eventually, the clearances are large enough
7500 in3/min. that the pump or motor is worn out.

The general rule used for determining if a pump or motor is worn out is:

• When volumetric efficiency for the pump or motor declines to 70% or less, the
pump or motor should be replaced.

General Information
The most common symptoms associated with excessive pump/motor leakage are:

• A loss of actuator speed as the fluid temperature increases.

• A moderate to high increase in the operating temperature of the fluid.
• Actuator stalling at low pump or motor speed.
• An increase in case pressure which could result in shaft seal leakage.
Any increase in internal leakage will result in increased flow into case drain lines of
externally drained pumps and motors. If case drain flow increases, case pressure will
increase because of higher flow resistance through drain port in the housing and case
drain lines. Excessive case pressure could result in shaft seal failure and case seal
leakage.

The most common symptoms associated with excessive pump/motor case pressure are:

• Shaft seal leakage

• Catastrophic shaft seal failure
• Case seal leakage
• Moderate to high increase in the operating temperature of the fluid

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 Troubleshooting Guidelines D20x22 Series II Navigator HDD Service

Directional Control Directional control valves have radial clearances between the valve bore and spool of
Valves between 5 to 15 micrometers (μm). If fluid is heavily contaminated with particles which
are equal in size, the particles will cause abrasive wear. Abrasive wear will gradually
increase the radial and diametrical clearances, resulting in increased cross-port leakage.

The most common symptoms associated with excessive directional control valve
leakage are:

• Increased actuator drifting while directional control valve is in the

NEUTRAL position.
• Moderate to high increase in the operating temperature of the fluid.
• Loss of precise position control.

Sequence Valves The most common symptoms associated with excessive sequence valve leakage are:

• Actuators do not operate sequentially.

• Actuators fail to respond (lock up) when control valve is actuated.
• Actuators fail to allow the actuator to move in opposite direction (reverse flow).
• Actuators operate erratically.
General Information

Lock Valves The most common symptoms associated with a excessive lock valve leakage are:

• Actuator appears to lock up when control valve is actuated.

• Actuator load drifts when control valve is in NEUTRAL.

Cylinders Hydraulic cylinders consist of a moveable piston and rod assemblies. Pistons have seals
to prevent leakage across the piston.

The most common symptoms associated with excessive cylinder leakage are:

• Cylinder fails to respond when directional control valve is actuated.

• Reduced cylinder rod velocity in one or both directions of travel.
• Moderate to high increase in the operating temperature of the oil.
• Cylinder rod speed reduction as the load increases.
• Actuator drifts when the directional control valve is in NEUTRAL position.
• Cylinder rod extends regardless of which port the oil enters.

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D20x22 Series II Navigator HDD Service Troubleshooting Guidelines

Required Tools
• Digital multimeter—for performing voltage, current and resistance tests
• Calculator—for doing simple arithmetic quickly and accurately
• Pyrometer or thermometer with a magnetic base—for temperature readings
• Pressure gauges—for measuring system pressure
• Vacuum gauge—for measuring inlet pressure
• Flow meter—for measuring system flow
• Needle valve—for imposing an artificial load
• Combination flow meter/needle valve/pressure gauge—for measuring flow,
pressure, and imposing artificial loads with one tool

Hydraulic Connections

WARNING: Pressurized fluid can penetrate body tissue and result in serious injury or
death. Leaks can be invisible. Keep away from any suspected leak. Relieve pressure in the

General Information
hydraulic system before searching for leaks, disconnecting hoses, or performing any other
work on the system. If you must pressurize the system to find a suspected leak, use an
object such as a piece of wood or cardboard rather than your hands. When loosening a
fitting where some residual pressure may exist, slowly loosen the fitting until oil begins to
leak. Wait for leaking to stop before disconnecting the fitting. Fluid injected under the skin
must be removed immediately by a surgeon familiar with this type of injury.

Avoid Trapped Never disconnect hoses or lines, unless the pressure has been relieved and the engine is
Pressure shut down.

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 Troubleshooting Guidelines D20x22 Series II Navigator HDD Service

Avoid Oil
Contamination
Warranty claims may be Use care to avoid allowing dirt, dust or debris to enter the hydraulic system.
denied if damage is Contaminated oil will ruin a pump in a short amount of time.
caused by contaminated
hydraulic fluid. • Clean dirt from hose connections before loosening any connection.
• Use new, clean plugs to plug disconnected hoses. If clean plugs are not available,
place plastic bags (such as sandwich bags) over the ends of hoses and hold them in
place with rubber bands.
• When adding oil, use new oil filtered through a 5-micron absolute filter. (New oil is
full of particles from metal storage containers and is not intended to be added
directly to the hydraulic tank.)
• One source of contamination is dirt adhering to the cylinder rod and being drawn
into the system when the rod is retracted. The wiper seals clean dirt from the rod as
it retracts, but scratches in the rod will allow dirt past the wipers. Take care to avoid
scratching the cylinder rods and regularly inspect rods for scratches. Draw your
fingernail across any scratches. If the scratch is deep enough to catch the fingernail,
the scratch should be polished out with fine emery cloth, or the rod replaced.
General Information

Connecting Flow Flow meters measure flow in one direction only. An arrow on the flow meter indicates
Meters the direction. The test setup instructions will state which way the flow arrow must point.

Often, adapters will be needed to plumb the flow meter into the line. It is important that
the flow through the meter is not restricted (unintentionally) by using a flow meter or
adapters that are of smaller diameter than the hose. Use a larger diameter flow meter if
needed, and use adapters to connect the smaller diameter hose to the larger diameter
flow meter.

Use a flow meter that is rated to safely withstand the pressure in the circuit.

Connecting a Needle valves are used to impose artificial loads on pumps so the performance of the
Needle Valve pump can be accurately measured. By slowly closing the needle valve while watching
the pressure gauge, you can easily set the pressure as needed for the flow measurement.

As with flow meters, you can safely use a larger diameter needle valve, but you must not
use smaller diameters.

NOTE: Do not attempt to use a ball valve in place of a needle valve. The ball valve is
not precise and tends to snap closed by itself when higher pressures are reached. This
will send a destructive pressure spike back through the system.

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D20x22 Series II Navigator HDD Service Troubleshooting Guidelines

Connecting Pressure gauges are selected according to the expected maximum pressure to be
Pressure Gauges observed during the test. Since the gauge is most accurate at the middle of its range, read
through the test to determine the expected maximum pressure and double that amount.
Thus, if you expect to see 3000 psi as the greatest pressure during the test, select a 0–
6000 psi gauge or a
0–7500 psi gauge.

IMPORTANT: If the gauge ever “pegs” (indicates pressure at the maximum reading),
the gauge is ruined. Discard it immediately so that another technician does not use it and
receive erroneous readings.

Thermometer or Pyrometer
The magnetic-base thermometer is placed on the oil tank to determine the temperature
of the oil. Allow time for the thermometer to react before taking a temperature reading.

The pyrometer is a non-contact thermometer. Place the projected red dot on the surface
and wait at least one second. The temperature of the surface is shown in the indicator

General Information
window.

Several readings may be required during the same test. It is important to take the
readings with the projected dot focused on the same spot on the surface.

Digital Multimeter
The multimeter is used to measure voltage, current, and resistance. It is also used to test
wires for continuity.

Measuring Voltage Voltage is defined as a difference in electrical potential between two points. If needed,
see the instruction booklet for your multimeter to determine proper settings. With the
multimeter set to measure volts DC in the appropriate setting do the following:

1. Turn off power to circuit or device.

2. Connect positive (red) lead to multimeter’s voltage or VΩ port. Place red probe on
wire or contact delivering power to device.
3. Connect negative (black) lead to common or COM port. Place black probe on wire
or contact leading to ground for device. In some cases you may place black probe on
metal structure of vehicle chassis (multimeter is in parallel with circuit).
4. Turn on power to device.
The multimeter will indicate the voltage available to power the device.

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 Troubleshooting Guidelines D20x22 Series II Navigator HDD Service

Measuring Resistance, measured in Ohms (Ω) is defined as the opposition to current flow. Set the
Resistance multimeter to measure resistance. If needed, see the instruction booklet for your
multimeter to determine proper settings. Then do the following:

1. Turn off power to circuit or device.

2. Connect positive (red) lead in multimeter’s voltage or VΩ port. Place red probe on
wire or contact delivering power to device.
3. Connect negative (black) lead in common or COM port. Place black probe on wire
or contact leading to ground for device (multimeter is in parallel with circuit).
The multimeter sends a small current through the device and indicates the amount of
resistance encountered. Resistance (Ohms or Ω) greater than or less than published
tolerances indicates the device is damaged and should be replaced.

Testing for Continuity is defined as the presence of a complete pathway for the flow of current.
Continuity With the multimeter set to test continuity, do the following:

1. Turn off power to device or circuit.

General Information

2. Disconnect section of harness in question.

3. Place one probe on one end of wire or terminal of device. Place other probe on other
end of same wire or opposite terminal of same device.
An indication of zero or very low resistance (Ohms or Ω), indicates continuity (good
wire or closed switch). High resistance or an indication of “OL” (overload) means there
is no electrical contact between the two probes, i.e., the wire is broken or the switch is
open. In this manual, the results of a continuity check are described as “continuity” or
“open.”

Some multimeters or continuity testers produce a beep or illuminate a bulb to indicate

continuity.

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D20x22 Series II Navigator HDD Service Repair Guidelines

Measuring Current Current, or amperage, is defined as the flow of electrons. Set the multimeter to measure
amps DC or milliamps DC. If needed, see the instruction booklet for your multimeter to
determine proper settings.) This involves plugging the leads to the proper ports in the
multimeter and setting the knobs and/or range switches correctly for measuring the
expected amount of current (microamps, milliamps or amps). Then do the following:

1. Turn off power to circuit or device.

2. Unplug device from wiring harness and install proper breakout box.
3. Disconnect exposed connector for desired wire.
4. Place red probe on one of exposed connectors for wire.
5. Place black probe on other exposed connector for wire (multimeter is in series with
circuit).
6. Turn on power to device.
The multimeter indicates the current in amps (A), milliamps (mA) or microamps (μA).

General Information
REPAIR GUIDELINES
Shop Requirements
Special Tools & Test To perform some tasks, special tools— available through Vermeer—may be required.
Equipment These tools, are specified at the beginning of the procedure where they are needed.

Refer to the Recommended Service Tools Users Guide (Vermeer P/N 105400T69) for
special tools and test equipment.

Personnel and Lifting Requirements

Review each task to determine the number of personnel needed for safe completion.

Determine if suitable lifting devices are needed to safely lift or lower the component.

20General Information

Replacement Parts
Part Numbers/Hose Refer to the most current D20x22 Series II Parts Manual, order number 105400ZKO
Lengths/Fitting for part numbers, hose lengths, and fitting orientations.
Orientation

Parts Ordering Contact the Vermeer Parts Center with part number information to order replacement
components.

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 Repair Guidelines D20x22 Series II Navigator HDD Service

Torque Values
Repair procedures in this manual will list torque values for any part that needs to be
tightened to an other-than-standard torque value. For (standard) torques on other parts,
refer to the torque tables, given in the Industrial Dealerships Technician’s Shop
Manual, order number 105400V80.
General Information

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D20x22 Series II Navigator HDD Service Shutdown Procedure

Chapter 2: Machine Information

SHUTDOWN PROCEDURE
Stopping the Machine
When stopping the machine, use the following shutdown procedure:

1. Shut off drilling fluid pump.

2. Reduce engine speed to idle.
3. Shut off engine and remove key.
For your safety and the safety of others, use shutdown procedure before servicing,
cleaning, unclogging, or inspecting machine.

IMPORTANT: If working on the drill string or drill tools at a remote location away
from the machine, follow the “Remote Lockout Procedure” or the “Lockout Procedure -
Without Remote Lockout System” as discussed in the D16x20 Series II/D20x22 Series
II Operator’s Manual.

Machine Information
A variation of the above procedure may be used if instructed within this manual or if an
emergency requires it.

Remote Lockout System - Shut Down

IMPORTANT: If the machine is shut down in Lockout mode, the remote unit must be
available upon machine start-up to cancel Lockout mode and enter Run mode.

1. Shut off machine and remove key.

2. Press Power Off Button and hold for 2 seconds to shut off remote transmitter.
3. Remove battery pack from remote transmitter and install in charger.
4. Return remote transmitter to docking station.

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 Starting Procedure D20x22 Series II Navigator HDD Service

STARTING PROCEDURE
WARNING: Read Operator’s Manual and safety signs before operating machine.

Starting the Engine

1. Shut off drilling fluid pump.
2. Set throttle at IDLE.
3. Ensure joysticks are in NEUTRAL.
4. Start engine. Shut off engine if oil light does not go out within 15 seconds.
IMPORTANT: Never run starter motor for more than 30 seconds at a time. Allow
starter motor to cool 2 minutes between attempts.

5. Adjust throttle to get an even idle speed and allow engine to warm up for 3–5
minutes.
IMPORTANT: Once engine reaches operating temperature, do not idle engine for
Machine Information

more than 5 minutes. Low combustion chamber temperatures can cause crankcase oil
dilution due to fuel not burning completely and permits formation of gummy deposits on
valves, pistons, and piston rings.

6. Turn remote lockout unit on.

7. Press run button and hold for 2 seconds to select Run mode.

Cold Weather Starting

Engine Before operating in cold weather, refer to the Engine Operation Manual for
recommended engine oil, fuel, and starting procedures.

IMPORTANT: Do not use starting fluid or ether.

On a cold engine, turn key to HEAT position for approximately five seconds so that
glow plugs activate.

Hydraulic Fluid Refer to "Fuel and Lubricants," page 2-12 for recommended hydraulic fluids.

When using ISO 68 hydraulic fluid below +23°F (-5°C) or ISO 100 hydraulic fluid
below +41°F (+5°C), warm up engine.

NOTE: Slow engine down, if hydraulic pump squeals because it does not get enough
oil.

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D20x22 Series II Navigator HDD Service Starting Procedure

Operation Overview
Hydraulic fluid distribution components route hydraulic fluid flow to and from the
various function circuits. As hydraulic fluid passes through components in the hydraulic
system it produces heat and warms the fluid. The hydraulic fluid distribution
components route the oil through the oil cooler and filters to clean and cool the
hydraulic fluid.

Remote Lockout, if engaged, prevents electrical power from reaching the rotation,
thrust/pullback, and drilling fluid functions that would result in movement of the drill
string or flow of drilling fluid.

The Strike Alert system provides an audible warning to the operator if the drill string
contacts an electrical source.

Legend for Reference Designators

The following is a list of all designators used on this machine. The list is divided
according to chapters and functions.

Machine Information
Chapter 2 - Machine • C148 Controller A5, including:
• CAN Bus Connector P69
• CAN Bus Resistors R2 and R3
• Display DP-10 E7
• Thrust/Pullback Joystick A1
• Rotation Joystick A2

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 Starting Procedure D20x22 Series II Navigator HDD Service

Chapter 3 - Power • Engine ENG1

• Battery BT1
• Alternator G1
• Starter Motor M1
• Throttle Actuator M2
• Fuses F1–F11
• Circuit Breakers CB1–CB2
• Auxiliary Jack J2
• Universal Locator Charger J3
• Start Relay K1
• Throttle Relays K2 and K3
• Glow Plug Relay K5
• Fuel Stop Solenoid L32
• Fuel Pump Motor M3
• Fuel Sender R1 and Resistors R4 and R5
• Tachometer E1
Machine Information

• Hourmeter E2
• Glow Plugs E9
• Switches S1–S3, S15, S16, S24, S37, S38 and S39

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D20x22 Series II Navigator HDD Service Starting Procedure

Chapter 4 - • Rotation/Thrust Pump PMP1, including:

Hydraulic Fluid • HPRV Valves DV8–DV11
Distribution
• EDC Solenoids L14, L15, L18 and L19
• PFC Pump PMP2
• Charge Pump PMP4
• Charge Pump Filter FL1
• Hydraulic Tank RES1, including:
• Return Manifold A17
• Return Filter FL2
• Oil Level Indicator GA1
• Oil Cooler HE1
• Diverter/Drilling Fluid Valve A9, including:
• Check Valve CV2
• Cartridge Valves DV16–DV18
• Relief Valve PV4
• Pressure Gauge E12

Machine Information
• Solenoids L17, L20 and L21
• Load Sense Cartridge Valve DV24
• Solenoid L9
• Suction Manifold A15
• Switches S10 and S11

Chapter 5 - • Stakedown Valve Assembly A12, including:

Stakedown • Directional Valves DV25–DV28
• Check Valves CV3 and CV4
• Solenoids L7, L8 and L10–L13
• Stakedown Motors MH7 and MH8
• Stakedown Cylinders CY4 andCY5
• Switches S25–S27

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 Starting Procedure D20x22 Series II Navigator HDD Service

Chapter 6 - Stabilizer • Transport Valve Assembly A11, including:

• Directional Valves DV22 and DV23
• Relief Valve PV5
• Stabilizer Cylinders CY2 and CY3
• Lock Valves FV2 and FV3

Chapter 7 - Rack • Transport Valve Assembly A11, including:

Angle • Directional Valve DV21
• Relief Valve PV5
• Rack Angle Cylinder CY1
• Lock Valve FV1

Chapter 8 - Ground • Transport Valve Assembly A11, including:

Drive • Directional Valves DV19 and DV20
Machine Information

• Relief Valve PV5

• Torque Limiter/Loop Flush Valve Assembly A7, including:
• Directional Valve DV5
• Track Motors MH5 and MH6
• 2-Speed Solenoid L34 and Switch S40

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D20x22 Series II Navigator HDD Service Starting Procedure

Chapter 9 - Rotation • Rotation/Thrust Pump PMP1

• Rotation Valve Assembly A6, including:
• Directional Valves DV1–DV3
• Relief Valve PV1
• Torque Limiter/Loop Flush Valve Assembly A7, including:
• Check Valve CV1
• Directional Valves DV4–DV7
• Relief Valves PV2 and PV3
• Solenoids L27, L28 and L33
• Rotation Motor MH1
• Right Joystick Assembly A2, including:
• Position Sensor B7
• R.A.T.T. PPU B4
• Rotation Pressure Sensor B8
• Rotation Gauge E5
• Display DP-10 E7, including:

Machine Information
• Switches S4–S6 and S8
• Torque Limiter Valve Gauge E10
• Switch S13

Chapter 10 - Thrust/ • Rotation and Thrust Pump PMP1

Pullback • Thrust/Pullback Valve Assembly A8, including:
• Directional Valves DV12–DV14
• Solenoid L29
• Thrust/Pullback Motors MH2–MH4
• Left Joystick Assembly A1, including:
• Position Sensor B6
• Thrust/Pullback Pressure Sensor B5
• Thrust Gauge Light E4
• Thrust/Pullback Pressure Gauge E11
• Switches S9, S31, S32, S34 and S35

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 Starting Procedure D20x22 Series II Navigator HDD Service

Chapter 11 - Rod • Rod Loader Valve Assembly A14, including:

Loader • Directional Valves DV34 and DV35
• Check Valve CV8–CV12
• Solenoids L2–L5
• Rod Lift Cylinders CY10–CY11
• Rod Lift Motor MH9
• Switches S17–S20 and S33

Chapter 12 - Vises • Vise Valve Assembly A13, including:

• Directional Valves DV29–DV33
• Solenoids L22–L26
• Check Valves CV5–CV7
• Pressure Relief Valve PV6
• Front Vise Cylinder CY7
• Rear Vise Cylinder CY8
Machine Information

• Rear Vise Rotation Cylinder CY9

• Switches S21 and S22

Chapter 13 - Rod • Vise Function Components

Greaser • Greaser Valve Assembly A16, including:
• Directional Valve DV36
• Solenoid L1
• Greaser Cylinder CY12
• Greaser Switch S12

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D20x22 Series II Navigator HDD Service Starting Procedure

Chapter 14 - Drilling • Drilling Fluid Pump PMP3

Fluid • Drilling Fluid Pump Motor MH10
• Diverter/Drilling Fluid Valve Assembly A9, including:
• Directional Valve DV18
• Solenoid L17
• Relief Valve PV4
• Check Valve CV2
• Fluid Shutoff Control Valve A19, including:
• Directional Valve DV15
• Solenoid L16
• Ball Valve A20
• Ball Valve Cylinder CY6
• Drilling Fluid Pressure Gauge Light E6
• Switches S7 and S14
• Drilling Fluid Motor PPU B3

Machine Information
Chapter 15 - Remote • Remote Lockout Base Module A4
Lockout • Remote Unit Battery Charger J1
• Antenna E1
• Remote Unit E8
• Remote Lockout Horn B2
• Remote Lockout Mode Jumper J4
• Hydraulic Lockout Plug P74
• Engine Shutdown Lockout Plug P75

Chapter 16 - Strike • Strike Alert Module A3

Alert • Strike Alert Coil L6
• Strike Alert Stake E3
• Strike Alert Horn B1

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 Specifications D20x22 Series II Navigator HDD Service

SPECIFICATIONS
Machine Reference and Orientation

Rear Front

Right
Left, right, front, and rear of the machine are determined by facing the power vises
while seated at the controls.
Machine Information

General Machine Specifications

Machine Dimensions Empty Rod Box (with Rod)
Approximate Weight 8600 lb (3900 kg) 10,600 lb (4808 kg)
Overall Length 16 ft 8″ (50.8 cm)
Overall Width 50.5″ (128 cm)
Overall Height (at top of exhaust stack) 75″ (191 cm)

Hydraulic Specifications
Rotation/Thrust Pump Flow 33gpm (125 L/min) @2400 rpm
System Pressure 3335 psi (230 bar) relief
Charge Pressure Relief 313 psi (21.5 bar)
System Relief 3335 psi (230 bar) relief

Continued on next page...

2-10
D20x22 Series II Navigator HDD Service Specifications

Electrical Specifications
Battery One 12-Volt BCI Group Size 31
Cold Cranking Amps 950 CCA
Circuit Breaker 1 60-Amp
Circuit Breaker 2 60-Amp

Fuse Ratings
F1 - Lights 15-Amp
F2 - Not Used
F3 - Display 15-Amp
F4 - Throttle 15-Amp
F5 - Left Joystick 15-Amp
F6 - Right Joystick 15-Amp
F7 - Controller 20-Amp
F8 - Switches and PPUs 15-Amp
F9 - Remote Lockout 15-Amp
F10 - Stakedown 15-Amp
F11 - Aux. Power 15-Amp

Machine Information
Engine Specifications
Model Kubota V3800 DI-T
Maximum power 83 hp (62 kW) at 2200 rpm
Fuel type/capacity diesel, 25 gal (95 L)
Oil capacity 1.85 gal (7 L)
Maximum engine inclination * 30° all directions
Mixture of 50% water and 50% ethylene glycol-base antifreeze to
Cooling Medium
-34° F (-37°C) protection
Engine coolant capacity 2.7 gal (10.3 L)
Alternator 90-Amp

* Engine operating angles do not indicate safe machine operating angles.

2-11
 Specifications
Fuel and Lubricants
Lubricant
Engine Oil
Hydraulic Fluid
Vermeer HyPower 46 or
Vermeer HyPower 68 or
Vermeer HyPower 100
All-Purpose Gear Lube
General Lubricating Oil
Vermeer Xtra Gold 10W30
Grease
Vermeer Ultra LC Grease
Machine Information
Drilling Fluid Pump Crankcase
Vermeer Xtra Gold 40
Drill Rod Thread Compound
2-12
D20x22 Series II Navigator HDD Service
Capacity Specifications / Notes
Refer to engine An Engine Operation Manual is supplied with each machine.
specifications Refer to the manual for engine service requirements.
Hydraulic system: ISO 46: -13° – 86°F (-25° – 30°C)
ISO 68: -4° – 104°F (-20° – 40°C)
40 gal (151 L)
ISO 100: 14° – 122°F (-10° – 50°C)
Tank: 27 gal (102 L) Use caution not to get dirt or other contaminants into the
system(s). Filter all fluid through a 5-micron filter before
adding to tank.
IMPORTANT: Use of any oils other than those recommended
without written factory approval will jeopardize warranty.
Rotation Gearbox:
Oils must conform to API GL5 or MIL-L-2105D specifications.
Up to Check Plug
-20° – 100°F (-30° – 40°C): 80W-90
Level
-20° to 100°F (-30° – 40°C): 80W-90
20° to 120°F (-10° – 50°C): 85W-140
As required SAE10W30
As required Lithium complex, extreme pressure NLGI Grade 2
To minimize condensation in bearings, grease machine after
it is shut down for the day.
Fittings and grease applicator nozzle must be clean before
applying grease. Replace all missing fittings.
4.5 qt (4.3 L) SAE- 40
(Classification MM or better)
Plusco Thread Compound (#235983-001)
As required
API Bulletin 7A1. This requires the compound to contain a
copper base to withstand high pressures and remain in the
threads.
D20x22 Series II Navigator HDD Service Machine Interlocks

MACHINE INTERLOCKS
An interlock is a component or an arrangement of components by which the functioning
of one component is controlled by the functioning of another. These separate
components when in predetermined positions (closed or opened), will complete or
interrupt an electrical circuit for operator safety purposes.

Engine Start Interlocks

The interlocks listed below must be positioned as follows to allow engine starting:

• Emergency stop switch S39 located at the rear transport control panel must be
closed (pulled out).
• The battery ground disconnect switch S1 in the engine compartment must be closed
(turned to the right).
• If the machine was shut down in the Remote Lockout mode, the remote unit must be
available to start the engine if shut down in engine lockout mode or to turn the
rotation, thrust and pullback, or the drilling fluid functions if shut down in hydraulic
lockout mode.

Machine Information
Engine Protection Interlock
• If engine oil pressure falls below 15 psi (103 kPa), the oil pressure warning light
illuminates.
• If engine coolant temperature rises to 220°F (104°C), the coolant temperature
warning light illuminates.

Operator Presence Interlock

• The operator presence switch S11 located under the drill station seat must be closed
(seat occupied). The machine is considered in Drill mode while seat is occupied, and
Transport mode while it is empty. If the seat switch is closed, transport controls will
not function. If the seat switch is open, drill rotation and thrust functions will not
operate.

2-13
 Controller A5 D20x22 Series II Navigator HDD Service

Remote Lockout Interlock

• Remote Lockout disables the drilling controls (rotation, thrust/pullback and drilling
fluid pump) when in Lockout mode. If hydraulic pressure is sensed in the rotation or
thrust/pullback circuits while in hydraulic lockout mode, the Remote Lockout
system will shut down the engine.
The hydraulic functions will not operate until the Remote Lockout controller
receives a RUN signal from its remote transmitter.
If the Remote Lockout system is in engine shutdown mode, the engine can be
started, if the operator is out of the seat (in Transport mode). The engine will shut
off, if the operator is in the seat (in Drill mode).
See Chapter 15 for detailed information on the Remote Lockout function.

CONTROLLER A5
Machine Information

J4 Brown

J1 Gray

J2 Black

J3 Green

The controller on the machine is connected by a CAN bus to the display, the Strike Alert
module, and the Remote Lockout module.

The controller has LEDs on the faceplate that assist in troubleshooting. The controller
A5 is located on the engine cover facing the operator console.

Continued on next page...

2-14
D20x22 Series II Navigator HDD Service Controller A5

Controller Faceplates

3 1 2

Machine Information
Labeled on the controller is the software revision (1), hardware revision (2), and part
number (3) of the controller.

The face of each controller shows a number of LEDs, and each LED is labeled. The
LED labels show their connection. J1 designates the gray connector J1; J2 designates the
black connector J2; J3 designates the green connector J3; J4 designates the brown
connector J4.

LED-A and LED-B indicate the condition of the CAN bus. Flashing green indicates
OK, and flashing red indicates a CAN bus fault. LED-C and LED-D are for
troubleshooting by factory personnel.

LEDs glow for outputs the controller is sending to some device (a solenoid or EDC),
and they glow for inputs the controller is receiving from various switches and sensors.
The first, third and sixth column of LEDs glow outputs. The second, fourth and fifth
column glow inputs.

The LEDs glow green for power from battery. In addition, the LEDs for J1-9, J1-10, J1-
11, J2-1, J2-2, J3-8, J4-6, and J4-7 also can glow red for GND (ground).

2-15
 Controller A5 D20x22 Series II Navigator HDD Service

Troubleshooting at the Controller

Troubleshooting issues associated with the controller can be difficult, as they can be
caused by a faulty wires, a solenoid or other output destination, a source of an input, the
program, or the controller hardware. Follow the steps below when troubleshooting.

1. If the LED for an input is glowing, a electrical signal is being received by the
controller. If not glowing, begin by checking for voltage at the switch.
2. If an output LED is glowing, the controller is sending the signal, but the solenoid or
EDC may not be receiving it. Test for voltage at the solenoid or EDC. If it has
voltage, either the solenoid or EDC has failed or the problem is hydraulic. If no
voltage is found, check continuity from the controller to the device and to ground.
If the output LED is not glowing, check for inputs that need to be available to
produce the desired output. Also, check to see if the output is shorted to ground.
3. Check DP-10 display for fault codes (SPN and FMI). Investigate the input or output
wiring and actuators based on the specific code. Refer to "Key to Fault Codes,"
page 2-21.
4. Connect machine to a computer running VCTool software with the appropriate
.jsym file. The logging and chart features in VCTool can help to determine:
Machine Information

• whether the input or output is within expected range or in the expected state
• whether the input or output is displaying a fault code (SPN and FMI)
• whether other inputs or outputs are out of range or in the wrong state
NOTE: Look at all the other LEDs. Other inputs or outputs can affect what the
controller program is telling the suspect input or output to do. They could also point to a
larger issue that has gone undetected. Look for:

• whether the issue is being seen intermittently or constantly

• whether the issue can be reproduced and recorded for analysis by the factory
• whether the issue is with the CAN line itself.
For more information on how to use VCTool software, refer to Chapter 17.

2-16
D20x22 Series II Navigator HDD Service Controller A5

Key to LEDs
Controller A5 The following tables show C148 Controller pin and LED assignments.
Assignments
Outputs
Pin Wire Number Description
J1-3 730-BR THR EDC+ Thrust EDC+ on PMP1
J1-4 792-GY THR EDC- Thrust EDC- on PMP1
J1-5 731-WH BALL VLVE Ball Valve Solenoid L16
J1-6 790-GN H2O ON Fluid Flow Control Solenoid L17
J1-7 985-YL CAN Hi
J1-8 986-GN CAN Lo
J1-12 370-BK B- GND Ground
J2-3 738-WH ROT EDC+ Rotation EDC+ on PMP1
J2-4 793-BR ROT EDC- Rotation EDC- on PMP1
J2-5 739-GY HYD EN IMP Hydraulic Enable Solenoid L20
J2-6 740-DG TRACK OFF Track Off Solenoid L21
L-V CLOSE Front Vise Clamp Close Solenoid
J3-2 746-TN
L22
L-V OPEN Front Vise Clamp Open Solenoid
J3-3 747-GY

Machine Information
L23
ROD LDR RE Rod Loader Motor Retract
J3-4 804-DG
Solenoid L2
ROD LDR EX Rod Loader Motor Extend
J3-5 803-GN
Solenoid L3
U-V OPEN Rear Vise Clamp Open Solenoid
J3-6 791-BR
L24
J3-9 751A-YL 5V DC Input for 5V Output
U-V CLOSE Rear Vise Clamp Close Solenoid
J4-2 755-WH
L25
J4-3 756-BU U-V OPEN Rear Vise Rotate Solenoid L26
ROT HI-SPD Rotation Speed Control Solenoid
J4-4 757-GN
L27
J4-5 758-BR TRQ LIMTR Torque Limiter Solenoid L28
THR HI-SPD Thrust Speed Control Solenoid
J4-6 759-DB
L29, L30 and L31
J4-7 213A-PK FUEL SOL Fuel Solenoid L32
Continued on next page...

2-17
 Controller A5 D20x22 Series II Navigator HDD Service

Inputs
Pin Wire Number Description
J1-1 129B-OR B+ Power BATT+
J1-9 820-DG REAR STOP Rear Stop Switch S31
J1-10 734-DB REAR SLDN Rear Slowdown Switch S32
ANTICRASH Rod Loader Anti-Crash Switch
J1-11 735-PU
S33
J2-1 736-YL FRONT STOP Front Stop Switch S34
J2-2 737-GN FRONT SLDN Front Slowdown Switch S35
H2O PICKUP Fluid Pump Motor Speed PPU
J2-7 741-BU
B3
J2-8 742-DB ROT DIR Rotation Direction PPU B4
J2-9 743-PU ROT POS Rotation Position PPU B4
J2-10 810-PK RD LDR SW Rod Loader Lift Switch S36
J2-11 400-DB ENG TACH Tachometer
J3-8 750-DB ENG TEMP Coolant Temperature Switch S37
J3-10 752-WH THR PRESS Thrust Pressure Sensor B5
LEFT JSK Thrust Left Joystick Base Sensor
J3-11 753-BU
B6
Machine Information

RIGHT JSK Rotation Right Joystick Base

J3-12 754-PU
Sensor B7
J4-8 745-YL OIL PRESS Engine Oil Pressure Switch S38
J4-9 439-PU TRACK HI-SPD Track 2 Speed
J4-10 213A-PK FUEL LVL Fuel Level
J4-11 214-PU ENG STAT E-stop Switch S39
J4-12 707-TN ROT PRESS Rotation Pressure Sensor B8

NOTE: The Power LED indicates the internal power supply has power and is feeding
the processor.

2-18
D20x22 Series II Navigator HDD Service Display DP-10 E7

DISPLAY DP-10 E7
1

J1 A

J2 B
2

3
Front Rear
The display is connected to the controller by CAN bus. The display sends signals from
switches and the joysticks to the controller. It indicates states, alarms, and faults based
on input from the controller. It also sends signals to the start relay K1 and throttle relay
K3. It is a slave device on the network, which means it performs no logical operations
(all programs run at controller, not here).

The display has two operational messages: CAN bus ERROR and NO Messages. CAN
bus ERROR displays when CAN bus is not connected. NO Messages displays when no
CAN messages are received for one minute.

Machine Information
The display enters self-test mode, when the display is powered up with the Service
Screen Key (1) pressed. Self-test mode allows all the switches to be tested; press a key
on the display and a LED on the controller will illuminate. It also gives the port number
and software of the controller.

Press Service Screen Key (1) once more to enter contrast adjustment mode. Use the
Increase and Decrease Keys (2) to adjust screen contrast and press Enter Key (3) when
done. Press Service Screen Key one more time to enter LED test mode. The LEDs turn
on and off in sequences, then the icons backlight turns on and off, and finally the LCD
backlight turns on and off. If no key is pressed in 60 seconds, the display returns to
normal operation.

The heater has an internal heater that starts in cold temperatures. The display will be
slow to respond until the heater has heated the display.

2-19
 Display DP-10 E7 D20x22 Series II Navigator HDD Service

Display DP-10 E7 The following table shows the display pin assignments.
Assignments
Pin Wire Number Description
J1-1 116B-OR BATT+ PWR
J1-2 232D-YL Glow Plug Light
J1-3 256D-YL Throttle Down Output
J1-4 208-WH Start Signal
J1-7 985-YL CAN LO
J1-8 986-GN CAN HI
J1-9 704-TN Cruise Resume
J1-10 702-DB Rotation Speed High/Low
J1-11 706-GY Thrust Speed High/Low
J1-12 312-BK GND
J2-1 716-GN Rod Loader Extend
J2-2 701-GY Cruise On/Off
J2-3 715-BR Rod Loader Retract
J2-4 710-PK Water Pump On/Off Hold for Full Flow
J2-5 714-DB Water Flow Control Inc/Dec
J2-6 711-TN Cruise Thrust Inc/Dec
J2-7 712-GY Cruise Rotation Inc/Dec
Machine Information

J2-8 713-PU Hydraulic Enable Switch

J2-9 202-WH Seat Switch
J2-10 708-BU Rear Vise Open/Close
J2-11 207-WH Key Start
J2-12 707-DG Front Vise Open/Close

2-20
D20x22 Series II Navigator HDD Service Display DP-10 E7

Key to Fault Codes

Fault codes refer to inputs from a sensor to
the controller or outputs from the controller to
a device, such as a solenoid or indicator light.
1
The controller is sensing the voltage used,
and comparing it to normal voltage required
for the device. If it is out of a normal range,
the fault code for the device (1) is listed on
the display.

When the code appears, it means that device—or the wiring to that device—is faulty.
There is a broken wire (discontinuity), a short to ground, or a short to power. The code
only appears when the controller is sending an output signal to that device, as indicated
by the correct output LED being lit.

Controller A5

Code Description
100-4 Oil Pressure Sensor Low - Voltage below normal, or shorted to ground
175-3 Engine Temperature Sensor High - Voltage above normal, or shorted

Machine Information
to high source
931-5 Fuel Solenoid Output - Current below normal or open circuit
2231-9 Remote Lockout Offline - Abnormal update rate
2233-9 Strike Alert Offline - Abnormal update rate
520192-3 Right Joystick Voltage High - Voltage above normal, or shorted to high
source
520192-4 Right Joystick Voltage Low - Voltage below normal, or shorted to
ground
520192-14 Right Joystick Voltage In Range With Ignition Switch On - Data valid,
but not normal relative to other inputs - Moderately severe level
520194-3 Left Joystick Voltage High - Voltage above normal, or shorted to high
source
520194-4 Left Joystick Voltage Low - Voltage below normal, or shorted to ground
520194-14 Left Joystick Voltage In Range With Ignition Switch On - Data valid, but
not normal relative to other inputs - Moderately severe level
520230-3 Rotation Pressure Transducer Voltage High - Voltage above normal or
shorted to high source
520230-4 Rotation Pressure Transducer Voltage Low - Voltage below normal or
shorted to ground
520231-3 Thrust Pressure Transducer Voltage High - Voltage above normal, or
shorted to high source
520231-4 Thrust Pressure Transducer Voltage Low - Voltage below normal, or
shorted to ground
520236-14 Rotation/Thrust Pressure Transducers Connections Switched Around
- Data valid, but not normal relative to other inputs - Moderately severe
level
520260-5 Thrust EDC Output - Current below normal or open circuit
Continued on next page...

2-21
 CAN Bus Connector and Resistors D20x22 Series II Navigator HDD Service

Code Description
520261-5 Rotate EDC Output - Current below normal or open circuit
520302-5 Track Enable Solenoid Output - Current below normal or open circuit
520303-5 Rear Vise Open Solenoid Output - Current below normal or open
circuit
520304-5 Rear Vise Close Solenoid Output - Current below normal or open
circuit
520305-5 Front Vise Open Solenoid Output - Current below normal or open
circuit
520306-5 Front Vise Close Solenoid Output - Current below normal or open
circuit
520307-5 High Speed Rotation Solenoid Output- Current below normal or open
circuit
520308-5 High Speed Thrust Solenoid Output - Current below normal or open
circuit
520309-5 Torque Limiter Solenoid Output - Current below normal or open circuit
520310-5 Water Valve Solenoid Output - Current below normal or open circuit
520311-5 Rod Loader Retract Solenoid - Current below normal or open circuit
520312-5 Rod Loader Extend Solenoid - Current below normal or open circuit
520313-5 Ball Valve Solenoid Output - Current below normal or open circuit
Machine Information

520314-5 Hydraulic Enable Solenoid Output - Current below normal or open

circuit
520315-5 Front Vise Rotate Solenoid Output - Current below normal or open
circuit
520408-4 Forward Thrust While Anti-Crash Low - Voltage below normal or
shorted to ground
520409-14 Drill Position Logic Error - Data valid, but not normal relative to other
inputs - Moderately severe level

CAN BUS CONNECTOR AND RESISTORS

CAN bus connector P69 provides a signal transfer point for the CAN bus lines from the
controller, display, Strike Alert module and Remote Lockout module. The 120-ohm
resistors R2 and R3 are attached to the connector.

2-22
D20x22 Series II Navigator HDD Service Thrust/Pullback Joystick A1

THRUST/PULLBACK JOYSTICK A1
P82 P80

P90 Pin Identification (12-Pin Connector)

Pin Wire I.D. Type Function

1 256A-PU control Supplies signal from joystick switch S15 to throttle - relay K2.

Machine Information
2 255B-TN control Supplies signal from joystick switch S16 to throttle + relay K3.
4 800-YL control Supplies signal from joystick switch S12 to greaser solenoid L1.
5 701-GY control Supplies signal from joystick switch S13 to display DP-10 E7.
12 710-PK control Supplies signal from joystick switch S14 to display DP-10 E7.

P85 Pin Identification (6-Pin Connector)

Pin Wire I.D. Type Function

1 366-BK GND Supplies ground from joystick to chassis ground.

3 121-OR power Supplies current from fuse F5.
4 751C-YL power Supplies 5 vDC from controller A5 output.
5 339-BK GND Supplies ground from joystick to chassis ground.
6 753-BU control Supplies signal from joystick base sensor B6 to controller A5.

2-23
 Rotation Joystick A2 D20x22 Series II Navigator HDD Service

ROTATION JOYSTICK A2
P90 P85

P80 Pin Identification (12-Pin Connector)

Pin Wire I.D. Type Function

3 804-DG control Supplies signal from joystick switch S18 to display DP-10 E7.
5 803-GN control Supplies signal from joystick switch S17 to display DP-10 E7.
Machine Information

6 801-YL control Supplies signal from joystick switch S19 to rod lift solenoid L4.
8 707-DG control Supplies signal from joystick switch S22 to display DP-10 E7
11 708-BU control Supplies signal from joystick switch S21 to display DP-10 E7.
12 802-PU control Supplies signal from joystick switch S20 to rod lower solenoid L5.

P82 Pin Identification (6-Pin Connector)

Pin Wire I.D. Type Function

1 367-BK GND Supplies ground from joystick to chassis ground.

3 127-OR power Supplies current from fuse F6.
4 751D-YL power Supplies 5 vDC from controller A5 output.
5 340-BK GND Supplies ground from joystick to chassis ground.
6 754-PU control Supplies signal from joystick base sensor B7 to controller A5.

2-24
D20x22 Series II Navigator HDD Service Hydraulic Valves

Testing Joysticks
The joysticks are potentiometers sending analog information (varying voltage) to the
pump EDC. Connect the machine to VCTool software and monitor the joystick voltage
to troubleshoot the joysticks.

If you do not see any problems with VCTool software and wish to verify the wiring,
follow the testing steps below.

1. Disconnect 12-pin connector at the base of the joystick. Attach 12-pin connectors of
the breakout box to the joystick plug and the harness jack.
2. Turn keyswitch on and sit in the seat.
3. Measure voltage from 1 to 2 on the breakout box while moving the joystick slowly
forward, and slowly back.
Expected result: 2.5 volts DC when the joystick is centered (NEUTRAL), 0 volts
DC when fully back and 5 volts DC when fully forward. If so, joystick appears to be
operating normally.

If there is no voltage, go to step 4.

Machine Information
If there is voltage, but it does not vary with stick position as described, replace
joystick.

4. Measure voltage with black probe grounded to chassis and the red probe at 1 on the
breakout box.
Expected result: 12 volts DC ± 1.2 volts. If so, refer to the electrical schematic. Test
continuity of the wires for 1 and 2 on the breakout box to the jack and plug
connected to the controller. If continuity is good, replace joystick. If not, repair or
replace faulty wire or harness segment.

HYDRAULIC VALVES
Throughout this machine, most of the valve assemblies are from a single vendor, and the
solenoids and valves are removed and installed with a common procedure.
Solenoids
1. Loosen and remove hex nut on top of coil.
2. Slide coil off spool valve. If double coil slide both coils off spool valve.
NOTE: Inspect spool valve for any damages.

Reverse removal steps when installing coils. Torque hex nut to specification or to 5 ft-lb
(6.8 Nm) if no other specification is given. Do not overtighten.

2-25
 Hydraulic Valves D20x22 Series II Navigator HDD Service

Valves

WARNING: Pressurized fluid can penetrate body tissue and result in serious injury or
death. Leaks can be invisible. Keep away from any suspected leaks. Relieve pressure in
the hydraulic system before searching for leaks, disconnecting hoses, or performing
any other work on the system. If you must pressurize the system to find a suspected
leak, use an object such as a piece of wood or cardboard rather than your hands. When
loosening a fitting where some residual pressure may exist, slowly loosen the fitting
until oil begins to leak. Wait for leaking to stop before disconnecting the fitting. Fluid
injected under the skin must be removed immediately by a surgeon familiar with this
type of injury.

1. Ensure manifold is clean and free from any dirt or contaminants.

2. Loosen large hex nut body on valve and unscrew valve from manifold.
NOTE: Observe orientation of the O-rings and backup washers.

3. Inspect valve for damage and ensure no external contaminants are present.
4. Inspect manifold cavity for burrs or other irregularities which could damage O-rings
during installation.
Machine Information

Continued on next page...

5. Install new O-rings and backup washers on the new valve as shown on the old valve.
6. Dip valve in clean filtered oil.
7. Screw valve in by hand until the O-ring makes contact with the manifold.
8. Using the appropriate torque specification, torque hex nut body on valve.

20

2-26
D20x22 Series II Navigator HDD Service Overview

Chapter 3: Power

OVERVIEW
The power chapter consists of the engine, pump drive and associated functions. This
chapter also consists of the circuits and components that supply and distribute the
electrical power from the battery and alternator to the circuit breaker and machine
functions.

THEORY
Functions/Circuits
The following functions and circuits are included in this chapter:

• Ignition OFF, ACC, RUN, and START Circuits

• Engine Monitoring Circuits including:
• Engine Oil Pressure Circuit
• Engine Coolant Temperature Circuit

Power
• Acceptable Battery Voltage Circuit

• Battery Charging Circuit

• Engine
• Engine Fuel Supply and Return function
• Engine Intake Air/Exhaust function

3-1
 Theory D20x22 Series II Navigator HDD Service

Components
The circuits and functions covered in this section include the following components:

• Engine ENG1
• Battery BT1
• Alternator G1
• Starter Motor M1
• Throttle Actuator M2
• Fuses F1–F11
• Circuit Breakers CB1–CB2
• Auxiliary Jack J2
• Universal Locator Charger J3
• Start Relay K1
• Throttle Relays K2 and K3
• Glow Plug Relay K5
• Fuel Stop Solenoid L32
• Fuel Pump Motor M3
• Fuel Sender R1 and Resistors R4 and R5
Power

• Tachometer E1
• Hourmeter E2
• Glow Plugs E9
• Switches S1–S3, S15, S16, S24, S37, S38 and S39

3-2
D20x22 Series II Navigator HDD Service Theory

Component Locations
AIR CLEANER

FUEL FILTER

THROTTLE ACTUATOR M2

OIL FILTER

ENGINE ENG1

PUMP DRIVE

Power
MUFFLER

ALTERNATOR G1

STARTER MOTOR M1 BATTERY BT1

FUEL SENDER R1

FUEL PUMP MOTOR M3

3-3
 Theory D20x22 Series II Navigator HDD Service

CONTROLLER A5

GLOW PLUG RELAY K5

START RELAY K1

CIRCUIT BREAKER CB2

CIRCUIT BREAKER CB1

GROUND DISCONNECT SWITCH S1

FUSES F1-F11
Power

RELAYS K2 AND K3

CONTROL PANEL SWITCHES

TACHOMETER E1

HOURMETER E2

AUXILIARY JACK J2

3-4
D20x22 Series II Navigator HDD Service Theory

IGNITION SWITCH S2

DISPLAY E7

HOURMETER E2

AIR CLEANER

THROTTLE ACTUATOR M2

OIL FILTER

Power
ENGINE ENG1

MUFFLER

STARTER MOTOR M1

ALTERNATOR G1

3-5
 Theory D20x22 Series II Navigator HDD Service

Engine
The D20x22 Series II Navigator HDD is powered by a Kubota V3800T turbo diesel
engine rated for 83 hp (62 kW) at 2200 rpm.The engine supplies the pump drive
assembly installed on the rear of the engine with power.

Engine Service
The Kubota engine is covered under Kubota’s warranty. Warranty will become void if
engine repair is attempted before warranty has lapsed. For information or service work
involving the internal parts or engine overhaul, refer to the engine manual supplied with
the machine, and/or contact an authorized Kubota industrial engine repair facility.

Engine Maintenance
Refer to the D16x20 Series II/D20x22 Series II Maintenance Manual for information
on regular engine maintenance schedules and procedures.
Power

3-6
D20x22 Series II Navigator HDD Service Theory

Engine Start Circuit

E7 DISPLAY DP10-A

Power
E7 DISPLAY DP10-B

Operation The components listed below must be positioned as follows to complete START circuit:

• Ground disconnect switch S1 must be closed.

• ALL joysticks must be in NEUTRAL position.
• Emergency stop switch S39 must be pulled out.
• Ignition switch S2 must be set to START.
Continued on next page...

When required operating conditions are met:

• A 12-volt DC voltage path which begins at the battery BT1 supplies voltage to 60A
circuit breaker CB1, and from there on to ignition switch S2.
• When ignition switch S2 is activated, voltage travels to the display E7 key start
input and fuses 1–10.
• Voltage travels from the key start output of the display to the start relay K1, and then
a signal passes to the starter motor M1.

3-7
 Theory D20x22 Series II Navigator HDD Service

Engine OFF Circuit

Operation The battery BT1 is a 12-volt DC battery that delivers 800 cold cranking amps to start the
engine or to run accessory items.
Power

The ground disconnect switch S1, when closed, electrically connects the negative post
of the battery to the frame of the machine. All other ground wires, except one, are
connected to the frame. Thus, if S1 is open, these circuits are not complete and will not
function.

When the ground disconnect switch S1 is closed, battery voltage is present at:

• B terminal of the alternator

• Circuit breaker CB1, which, if closed, allows voltage at the open contacts of fuse
F11 and ignition switch S2.
• Circuit breaker CB2, which, if closed, allows voltage at the glow plug relay K5.
Battery charger J1 is used to charge the remote lockout transmitter battery. The charger
is connected to the positive terminal of the battery through fuse F11.

3-8
D20x22 Series II Navigator HDD Service Theory

Engine Heat Circuit

E7DISPLAYDP10-A

Operation The components listed below must be positioned as follows to complete START circuit:

• Ground disconnect switch S1 must be closed.

Power
• Ignition switch S2 must be set to HEAT.
When required operating conditions are met:

• A 12-volt DC voltage path which begins at the battery BT1 supplies voltage to 60A
circuit breaker CB1, and from there on to ignition switch S2, and circuit breaker
CB2.
• When ignition switch S2 is activated, voltage travels to the display E7 glow plug
input, glow plug relay K5. Relay K5 is triggered and voltage travels to the glow
plugs E9.
• When circuit breaker CB2 is closed, voltage travels to glow plug relay K5.

3-9
 Theory D20x22 Series II Navigator HDD Service

Engine RUN or ACC Circuit

TO LIGHTS AND GAUGES

E 7 D IS P L A Y D P 1 0 -A

E 7 D IS P L A Y D P 1 0 -B

TO LEFT JOYSTICK
Power

TO RIGHT JOYSTICK

TO THROTTLE AND STRIKE ALERT

TO CONTROLLER

TO PROXIMITY SWITCHES

TO REMOTE LOCKOUT

TO STAKEDOWNS

Operation When the keyswitch S2 is moved to RUN, it delivers voltage to fuses F1 to F10. The
fuses supply voltage on to the functions of the machine.

3-10
D20x22 Series II Navigator HDD Service Theory

Battery Charging Circuit

Power
E 7 D IS P L A Y D P 1 0 - A

E 7 D IS P L A Y D P 1 0 - B

C 148 C O N TR O LLER

J1 - G RAY

J2- B LAC K

J4- B R O W N

Operation When the engine is running, the radiator fan belt also drives the alternator.

Continued on next page...

3-11
 Troubleshooting D20x22 Series II Navigator HDD Service

Power from fuse F7 connects to alternator G1 at terminal G. It creates an

electromagnetic field in the windings of the alternator.

The permanent magnets, spinning on the alternator shaft, generate alternating current
(AC) which is picked up by brushes in the alternator. The AC current is electronically
rectified to direct current (DC) by diodes inside the alternator, and delivered through
terminal B to the positive terminal of the battery.

Terminal P on the alternator delivers an input signal to the tachometer.

The alternator is grounded through its case to the engine and the frame.

TROUBLESHOOTING
Before performing any troubleshooting or testing on a electrical circuit or component,
perform a pretest inspection of the machine. See "Pretest Inspection," page 3-12.
Often problems can be solved by doing a walk-around inspection of the machine and
looking for obvious problems.
Power

Pretest Inspection
If a function fails to perform properly, do the following visual checks to inspect for
obvious signs of failure before any exhaustive troubleshooting or testing is performed.

• Inspect for any mechanical failures.

• Ensure the fuel, engine coolant, and oil levels are adequate.
Inspect electrical circuits for clues of the malfunction. Always check the following items
before turning on switches or running the unit.

• Look for bare wires that could cause grounds or shorts.

• Look for broken, missing, corroded, or loose connections on the power wires that
supply electrical circuit components.
• Check all ground connections on the machine and chassis for tight
connections. Cleaning harness connections or ground connections can often correct
what appears to be a malfunctioning component.
• Check for overheated components after the unit has been stopped for awhile. They
will often smell like burned insulation.

3-12
D20x22 Series II Navigator HDD Service Troubleshooting

Test Equipment Needed

To perform the troubleshooting procedures in this chapter, the following test equipment
will be needed:

• Multimeter for continuity tests, voltage measurements, resistance

measurements in the various electrical circuits

Testing the Circuits

The purpose of the power circuit is to provide voltage to the fuses and the controllers.

Measure Battery Voltage

With key OFF and ground disconnect switch S1 open, remove battery box cover and
read voltage at battery.

Expected result: 12.6 volts DC, ± 1.2 volts. If so, continue below. If less, recharge
battery.

Power
Check for Power at Controller and Remote Lockout Charger
1. Close ground disconnect switch S1.
2. Turn keyswitch S2 to RUN.
3. Look at power LED on the faceplate of the controller. Also, look at power indicator
on the charging station for the remote lockout transmitter battery (battery must be in
charging station).
Expected result: The power LED are glowing, and charging indicator is glowing.

If power LED is glowing, fuse F7 is good.

If the power LED is glowing, follow the steps under "Testing Fuses," page 3-15. If
the charging indicator is glowing, fuse F11 is good. If not, test fuse F11.

3-13
 Troubleshooting D20x22 Series II Navigator HDD Service

Troubleshooting the Battery Charging Circuit

If the battery is not being charged, do the following:

• Inspect terminals and connections on both battery cables for corrosion at the battery,
the alternator and the frame If needed, clean connections and terminals.
• Inspect alternator belt condition and tension. Consult Kubota engine manual for
proper belt tension.
• Load test the battery. Old or damaged batteries will not accept a full charge.
It is possible that the wire or cables are damaged internally. If damage is suspected, do
the following:

• Check continuity of cables from end to end. Replace any that show resistance.
• Test continuity in wire 100 to the B terminal on the alternator. If open, repair or
replace the faulty wire or harness segment.
If these items appear to be working, replace alternator or contact a Kubota service
facility to have it rebuilt or repaired.
Power

3-14
D20x22 Series II Navigator HDD Service Troubleshooting

Testing Fuses
1. In the engine bay, set multimeter to read
DC voltage in the 40-volt range. Connect
black probe to either terminal of the
ground disconnect switch S1 (1).
2. Test circuit breaker CB1 (2), in the
engine bay, first. If it is open, fuses F1 to
F10 will not have voltage. Test ignition
switch S2 next. If the switch is faulty, 2
fuses F1 through F10 will not have 1
voltage.
3. Open left operator console cover and open fuse panel cover.
4. Each fuse (3) has two small metal tabs
sticking out of the face of the fuse. On
each fuse, place red probe on each tab
and compare resulting voltages. 3
Expected result: On each fuse, the tabs
will each have battery voltage, ± 10%. If
so, fuse holder has voltage and fuse is
good.

Power
If one side of the fuse has voltage and the
other shows none, fuse is blown. Replace
fuse.

If neither side shows voltage, fuse holder

does not have voltage or fuse is loose. Remove fuse, and reinstall it, and test it
again.

If F1 has voltage, but F3 does not, F4 does not or F5 does not have voltage, remove
and reinstall fuses to ensure they are set tightly in their sockets. If so, fuse panel is
faulty. Replace fuse panel, see "Fuse Panel," page 3-19.

If no fuses have voltage, test continuity across S1. Test continuity of wires from S1
to negative terminal of battery and to frame.

3-15
 Troubleshooting D20x22 Series II Navigator HDD Service

Troubleshooting the Circuit Breakers

Circuit breaker CB1 feeds power to fuse F11 and ignition switch S2 which connects to
fuses F1 through F10. CB1 is rated for 60 amps.

The 11 fuses it feeds are rated for a total of 115 amps.

The controller has a supply current maximum draw of 32 amps. Added to the 115
possible amp draw through the eleven fuses, this would be 147 Amps. This would
require each driver to be working against the highest load—not a likely situation, but
you may want to ask the operator what exactly he was doing with the machine when the
breaker tripped.

A more normal situation is a short to ground in wire 100-RD or 102-RD.

Wire 102-RD runs from the breaker to ignition switch S2, so it can be inspected for any
missing insulation or other causes of shorting to the frame.

For wire 100-RD, test continuity to the frame or the ground disconnect switch. If the
wire has been moved since the short occurred, it may no longer be contacting the frame,
so these shorts can be frustrating to hunt down.

If it is still shorted to the frame (continuity), narrow the search by disconnecting engine
bay harness and the console harness at the connector and testing both sides. Carefully
Power

inspect harness for worn insulation and replace or repair the faulty section.

Circuit breaker CB2 feeds power to glow plug relay K5. CB2 is rated for 60 Amps.

Test for voltage to relay K5 on wire 105-RD. Also inspect for any missing insulation or
other causes of shorting to the frame.

For wire 100-RD, test continuity to the frame or the ground disconnect switch. If the
wire has been moved since the short occurred, it may no longer be contacting the frame,
so these shorts can be frustrating to hunt down.

3-16
D20x22 Series II Navigator HDD Service Troubleshooting

Testing Circuit Breakers

With the black probe connected to a terminal
at the ground disconnect switch S1 (1), read
voltage with red probe at each terminal of the
circuit breaker CB1 or CB2 (2). 2

Expected result: Battery voltage on both

posts. If so, circuit breaker has voltage
1
and breaker is closed—continue below.

If there is voltage at one post and not the

other, the breaker is open. If it has not reset
automatically, replace the breaker (see
"Circuit Breakers CB1 and CB2," page 3-19). If it has reset, you need to determine
why it tripped, see "Troubleshooting the Circuit Breakers," page 3-16.

If neither post of the breaker has voltage, test continuity of wire 100-RD to the battery.
Repair or replace defective wire.

Testing the Emergency Stop Switch

Power
Emergency stop switch S39 is located at the transport station. You can access its
terminals by removing cover panel on transport station.

Test switch by testing continuity between the terminals when the knob or button is
pulled out and pushed in. When pulled out, there must be continuity and when pushed
in, the switch must be open. If so, switch is good. If not, replace the switch.

Testing the Ignition Switch

With the drill station control panel removed, and the harness
disconnected from keyswitch S2, test voltage at the blades on
the switch while turning the key through its positions.
19 50
When in Preheat position, current should be available at 19,
30, and AC. When at Off, current should not be available. 17 AC
When at Start, current should be available at 30 and AC.
30
When at Run, current should be available at all 30, 17, 50 and
AC.
Switch face
If any blade does not have 12 volts, replace switch. See
"Ignition Switch S2," page 3-21.

3-17
 Troubleshooting D20x22 Series II Navigator HDD Service

Specifications
Listed below are specifications for components in this chapter.

Electrical System Nominal circuit voltage - 12 volts DC

Battery 950 CCA 12-volt BCI group size 31

Circuit Breaker • CB1 - 60-amp

• CB2 - 60-amp
Fuse Ratings • F1 to F6 - 15-amp
• F7 - 20-amp
• F8 to F11 - 15-amp
Engine Model - Kubota V3800T

Maximum Power - 83 hp (62 kW) at 2200 rpm

Fuel type/capacity - diesel, 25 gal (95 L)

Oil capacity - 1.85 gal (7 L)

Maximum engine inclination - 30° all directions

Power

NOTE: Engine operating angles do not indicate safe machine operating angles.

Cooling medium - mixture of 50% water and 50% ethylene glycol-base antifreeze to -
34° F (-37°C) protection

Engine coolant capacity 2.7 gal (10.3 L)

Alternator - 90-amp

Component Repair/Replace
If troubleshooting procedures determine a component is in need of repair or
replacement, refer to the appropriate procedures at the back of the chapter or other
chapters where instructed.

3-18
D20x22 Series II Navigator HDD Service Component Repair

COMPONENT REPAIR
Fuse Panel
Remove 1. Open left operator console cover.
2. Remove plastic snap-on cover from fuse
panel.
3. Remove four mounting screws and
washers (1).
4. Push fuse panel back into mounting
bracket so that it can be pulled out of its
mounting bracket.
5. Disconnect wire harness at all
1
connectors.
NOTE: Fuse panel is integral to wiring
harness and must be removed as a unit.

Power
Install 1. Connect wiring harness removed during removal steps.
2. Return panel to its mounting position and install mounting screws and washers.
Remember to attach strap for plastic cover under lower right screw.
3. Snap plastic cover back in place.

Circuit Breakers CB1 and CB2

1. Open engine bay doors.
2 1
2. Label and remove electrical wiring (1)
from breaker.
3. Remove two mounting screws (2) and
nuts and remove breaker from machine.
Reverse removal steps to install breaker.

3-19
 Component Repair D20x22 Series II Navigator HDD Service

Relays
NOTE: Relays K1 and K5 are shown below. When replacing a relay, remove nuts,
bolts, and wires from relay.

1. Open engine bay doors.

2
2. Label and remove electrical wiring (1)
from relay.
3. Remove mounting screws (2) and nuts
and remove relay from machine.
1
Reverse removal steps to install relay.

NOTE: Relays K2 and K3 are located in the

fuse panel. To remove relay K2 or K3, simply
unplug from fuse panel.

Emergency Stop Switch S39

Replace 1. Remove cover panel, on rear transport station, above switch.
Power

2. Unplug switch from harness (1).

3. Unscrew plastic knob from switch. 1
4. Loosen and remove retaining ring.
5. Push switch through panel.
Reverse removal steps to install switch.

3-20
D20x22 Series II Navigator HDD Service Component Repair

Ignition Switch S2
1. Open door on rear of right operator
console.
2. Disconnect wires from back side of
switch.
1
3. On front side of control panel, unscrew
retaining ring around barrel of switch. Pull
switch out from back side of panel.
Reverse removal steps to install switch S2.

Battery Disconnect Switch S1

Replace 1. Open engine bay doors.
2. Label and remove electrical wiring
from switch S1.
1
3. Loosen jam nut, remove washer, and

Power
slide switch out from mount.
Reverse removal steps to install switch S1.

3-21
This page intentionally left blank.
D20x22 Series II Navigator HDD Service Overview

Chapter 4: Hydraulic Fluid Distribution

OVERVIEW
This chapter consists of the components needed for all machine hydraulic functions.
These components provide the means for fluid supply, distribution, filtering, and
cooling.

All remaining machine hydraulic components are considered specific to individual

functions. Refer to the appropriate function chapters for component locations, and
explanations of the various functions.

THEORY
Functions

Hydraulic Fluid Distribution

The following functions are included in this chapter:

• Oil Supply
• Oil Filtering
• Oil Cooling
• Hydraulic Fluid Sampling

4-1
 Theory D20x22 Series II Navigator HDD Service

Components
The following components are discussed in this section:

• Rotation/Thrust Pump PMP1, including:

• HPRV Valves DV8–DV11
• EDC Solenoids L14, L15, L18 and L19
• PFC Pump PMP2
• Charge Pump PMP4
• Charge Pump Filter FL1
• Hydraulic Tank RES1, including:
• Return Manifold A17
• Return Filter FL2
• Oil Level Indicator GA1
• Oil Cooler HE1
• Diverter/Drilling Fluid Valve A9, including:
Hydraulic Fluid Distribution

• Check Valve CV2

• Cartridge Valves DV16–DV18
• Relief Valve PV4
• Pressure Gauge E12
• Solenoids L17, L20 and L21
• Load Sense Cartridge Valve DV24
• Solenoid L9
• Suction Manifold A15
• Switches S10 and S11

4-2
D20x22 Series II Navigator HDD Service Theory

Component Locations
DIVERTER/FLUID VALVE A9 SUCTION MANIFOLD A15

HYDRAULIC
TANK RES1

OIL COOLER HE1

Hydraulic Fluid Distribution

ROTATION AND THRUST PUMP PMP1
PFC PUMP PMP2
CHARGE GEAR PUMP PMP4
HYDRAULIC ENABLE SWITCH S10

4-3
 Theory D20x22 Series II Navigator HDD Service

Hose Connections — Fluid Supply

THRUST MANIFOLD A8

ROTATION MOTOR MH1

CHARGE FILTER FL1
PFC PUMP DIVERTER/FLUID
PMP2 VALVE A9

CHARGE
PUMP PMP4
ROTATION &
THRUST PUMP
PMP1
Hydraulic Fluid Distribution

FLUID SHUTOFF
VALVE DV16

SUPPLY
MANIFOLD A15

HYDRAULIC
TANK RES1
TORQUE LIMITER VALVE A7

4-4
D20x22 Series II Navigator HDD Service Theory

Hose Connections — Fluid Return

PFC PUMP
ROTATION & PMP2 CHARGE
THRUST PUMP PUMP PMP4 FROM ROD LOADER VALVE A14
PMP1 & VISE VALVE A13

DIVERTER/FLUID OIL COOLER

VALVE A9 HE1
HYDRAULIC
TANK RES1 TRANSPORT
VALVE A5

FLUID SHUTOFF
VALVE DV16

Hydraulic Fluid Distribution

RIGHT TRACK FLUID PUMP
TORQUE LIMITER VALVE A7 MOTOR MH5 MOTOR MH10
LEFT TRACK
MOTOR MH6

Hydraulic Schematic
Refer to Addendum.

4-5
 Theory D20x22 Series II Navigator HDD Service

Oil Supply Function

PFC Pump PMP2

DIVERTER/FLUID
VALVE A9
Hydraulic Fluid Distribution

FLUID SHUTOFF
VALVE A19

PFC PUMP PMP2

SUCTION MANIFOLD A15

Operation With all functions at rest (control valves in neutral) and engine running:

• Fluid is drawn from the fluid tank RES1 which contains approximately 27 gal (102
L) of hydraulic fluid, through the 200-micron suction screen and suction manifold
A15, to inlet port of PFC pump PMP2.
• PFC Pump PMP2 will remain in low pressure standby mode at 250 psi (17 bar). The
pump produces only enough flow to make up for internal leakage.
• Leakage in pump PMP2 goes directly to port L1 and drains back into the hydraulic
tank RES1 and is redistributed.
Continued on next page...

4-6
D20x22 Series II Navigator HDD Service Theory

When a hydraulic function is actuated during vise or rod loader functions or during
transport or machine anchoring:

• PFC pump PMP2 distributes fluid through diverter/drilling fluid valve manifold A9
to the ground drive, stabilizer, rack angle, rod loader, vises, stakedown, optional
greaser if equipped, and drilling fluid functions.
• Load sense valve DV24 allows circuit pressure from the vise, stakedown, greaser,
and rod loader circuits to adjust the pump displacement to increase the flow required
at only the pressure required to operate the function.
• PFC pump PMP2 will strive to maintain the flow required, under all working
conditions of the machine.
• If the load in the system produces a hydraulic pressure that is equal to the 3300 psi
(227 bar) high pressure setting of PFC Pump PMP2, the pump will go into high
pressure standby mode until the load is overcome or the control valves are returned
to neutral.

NOTE: If performance problems are noted in any of the circuits listed above, but
rotation and thrust/pullback functions are OK, PFC pump PMP2 should be investigated.

Hydraulic Fluid Distribution

See "Troubleshooting/Testing PFC Pump PMP2," page 4-17.

4-7
 Theory D20x22 Series II Navigator HDD Service

Rotation and Thrust Closed-Loop Pump PMP1

ROTATION EDC THRUST EDC
TO 2-SPEED
PORT CP

HPRV HPRV

TO TANK
RES1
Hydraulic Fluid Distribution

ROTATION AND THRUST PUMP PMP1

TO TORQUE LIMIT
MANIFOLD A7 TO THRUST
MANIFOLD A8

CHARGE FILTER F1

Operation - Charge Rotation and thrust pump PMP1 supplies fluid to the drill rotation and thrust/pullback
Pressure Mode hydrostatic closed loops. When the control is in NEUTRAL position (pump swashplate
centered), both sides of the closed loop are at charge pressure.

A charge pump PMP4 is driven off the main pump shaft. The charge pump is necessary
to:

• supply cool oil to the system

• maintain positive pressure in the main system loop
• provide pressure to operate the servo control system
• make up for component internal leakage
Continued on next page...

4-8
D20x22 Series II Navigator HDD Service Theory

The charge pressure must be at its specified pressure under all conditions to prevent
damage to the system. The charge relief valve in the pump serves to maintain charge
pressure at a setting of 313 psi (21.5 bar).

Upon engine start-up:

• Oil is forced by atmospheric pressure, through a suction screen located in the oil
tank RES1, to the charge pump.
• Flow from the charge pump enters and exits low pressure charge filter FL1, then
enters both sides of the closed loop through dual charge check valves. These check
valves are integral to the pump high pressure relief valves (HPRV).
• When the closed loop is entirely full of oil, flow from charge pump is diverted
through the neutral charge pressure relief valve, and into the pump case (port E).
Operation - High A high pressure relief valve is used in each closed-loop port to limit the system pressure
Pressure Mode and to allow charge oil to keep the closed loop filled.

If the closed loop oil pressure exceeds a preset limit of 3335 psi (229.8 bar), oil is added
from the high pressure system loop into the charge gallery, and into the low pressure

Hydraulic Fluid Distribution

system loop via the charge check valve.

Within the electrical displacement control (EDC), the pressure control pilot valve
receives electrical input from the controller, which has received signals from the
joystick controls. The pressure control pilot valve converts the electrical signal to a
hydraulic signal which operates a spring-centered 4-way servo valve. This valve ports
hydraulic pressure to either side of a dual-acting servo piston. The servo piston rotates
the swashplate through an angular rotation to vary the pump’s displacement from full
displacement in one direction to full displacement in the opposite direction.

While the rotation or thrust function is in operation:

• One side of the loop will be under high pressure (load-generated pressure).
• The opposite side of the loop is at charge pressure, plus case pressure.
• As soon as the pump swashplate moves off center position, oil will flow from either
the A or the B port depending on the position of the control handle.

• Oil will flow through the high pressure side of the closed loop to either rotation
motor MH1 or to thrust/pullback motors MH2, MH3 and MH4 to allow variable
speed, bi-directional rotation of the motor.

NOTE: If drill rotation function does not operate as expected, see "Troubleshooting
Machine Performance," page 9-24. If thrust/pullback function does not operate as
expected, see "Troubleshooting Machine Performance," page 10-13.

4-9
 Theory D20x22 Series II Navigator HDD Service

Pump PMP1 Ports

Port Function Recommended Gauge Size Fitting

M1 system pressure port ‘A’ 10,000 psi or 1000 bar gauge 9/16”–18 O-ring fitting
M2 system pressure port ‘B’ 10,000 psi or 1000 bar gauge 9/16”–18 O-ring fitting
M3 charge pressure (after filter) 1000 psi or 100 bar gauge 9/16”–18 O-ring fitting
M6 charge pressure (before 1000 psi or 100 bar gauge 9/16”–18 O-ring fitting
filter)
M4 servo pressure 500 psi or 50 bar gauge 9/16”–18 O-ring fitting
M5
L1 case pressure 100 psi or 10 bar gauge 1-1/16”–12 O-ring fitting
L2
X1 EDC pressure 1000 psi or 100 bar gauge 7/16”–20 O-ring fitting or
X2 9/16”–18 O-ring fitting
X3 external control pressure 1000 psi or 50 bar gauge 9/16”–18 O-ring fitting
Hydraulic Fluid Distribution

S charge pump inlet vacuum gauge—tee into inlet line 1-5/8”–12 O-ring fitting

4-10
D20x22 Series II Navigator HDD Service Theory

Oil Filtering Function

With Functions • The 200-micron suction screen,
Operating or At Rest installed in the bottom of the tank at the
port to the inlet manifold, will capture
FILTER FL2
particles that may reside in the tank as
the fluid is delivered to the pumps.
SUCTION SCREEN
• The 5-micron return filter FL2 filters the
fluid as it is returned to the tank. SIGHT GAUGE

During normal operation, if back

pressure in the return line reaches 25 psi
(1.7 bar) indicating the filter is plugged,
the spring located on the filter frame
will allow the filter to move and fluid to
bypass into the tank.
• Charge filter FL1 filters the fluid in the
charge circuits of pump PMP1.
• The sight gauge on the oil tank gives the

Hydraulic Fluid Distribution

operator a visual reference of the fluid
level. The oil should be visible in the
sight glass when the machine is at rest.
TANK RES1

RETURN MANIFOLD

4-11
 Theory D20x22 Series II Navigator HDD Service

Oil Cooling Function

FROM FROM
FROM FLUID PUMP & RIGHT LEFT FROM DIVERTER VALVE
TRANSPORT VALVE TRACK TRACK & ROTATION

FROM ROD LOADER,

OIL COOLER HE1 VISES, STAKEDOWNS

RETURN MANIFOLD A17

Operation All hydraulic functions on the machine

share the hydraulic fluid in tank RES1.
Hydraulic Fluid Distribution

Hydraulic fluid returns to the tank by one 1 2

of three ways: return manifold A17 (ports
1–6), filter FL2 (ports 7–10) or directly to 7 8
tank RES1 (ports 11 and 12). 3 4
9 10
Oil cooler HE1 receives oil from return 5 6
manifold A17 and from a shared line from
the drilling fluid pump motor and transport
valve. 11 12

When fluid enters return manifold A17:

• Oil is routed to the inlet of cooler HE1

where it is cooled before returning to
tank RES1.
• If the pressure in return manifold A17 reaches 85 psi, a check valve opens and
excess oil goes directly to the hydraulic tank.

4-12
D20x22 Series II Navigator HDD Service Theory

Specifications
Listed below are the electrical and hydraulic specifications for the hydraulic fluid
distribution components.

Electrical:

• Nominal circuit voltage - 12 volts DC

• Diverter/drilling fluid valve assembly A9 solenoid coils L17, L20 and L21
resistance - 7.2 ohms @ 68°F (20°C)
• Diverter/drilling fluid valve assembly A9 solenoid coil L9 resistance - 9.8 ohms @
68°F (20°C)
Hydraulic:

• Hydraulic oil tank capacity - 27 gal (102 L)

• Oil Cooler HE1 typical inlet pressure - up to 65 psi (4.5 bar)
• Rotation and thrust pump PMP1 normal output flow - 33 gpm (125 L/min) @ 2400
engine rpm

Hydraulic Fluid Distribution

• Rotation and thrust pump PMP1 displacement - 3.2 cid (52.4 cc)
• Rotation and thrust pump PMP1 charge relief valve setting - 313 psi (21.5 bar)
• Rotation and thrust pump PMP1 high pressure relief valve setting - 3335 psi (230
bar)
• Rotation and thrust pump PMP1 maximum vacuum at inlet - 5 in. Hg
• PFC pump PMP2 normal output flow - variable to 24 gpm (90.8 L/min)
• PFC pump PMP2 standby pressure compensator valve setting - 250 psi (17.2 bar)
• PFC pump PMP2 high pressure compensator valve setting - 3300 psi (227.5 bar)
• PFC pump PMP2 maximum vacuum at inlet - 1 in. Hg
• Diverter/drilling fluid valve assembly A9 relief valve - 1365 psi (94 bar)

4-13
 Troubleshooting D20x22 Series II Navigator HDD Service

TROUBLESHOOTING
Perform the pretest inspection and look for obvious clues to malfunctions. See "Pretest
Inspection," page 4-16.

If obvious signs of faults are not found, then more exhaustive checks must be carried
out. The procedures continue by instructing the technician to operate all the actuator
functions of the machine to help isolate the fault to one or more functions, or
components.

If there are faults in multiple functions with hydraulic circuits, the hydraulic fluid
distribution components should be investigated.

Actuators or functions that are malfunctioning may exhibit symptoms including:

• excessive heat
• excessive noise
• excessive vibration
Hydraulic Fluid Distribution

• external leakage

If excess heat and/or external leakage is generated while operating, see

"Troubleshooting/Testing the Oil Cooling Function," page 4-20.

If excessive noise and/or vibration is noticed while operating, see below.

Excessive Noise/ If excess noise and/or vibration is observed:

Vibration
1. Check fluid level at sight gauge on tank. The level should be visible in the indicator
glass.
2. If not, filter new fluid through a 5-micron filter before adding it to fluid tank RES1.
3. Refer to Machine Information chapter, "Fuel and Lubricants," page 2-12, for
correct fluid requirements. If problems persist, continue.
4. Check hydraulic fluid for signs of foaming. If foaming is noticed, it is an indication
of air contamination. Air contamination is a symptom of cavitation and is usually
associated with excessive noise.

NOTE: If there is excessive noise, it may come from a pump, or pumps, cavitating
from an inlet restriction or ingesting air through a leaking suction hose or pump seal.
Another source of excessive noise may be a relief valve that is faulty or set incorrectly.

Continued on next page...

4-14
D20x22 Series II Navigator HDD Service Troubleshooting

Cavitation is the formation of gaseous cavities in the liquid. Cavitation will interfere
with lubrication and destroy metal surfaces in the pump. If allowed to continue, the
pump will ultimately fail and contaminate the entire system.

Cavitation can be caused by restricted fluid flow at the inlet of the pumps or if air is
entering the inlet port of pump because of a leak in a suction line or a bad pump shaft
seal.

The most pronounced indication of pump cavitation is a high-pitched sound. Pump

cavitation resulting from inlet restriction will have a steady, high- pitched sound. Pump
cavitation resulting from air ingestion will have somewhat of an erratic sound.

5. If it is determined that excessive noise is coming from one or more pumps, continue
with step 6. If it is determined that excessive noise is coming from a relief valve,
continue with step 10.
6. Inspect suction lines for restriction or collapse, loose connections, leaking
connections, or hose deterioration. Inspect pumps for seal leakage. Repair or replace
as necessary. If nothing is found, continue.

Hydraulic Fluid Distribution

7. Inspect tank outlet suction strainer SR1 for contaminates. The suction strainer must
be totally clean. Clean or replace as necessary.
8. Replace charge filter FL1. Charge filter FL1 is used in the closed loop of the drill
rotation and thrust/pullback functions. If the filter becomes restricted, adequate
charge pressure will not be available.
9. If no problem is found, a pump may be experiencing excessive internal leakage,
refer to pump troubleshooting procedures in this chapter.
NOTE: A noisy relief valve will have a steady high-pitched screeching or screaming
noise. The drill rotation and thrust/pullback closed-loop hydraulic systems have relief
valves integral to pump PMP1.

The ground drive and rack angle functions have a relief valve integral to transport valve
A11. If it is determined that excessive noise is coming from a relief valve as noted
above, refer to the appropriate chapter:

• For pump PMP1 relief valve, forward and reverse torque relief valves, refer to drill
rotation function chapter for information.
• For transport relief valve, refer to Stabilizer chapter.

4-15
 Troubleshooting D20x22 Series II Navigator HDD Service

Pretest Inspection

WARNING: Pressurized fluid can penetrate body tissue and result in serious injury or
death. Leaks can be invisible. Keep away from any suspected leak. Relieve pressure in the
hydraulic system before searching for leaks, disconnecting hoses, or performing any other
work on the system. If you must pressurize the system to find a suspected leak, use an
object such as a piece of wood or cardboard rather than your hands. When loosening a
fitting where some residual pressure may exist, slowly loosen the fitting until oil begins to
leak. Wait for leaking to stop before disconnecting the fitting. Fluid injected under the skin
must be removed immediately by a surgeon familiar with this type of injury.

Do the following visual checks to inspect for obvious signs of failure before any
exhaustive troubleshooting or testing is performed.

Check hydraulic circuits for any failures.

• Look for broken, kinked, collapsed, loose, or leaking hoses and fittings on supply,
pressure, and return to hydraulic components.
Hydraulic Fluid Distribution

• Check fluid level in hydraulic tank. Low fluid can cause erratic behavior in
hydraulic circuits. Correct level is between the two lines on the sight gauge. If
needed, add new fluid that has been filtered through a 5-micron filter.

Also review information in the General Information chapter under "Troubleshooting

Guidelines," page 1-8. Correct any problems found during the inspection. Operate
machine to verify the fault is fixed.

Test Equipment Needed

To perform the troubleshooting procedures in this chapter, the following test equipment
will be needed:

• Multimeter for continuity tests, voltage measurements, resistance

measurements in the oil cooler fan motor electrical circuit.
• Pyrometer and magnetic thermometer for taking temperature readings.
• Various hydraulic testing tools.

NOTE: The hydraulic component test procedures discussed in this chapter will refer
the technician to the Vermeer Industrial Dealerships Technician’s Shop Manual
(Vermeer P/N 105400V80). Test procedures and equipment needed for performing the
various tests on hydraulic components will be listed in the manual.

4-16
D20x22 Series II Navigator HDD Service Troubleshooting

Troubleshooting/Testing Pump PMP1

NOTE: Information on testing and troubleshooting rotation pump PMP1 is provided
in "Troubleshooting," page 4-14.

Troubleshooting/Testing PFC Pump PMP2

NOTE: PFC pump PMP2 is installed on the rear of rotation and thrust pump PMP1. If
pump PMP1 fails, and affects engine RPM, it will directly affect the output of pump
PMP2. Refer to "Troubleshooting," page 9-16 for pump PMP1 troubleshooting.

1. If there is excessive noise associated with the pump, refer to the table below.

Troubleshoot Possible Effect Action

Check fluid level in Low hydraulic oil level can cause

Fill hydraulic oil to correct level.
tank. cavitation.

Hydraulic Fluid Distribution

Check for air in Air in system will cause noisy, erratic Purge air and tighten fittings. Check
system. control. inlet for leaks.
Check pump inlet Improper inlet conditions will cause Correct pump inlet pressure
pressure. Check for erratic behavior and low outlet flow. conditions.
vacuum.
Check hydraulic fluid Hydraulic fluid viscosity above Allow system to warm up before
viscosity. acceptable limits or low fluid operation or use fluid with the
temperature will not allow the pump to appropriate viscosity grade for
fill or control to operate properly. expected operating temperatures.

Continued on next page...

4-17
 Troubleshooting D20x22 Series II Navigator HDD Service

2. If the pump sounds normal, but there is excessive heat generated by the drill rotation
or drill fluid circuits, refer to table below.

Troubleshoot Possible Effect Action

Check fluid level in Insufficient volume of hydraulic fluid Fill hydraulic oil to correct level.
tank. will not meet cooling demands of
system.
Inspect oil cooler. Insufficient flow or high input Clean, repair or replace oil cooler as
temperature will not meet cooling required.
demands of the system.
Check system relief Fluid passing through relief valve adds Adjust relief valve setting. Refer to
valve setting. heat to the system. "Specifications," page 4-13. Relief
valve setting must be above pressure
compensator setting.
Check pump inlet High inlet vacuum adds heat to the Correct inlet pressure conditions.
pressure for vacuum. system.

3. If machine function response is sluggish, refer to the table below.

Hydraulic Fluid Distribution

Troubleshoot Possible Effect Action

Check system relief Low relief valve setting will slow down Adjust relief valve setting. Refer to
valve setting. system. "Specifications," page 4-13. Relief
valve setting must be above pressure
compensator setting.
Check pressure Low pressure compensator setting will Adjust pressure compensator and/or
compensator and load prevent the pump from achieving full load sense setting.
sense control setting. stroke. Low load sense setting will limit
output flow.
Check load sense Incorrect load sense signal will not Inspect system, ensure that proper
control signal allow pump to operate correctly. load sense signal is transmitted to the
pressures. pump.
Inspect pump for Worn internal parts will not allow the Refer to a Sauer authorized repair
internal system leaks. pump to operate properly. facility, if under warranty.
Check viscosity of Hydraulic fluid viscosity above Allow system to warm up before
hydraulic fluid. acceptable limits or low fluid operation or use fluid with the
temperature will not allow the pump to appropriate viscosity grade for
fill or control to operate properly. expected operating temperatures.
Check diverter/fluid Malfunctioning valve may not allow Refer to "Diverter/Fluid Valve
valve. system to respond properly. Assembly A9," page 4-30.
Check pump case High case pressure will cause the Correct case drain line restrictions.
pressure. system to be sluggish.
Check pump inlet High inlet vacuum adds heat to the Correct inlet pressure conditions.
pressure for vacuum. system.

Continued on next page...

4-18
D20x22 Series II Navigator HDD Service Troubleshooting

4. Test flow from pump. At high idle of 2400 rpm, maximum flow should be 24 gpm
(90 L/min). At rated speed of 2200 rpm, maximum flow should be 22 gpm (83 L/
min). If output flow is low, refer to the table below.

Troubleshoot Possible Effect Action

Check system relief Relief valve setting below pressure Adjust relief valve setting. Refer to
valve setting. compensator setting will cause low "Specifications," page 4-13. Relief
output flow. valve setting must be above pressure
compensator setting.
Check pressure Low pressure compensator setting will Adjust pressure compensator and/or
compensator and load prevent the pump from achieving full load sense setting.
sense control setting. stroke. Low load sense setting will limit
output flow.
Check fluid level in Insufficient volume of hydraulic fluid Fill hydraulic oil to correct level.
tank. will limit output flow and cause internal
damage to pump.
Check viscosity of Hydraulic fluid viscosity above Allow system to warm up before
hydraulic fluid. acceptable limits or low fluid operation or use fluid with the
temperature will not allow the pump to appropriate viscosity grade for

Hydraulic Fluid Distribution

fill or control to operate properly. expected operating temperatures.
Check input speed. Low input speeds decrease flow. Adjust input speed.
Check pump inlet High inlet vacuum adds heat to the Correct inlet pressure conditions.
pressure for vacuum. system.

5. If unstable pressure is indicated at diagnostic port or unstable flow is found in

system, refer to the table below.

Troubleshoot Possible Effect Action

Check for air in Air in system will cause noisy, erratic Purge air and tighten fittings. Check
system. control. inlet for leaks.
Check control spools. Sticking control spools will cause Inspect spools for free movement in
erratic operation. bore. Clean or replace as necessary.
Check load sense Low load sense setting may cause Adjust load sense to proper level.
setting. instability.
Check load sense Blocked load sense signal line will Remove blockage.
signal line. interfere with proper load sense
operation.
Check relief valve and Relief valve setting below pressure Adjust relief valve setting. Refer to
pressure compensator compensator setting will cause low "Specifications," page 4-13. Relief
setting. output flow. valve setting must be above pressure
compensator setting.
Check relief valve. Chattering relief valve may cause Adjust or replace relief valve.
unstable feedback to pump control.

Continued on next page...

4-19
 Troubleshooting D20x22 Series II Navigator HDD Service

6. If the pump stays at standby pressure, the load sense solenoid may not be receiving
a signal. Check the wiring to the solenoid and solenoid operation.
7. If high inlet pressure vacuum is found, check the following. Check fluid
temperature; if temperature is low, allow system to warm up before operation.
Inspect inlet screen; clean screen and remove any blockages. Inspect inlet piping;
eliminate excess fittings. Check grade of hydraulic fluid; replace fluid if it is not the
Vermeer recommended grade.
8. Test efficiency of the pump. Refer to the Vermeer Industrial Dealerships
Technician’s Shop Manual (Vermeer P/N 105400V80), for information on testing
hydraulic pumps.
PFC Pump PMP2 should be replaced if leakage approaches or exceeds
2.36 gpm (8.93 L/min) when tested at full throttle when circuit pressure achieves the
pump compensator setting of 3300 psi (227 bar).

Troubleshooting/Testing the Oil Cooling Function

Hydraulic Fluid Distribution

Excessive Heat/Leakage

Inefficiency in the form of heat can be expected in all hydraulic systems. However, oil
temperature in the case drain lines should not exceed 220°F (104°C) continuous during
normal work cycles.

If excess oil temperature is generated from one or more functions:

1. Check thermometer in sight gauge to measure the temperature of the external walls
of the fluid tank. If fluid temperature is above design specification, continue.
NOTE: Refer to the Vermeer Industrial Dealerships Technician’s Shop Manual
(Vermeer P/N 105400V80), for helpful information on testing electrical circuits for
shorts, opens, and high resistance.

2. Inspect oil cooler HE1 for debris or damage that may be blocking air flow through
the cooler.
3. Use a pyrometer to check the temperature at the inlet and outlet ports of the oil
cooler for a temperature differential while the drill rotation motor is rotating.
If there is not a temperature differential, the cooler may be partially obstructed
internally. If damaged, flush or replace. If OK, continue.
4. Follow hoses or drain lines upstream from the tank to locate the heat source. The
pyrometer readings should increase or maintain temperature to the restriction, then
decrease dramatically as it is moved upstream from the restriction.
If the problem is found, refer to the appropriate function chapter for component(s)
troubleshooting and repair instructions.

4-20
D20x22 Series II Navigator HDD Service Troubleshooting

Flow Test for PFC Pump

Set Up You will need a pressure flow test device, equipped with a 0–6000 psi pressure test
gauge, a flow meter capable of reading 25 gpm in the middle of its flow range, a needle
valve and a handheld pyrometer.

WARNING: Pressurized fluid can penetrate body tissue and result in serious injury or
death. Leaks can be invisible. Keep away from any suspected leaks. Relieve pressure in
the hydraulic system before searching for leaks, disconnecting hoses, or performing any
other work on the system. If you must pressurize the system to find a suspected leak, use
an object such as a piece of wood or cardboard rather than your hands. When loosening
a fitting where some residual pressure may exist, slowly loosen the fitting until oil
begins to leak. Wait for leaking to stop before disconnecting the fitting. Fluid injected
under the skin must be removed immediately by a surgeon familiar with this type of
injury.

Case Drain Flow Conduct this test with a rod loaded in the
Test machine.

Hydraulic Fluid Distribution

1. With the machine shut down and all the
cylinders in a resting, de-energized
state, disconnect case drain line hose at
PFC pump return port 12 of hydraulic
tank (1).
2. Connect a 25 gpm flow meter to the
case drain line at the tank. Ensure flow
arrow on the meter is pointing to the
tank.
3. Have an assistant start and operate the
machine while you observe the flow
meter. The assistant will need to operate
the stabilizer or rack angle controls. 1
Take the cylinder to full extension and
continue to hold the handle (deadhead).
4. Ensure pump is at full displacement.
Note carefully the engine speed at the moment you note the indicated flow.
5. Observe and record the highest flow shown on the flow meter, and engine speed on
the tachometer when the pump is under as great a load as conditions allow.
6. Bring cylinder back to a resting state, shut down machine, remove flow meter, and
reconnect case drain line to tank. Analyze results.

4-21
 Troubleshooting D20x22 Series II Navigator HDD Service

Case Drain Flow Case drain flow shows the amount of leakage between the moving parts of the pump.
Analysis Internal leakage increases as the pressure on the high side of the loop increases in
relation to the pressure on the low side of the loop.

This is a piston pump, with an expected volumetric efficiency of 97–98% when new—
meaning they internally leak 2–3% of flow at working pressure. This pump is
considered worn beyond useful life when its volumetric efficiency declines to 90%
(10% internal leakage).

This pump displacement is 2.32 in3. The engine will pull down as a load is placed on the
system, so it is important to use the actual speed at the time the flow was noted.

• Multiply the speed (RPM) noted in the test times 2.32 to obtain theoretical flow
from the pump, in cubic inches per minute.
• Divide this by 231 to express this volume in gallons per minute (gpm).
• Multiply this by 0.10 to see the maximum allowable leakage for this engine speed.
• Example: If the speed was 2350 rpm at the highest flow...
2.32 in3 x 2350 rpm = 5452 in3/min
Hydraulic Fluid Distribution

5452 in3/min ÷ 231 = 23.6 gpm

23.6 gpm x 0.10 = 2.36 gpm max allowable case drain flow at 2350 rpm

If actual case drain flow is greater than the maximum allowed at that engine speed,
replace pump PMP2.

4-22
D20x22 Series II Navigator HDD Service Troubleshooting

Case Pressure Test 1. Disconnect and cap hoses at port M2 (1)

and port X (2). Install a 3/8'' hose with a
2
3000 psi rating between port M2 and port
1
X on compensator.
2. Install a T-fitting at port B (3). Attach one
end of a 1-inch diameter 3000 psi rated
hose to the fitting and the other end to the
inlet side of the flow meter. Ensure flow
arrow is pointing away from valve
manifold A9.
3. Connect hose which was at Port B to flow
meter. The other end of the hose will be
at the hydraulic tank.
3
4. Ensure needle valve on the flow meter is
fully open.
5. Connect a 1'' hose with a 3000 psi pressure rating to the fitting at port B. Connect
the other end of the hose to pressure gauge.

Hydraulic Fluid Distribution

6. Start engine and check all connections for leaks. Shut down and tighten connections
as needed to stop leaks.
7. Increase engine speed to 2400 rpm.
8. Use the pyrometer to ensure temperature of the fluid in the tank is at least 100°F
(38°C). If not, run gearbox forward and back to warm the fluid.
9. Observe tachometer and record the engine RPM, flow indicated on the meter, and
the pressure gauge at the beginning of the test.
10. Slowly turn in the needle valve on the pressure flow test device until the pressure
reaches 3300 psi (227 bar), then record the amount of flow indicated.
11. Observe tachometer and record the engine speed while the pressure flow test device
is indicating 3300 psi (227 bar).
12. Shut down machine, remove equipment and review results. Reconnect load sense
lines and other hoses.

4-23
 Troubleshooting D20x22 Series II Navigator HDD Service

Outlet Flow Test 1. Disconnect and cap hoses at ports M2 (1) and X (2) of PFC pump PMP2.
3

2. Remove diverter/fluid valve manifold A9 from port B (3) of PFC pump. Refer to
"PFC Pump PMP2," page 4-32.
Hydraulic Fluid Distribution

3. Install one end of a 3/8" diameter 3000 psi rated hose to the fitting at port M2 (1)
and the other end to the fitting at port X (2).
4. Disconnect hose attached to return line at port T of diverter/fluid valve A9.
5. Install a 3/8" diameter 3000 psi rated hose to the B port (3) of the PFC pump. Install
a flow meter between the B port of the PFC pump and the return line which was
disconnected from diverter/fluid valve A9. Ensure flow arrow is pointing away from
PFC pump.
6. Ensure needle valve on the flow meter is fully open.
7. Start engine and check all connections for leaks. Shut down and tighten connections
as needed to stop leaks.
8. Increase engine speed to 2400 rpm.
9. Use thermometer on the sight gauge to ensure temperature of the fluid in the tank is
at least 100°F (38°C). If not, run gearbox forward and back to warm the fluid.
10. Observe tachometer and record the engine RPM, flow indicated on the meter, and
the pressure gauge at the beginning of the test.
11. Slowly turn in the needle valve on the pressure flow test device until the pressure
reaches 3300 psi (227 bar), then record the amount of flow indicated.
Continued on next page...

4-24
D20x22 Series II Navigator HDD Service Troubleshooting

12. Observe tachometer and record the engine speed while the pressure flow test device
is indicating 3300 psi (227 bar).
13. Shut down machine, remove equipment and review results. Reconnect load sense
lines and other hoses.

A: Beginning B: Ending (at 3300 psi or 227 bar)

A1: engine speed: _________________________ rpm B1: engine speed: ________________________ rpm

A2: indicated flow:___________________gpm (L/min) B2: indicated flow:__________________ gpm (L/min)

A3: indicated pressure: _________________ psi (bar) B3: indicated pressure: ______3300 psi (227 bar)___

Understanding the The theoretical flow from this 2.32 cid (38 cc) pump, if run at 2400 rpm, is 24 gpm. This

Hydraulic Fluid Distribution

Results of Flow Test figure does not allow for any internal leakage. All pumps have some internal leakage
between the moving parts of the pump. Leakage drains into the case of the pump. The
case drain line carries this back to the tank.

This is a piston pump. New piston pumps are expected to be about 97% efficient, so
expected flow at 2400 rpm at 3000 psi is 23.3 gpm for this pump when new, and 17.5
gpm for a pump at the end of its useful life.

The engine may pull down as the pressure builds during the test. This will alter the flow.
It is important to calculate pump flow at the actual engine speed.

Calculating 1. Multiply value in B1 (ending engine speed) times 2.32 (displacement of the pump).
Theoretical Flow This is the theoretical flow in cubic inches per minute for this engine speed.
and Acceptable
Flow 2. Divide this amount by 231 to convert the cubic inches per minute to gallons per
minute.
3. Multiply this value by 0.90. The result is the minimum acceptable flow from this
pump at this engine speed.
Compare minimum acceptable flow value with the value recorded in B2. If B2 is lower,
the pump is worn beyond its useful life and should be replaced. See "PFC Pump
PMP2," page 4-32.

4-25
 Hydraulic Fluid Sampling D20x22 Series II Navigator HDD Service

HYDRAULIC FLUID SAMPLING

Preventive Maintenance
Sampling hydraulic fluid should be performed as part of a preventive maintenance
program. Analyzing the condition of the fluid may head off potential future
malfunctions.

Hydraulic Fluid Sampling

Once a circuit problem is found and the required repairs have been made, inspect oil
condition by taking a sample before returning the machine to service. Remove hydraulic
tank cap and smell hydraulic fluid. The fluid should have a bland or non-descript odor. If
the oil smells burnt or has a pungent odor, it may have been degraded by heat or
oxidation.

Draw a sample and compare it to a sample of new oil. It should appear clean, clear and
Hydraulic Fluid Distribution

amber in color. A milky haze or smoky appearance indicates there is water present. If so,
replace oil and filter. Refer to the D16x20 Series II/D20x22 Series II Maintenance
Manual for details.

Before start-up of a closed or open-loop circuit that has been repaired, the hydraulic oil
should be sampled and tested to determine levels of contamination. Samples can be
tested using an automatic, portable particle counter which uses light obstruction to
determine particle count.

The particle counter must be able to display ISO codes at 4, 6, & 14-micron levels and
also be able to produce a hard copy of data. The equipment must also be rated for at least
6000 psi (414 bar).

Using this method offers a multitude of uses and benefits which:

• verifies filter performance

• verifies pump condition
• verifies stored fluid cleanliness
• verifies changing atmospheric contamination
• confirms system flushing efficiency
• helps to troubleshoot and isolate problems
• determines optimum filter replacement intervals
• identifies new filter defects
• detects high corrosive wear
• identifies abrasive wear conditions
Continued on next page...

4-26
D20x22 Series II Navigator HDD Service Hydraulic Fluid Sampling

• confirms that target cleanliness levels have been achieved

• verifies breather condition
• recognizes filter bypass condition
• determines new fluid cleanliness
• identifies cavitation conditions
• identifies fluid film failure problems
NOTE: If not equipped with this type of sampling machine, fluid samples can be
obtained using hydraulic sampling kit, Vermeer P/N 108892001. Contact the Vermeer
Parts Center for information. The kit includes a vacuum gun and ten sampling bottles.

To order additional sample bottles, use Vermeer P/N 108890001. Samples are drawn
from the fluid tank, or diagnostic ports at different locations (see below), sealed in the
bottle supplied, and sent to the address supplied with kit.

Fluid Sampling Criteria:

• Ensure hydraulic fluid temperature is at least 100°F (38°C). Warm the fluid by
running the ground drive.

Hydraulic Fluid Distribution

• The engine speed must be set to low idle.
• All components in the hydrostatic circuit from which the sample is being taken must
be connected and pump must be at full stroke.

4-27
 Hydraulic Fluid Sampling D20x22 Series II Navigator HDD Service

Fluid Sample
Collection Points

To sample the drill rotation and thrust/pullback closed-loop circuit, use charge pressure
port M3 (1) of pump PMP1. You will need to disconnect the hose to the torque limiter
valve. To sample open-loop circuits, use PFC pump return port 12 (2) of hydraulic tank
Hydraulic Fluid Distribution

RES1.

Cleanliness Approval Criteria:

• Fluid sample must be at 4, 6, & 14 micron ISO code of 18/16/13 or less.

• If a hydraulic tank sampling is above ISO code 18/16/13, the hydraulic fluid, charge
and return filters, should be replaced. The suction screen should also be cleaned or
replaced. Refer to the D16x20 Series II/D20x22 Series II Maintenance Manual for
instructions.
• If a sample taken from the drill rotation closed loop or thrust/pullback closed loop is
above ISO code 18/16/13, high pressure closed-loop filtration should be installed
and operated for 15 minutes, then resampled.
• If sample is still above ISO code 18/16/13, the hydraulic fluid, charge and return
filters should be replaced. Refer to the D16x20 Series II/D20x22 Series II
Maintenance Manual for instructions.

4-28
D20x22 Series II Navigator HDD Service Component Repair

Flushing the Implement and Transport System

General Guidelines When replacing hydraulic components, do not allow contaminants to enter the circuit.
for Hydraulic
Circuits • Clean components and fittings before disconnecting them.
• For parts that will remain on the machine, cap or plug all fittings and components
using clean plastic caps and plugs. If clean caps are unavailable, use plastic
sandwich bags wrapped over fittings held in place with rubber bands.
• Keep protective caps on hose ends and in fittings as long as possible during the
installation process.
• All oil supply components (tank, hoses, tubes, fittings) must be clean. If possible,
use a foam projectile cleaning system, part number 307480001 to clean hoses.
Otherwise, rinse all components with clean solvent (solvent must be filtered through
a 5-micron filter), and dried with filtered air before installation.
• Fill all hoses with new filtered oil during reassembly.
• For any externally drained motor or pump, fill case with new, filtered oil through the
highest case drain port. The case drain hose is usually attached to the highest drain
port.

Hydraulic Fluid Distribution

• Start engine and run at idle. Check for leaks, and operate machine functions. Expect
jerky motion of cylinders and motors (keep people and property clear) until trapped
air is worked out of the circuit. When motion is smooth, run engine at normal
operating speed, recheck all connections and operate the functions.
• After the functions are operating smoothly, check hydraulic tank fluid level. If
needed, add new fluid run through a 5-micron filter.

COMPONENT REPAIR

WARNING: Pressurized fluid can penetrate body tissue and result in serious injury or
death. Leaks can be invisible. Keep away from any suspected leak. Relieve pressure in
the hydraulic system before searching for leaks, disconnecting hoses, or performing any
other work on the system. If you must pressurize the system to find a suspected leak, use
an object such as a piece of wood or cardboard rather than your hands. When loosening a
fitting where some residual pressure may exist, slowly loosen the fitting until oil begins
to leak. Wait for leaking to stop before disconnecting the fitting. Fluid injected under the
skin must be removed immediately by a surgeon familiar with this type of injury.

4-29
 Component Repair D20x22 Series II Navigator HDD Service

Diverter/Fluid Valve Assembly A9

6

8
7

2 5

4
3
Hydraulic Fluid Distribution

9
Remove 1. Label, disconnect, and cap all fittings and hoses.
2. Remove bolts (3), washers (4) and nuts (5) holding valve (1) to mounting plate (2).
3. Remove fitting (6). Leave fitting on PFC pump.
4. Lift valve out of engine bay.
5. Remove fittings (7, 8, and 9).
Reverse steps to install valve. Torque bolts (3) to 35 ft-lb (47 Nm).

4-30
D20x22 Series II Navigator HDD Service Component Repair

Directional Valve DV16–DV18 and DV24 and Relief Valve PV4

Disassembly 1. Remove nuts (1) and solenoid coils (2).
2 5 1 2
2. Remove nut (3) and solenoid coil (4).
3. Remove cartridge valve and O-rings.
4. Inspect cartridge valves and O-rings for
damage and ensure no external
contaminants are present.
5. Remove relief valve (5).
6. Inspect relief valve for damage. 1 3 4

7. Inspect valve body cavity for burrs or other

irregularities which could damage O-rings
during installation.

Hydraulic Fluid Distribution

Assembly When assembling valve, reverse disassembly procedure.

Torque solenoid coil nuts (1) to 5 ft-lb (6.8 Nm). Torque solenoid coil nut (3) to 4–5 ft-lb
(5.4–6.8 Nm). Torque solenoid coils (2) to 25 ft-lb (33.9 Nm). Torque solenoid coils (4)
to 33–37 ft-lb (44.9–50.3 Nm). Use a hex-head Allen wrench to install relief valve.
Torque relief valve to 20 ft-lb (27 Nm).

When installing control valve, reverse removal procedures.

Torque mounting bolts to 35 ft-lb (47 Nm).

4-31
 Component Repair D20x22 Series II Navigator HDD Service

PFC Pump PMP2

6
5

2
7
3
Hydraulic Fluid Distribution

Remove 1. Drain hydraulic tank of fluid.

2. Clean pumps and surrounding area.
3. Label, disconnect and cap all hoses and fittings.
4. For clearance, remove controller and diverter/fluid valve A9.
5. Support pump (1) from beneath.
6. Remove nuts (2) holding pump support plate (3) to pump support weldment (4).
Remove mounting bolts (5), washers (6) and nuts (7) holding pump to rotation and
thrust pump.
7. Disengage shaft from rotation and thrust pump.
8. Lift PFC pump from engine bay.
IMPORTANT: If hydraulic pumps are under warranty, all repair must be done by a
Sauer Danfoss Service Center or warranty will be voided.

Install Reverse removal steps to install pump. Apply light coating of oil to splined shaft of
pump. Torque mounting bolts (5) to 90 ft-lb (120 Nm).

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D20x22 Series II Navigator HDD Service Component Repair

Disassembly – Shaft 1. Using appropriate snap-ring pliers,

Seal Replacement remove retaining ring (1) from housing. 1
2
2. Remove shaft seal (2) from bore in pump
housing and discard. Avoid damaging
pump housing or shaft.
NOTE: Puncture face of seal with a packing
hook, or use a slide-hammer type puller to
remove seal.

Assembly – Shaft 1. Inspect pump housing and new seal for damage. Inspect sealing area on shaft for
Seal Replacement rust, wear or contamination. Polish sealing area on shaft, if necessary.
2. Lubricate lip of new shaft seal with clean hydraulic fluid. Place a protective sleeve
over shaft end to prevent damage to seal during installation.
3. While keeping seal perpendicular to shaft, press new seal into housing just far

Hydraulic Fluid Distribution

enough to clear retaining ring groove. Install seal with cupped side toward shaft
bearing. Do not damage seal during installation.
Press seal into housing only far enough to clear retaining ring groove.

WARNING: Premature bearing failure can result if shaft seal contacts shaft bearing.

4. Using appropriate snap-ring pliers, install seal retaining ring.

5. Remove installation sleeve.

4-33
 Component Repair D20x22 Series II Navigator HDD Service

Disassembly – 1. Remove two screws (1) retaining gear

Auxiliary Pads pump. Remove gear pump and its
sealing O-ring (2).
2. Remove drive coupling (3).
6
3. Remove four screws (4) retaining pad 4
adapter (5) to end cap. Remove and 2
discard two pad adapter O-rings (6).
3

5
1

Assembly – 1. Lubricate new O-rings with petroleum jelly. Install pad adapter to end cap.
Auxiliary Pads
2. Install four screws and torque to 35–45 ft-lb (47–61 Nm).
3. Install drive coupling.
Hydraulic Fluid Distribution

4. Install gear pump with new O-ring.

5. Install two screws and torque to 27–37 ft-lb (37–50 Nm).

4-34
D20x22 Series II Navigator HDD Service Component Repair

14
15
16
3 17
1 11 18 4
12
5

6
13
7
20 2
19

21
10
9
8

Hydraulic Fluid Distribution

Disassembly – 1. Remove four screws (1) holding control housing onto end cap.
Pump Control
2. Remove control. Remove and discard three interface O-rings (2).
3. Remove pressure compensator setscrew (3), pressure compensator adjustment
screw (4), O-ring (5), springs (6), and seat (7). Discard O-ring.
4. Remove plug (8), O-ring (9), and pressure compensator spool (10) from control
housing; discard O-ring. Note orientation of spool for reassembly.
5. Remove plug (11) and O-ring (12); discard O-ring.
6. Remove load sense setscrew (13), load sense adjustment screw (14), O-ring (15),
backup rings (16), springs (17), and seat (18). Discard O-ring.
7. Remove plug (19), O-ring (20), and load sense spool (21) from control housing.
Discard O-ring. Note orientation of spool for reassembly.

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 Component Repair D20x22 Series II Navigator HDD Service

Assembly – Pump 1. Inspect adjustment screws for wear at tips and where they contact springs. Replace
Control as necessary.
2. Inspect springs and spring guides for wear or damage. Replace as necessary.
3. Carefully inspect spools. Ensure sealing area is free of nicks and scratches. Check
ends that contact spring guides for wear. Replace spools as necessary.
4. Inspect control housing for damage. Check spool bores for excessive wear.
5. Clean all parts and lubricate spools, springs, guides and new O-rings with clean
hydraulic fluid.
6. Install pressure compensator spool, spherical end first into pressure compensator
bore. Pressure compensator spool is shorter spool.Using a new O-ring, install plug.
Torque to 8–10 ft-lb (11–14 Nm).
7. Place two pressure compensator springs onto spring guide and install into pressure
compensator bore. Place a new O-ring onto pressure compensator adjustment screw
and thread it into bore until flush, then make another full turn. Install setscrew and
torque to 6–8 ft-lb (7–11 Nm).
Hydraulic Fluid Distribution

8. Install load sense spool, spherical end first into load sense bore. Load sense spool is
longer spool. Using a new O-ring, install plug. Torque to
8–10 ft-lb (11–14 Nm).
9. Place two load sense springs onto spring guide and install into load sense bore.
Place a new O-ring onto load sense adjustment screw and thread it into bore until
flush, then make another full turn. Install setscrew and torque to 6–8 ft-lb (7–11
Nm).
10. Using a new O-ring, install plug. Torque to 8–10 ft-lb (11–14 Nm).
11. Using petroleum jelly to retain them, install three interface O-rings in recesses on
control housing.
12. Install control assembly onto end cap using four screws. Torque to 11–13 ft-lb (15–
18 Nm). Torque screws in a criss-cross pattern and re-torque first screw to ensure
proper torque retention.
13. Check and adjust control setting.

Rotation/Thrust Pump PMP1

Refer to "Rotation and Thrust Pump PMP1," page 9-47.

4-36
D20x22 Series II Navigator HDD Service Component Repair

Charge Pump PMP4

Refer to "Charge Pump," page 9-8.

Oil Cooler/Radiator HE1

5
8 2
7
6

3
4

Hydraulic Fluid Distribution

1
11

10 3
12
9 4

1. Lift engine bay hood.

2. Label, disconnect and cap hoses on cooler assembly (1).
3. Remove fittings (2).
4. Loosen hose clamps (3) on radiator hoses (4) at radiator. Disconnect hoses.
5. Remove bottle (5).
6. Remove metric M8 bolts (6) on upper radiator mounting plate (7). Remove upper
radiator mounting plate (7) and upper radiator rubber mount (8).
7. Remove bolts (9) and washers (10) attaching engine fan cover (11) to cooler
assembly.
8. Remove bolts (12) on radiator/cooler assembly mount.
9. Use hoist to lift cooler assembly from machine.
Reverse steps above to install cooler assembly. Torque bolts (12) to 10 ft-lb (13 Nm).

4-37
This page intentionally left blank.
D20x22 Series II Navigator HDD Service Overview

Chapter 5: Stakedown

OVERVIEW
The stakedown circuits are made up of electrical and hydraulic components that control
the stakedown motors and stakedown cylinders. Two hydraulic motors rotate the stakes.
While the stake is rotating, the left or right stakedown cylinder can be extended to drive
the stake into the ground. When driven into the ground, they stabilize the machine
during operation.

THEORY
Functions/Circuits
The stakedown function is comprised of two circuit groupings that rely on pump PMP2
for their hydraulic function. The two circuits are:

• Stake Rotation Circuit

• Stake Lower/Raise Circuit

Stakedown
Components
The functions covered in this section include the following components:

• Stakedown Valve Assembly A12, including:

• Directional Valves DV25–DV28
• Check Valves CV3 and CV4
• Solenoids L7, L8 and L10–L13
• Stakedown Motors MH7 and MH8
• Stakedown Cylinders CY4 andCY5
• Switches S25–S27

5-1
 Theory D20x22 Series II Navigator HDD Service

Component Locations

STAKEDOWN CYLINDER CY4 OR CY5

STAKEDOWN MOTOR MH7 OR MH8

STAKEDOWN LEFT/RIGHT SWITCH S27

STAKEDOWN LIFT/LOWER SWITCH S25
Stakedown

STAKEDOWN ROTATE SWITCH S26

STAKEDOWN VALVE A12

5-2
D20x22 Series II Navigator HDD Service Theory

Hose Connections

RIGHT STAKEDOWN
CYLINDER CY5 RIGHT STAKEDOWN
MOTOR MH7

STAKEDOWN
VALVE A12

VISE LEFT STAKEDOWN

VALVE MOTOR MH8
A13

Stakedown
DIVERTER/FLUID
VALVE A9

TO PFC PUMP LEFT STAKEDOWN

LOAD SENSE PORT CYLINDER CY4

5-3
 Theory D20x22 Series II Navigator HDD Service

Hydraulic Schematic
LEFT STAKEDOWN RIGHT
MOTOR MH7 STAKEDOWN
MOTOR MH8
LEFT STAKEDOWN RIGHT
CYLINDER CY4 STAKEDOWN
CYLINDER CY5
DIVERTER/FLUID VALVE A9

DV17
DV25 DV26
DV28
DV27

PV7

STAKEDOWN
VALVE A12
Stakedown

VISE VALVE A13

PFC PUMP PMP2

RETURN MANIFOLD A17

SUCTION MANIFOLD A15

5-4
D20x22 Series II Navigator HDD Service Theory

Electrical Schematic

Stakedown

5-5
 Theory D20x22 Series II Navigator HDD Service

Shared Components
The stakedown function shares the common hydraulic fluid distribution components, as
well as diverter/drilling fluid valve assembly A9. The hydraulic fluid distribution
components are shared by all functions with hydraulic circuits. These components
include:

• Hydraulic Tank RES1

• Oil Cooler HE1
• PFC Pump PMP2
For more information on the hydraulic fluid distribution components and diverter/
drilling fluid valve assembly A9, refer to Chapter 4.

Stakedown Valve Assembly A12

M2
C4
C2
M4
Stakedown

C1
C3
P1
M1 M3 T
T1 P
Solenoid-operated directional valve DV25 within the stakedown manifold selects right
or left cylinder function. Directional valve DV26 simultaneously selects between right
or left motor functions. Individual 3-position, 4-way solenoid valves select “stake
down” or “stake up” operation of cylinder CY4, cylinder CY5, motor MH7, and motor
MH8.

Relief pilot valve PV7 allows oil to flow to the motor-controlling valves when the
incoming oil pressure reaches 2500 psi (172 bar) in the
cylinder-controlling line.

5-6
D20x22 Series II Navigator HDD Service Theory

Stakedown Cylinder Left Stake Down Mode

CY4 CY5
DIVERTER/FLUID VALVE A9

FROM HYDRAULIC
ENABLE S10 L20

DV17
L12
FROM
STAKE DV25
DV27
LOWER
S25 L7
L9

FROM STAKE
LOWER S25
DV24

STAKEDOWN VALVE A12

Stakedown
Operation To operate the left stake DOWN mode:

• Seat switch S11 must be closed (operator in seat).

• Remote Lockout system must be in RUN mode.
• Hydraulic enable switch S10 must be pressed to ENABLE.
• Stakedown Left/Right switch S27 must be set to L position.
• Stakedown cylinder switch S25 must be set to DOWN position.
When required operating conditions are met:

• Oil flows from PFC pump PMP2 to diverter/drilling fluid valve A9.
• Hydraulic enable switch S10 sends a signal to solenoid L20 that activates DV17 in
diverter/drilling fluid valve A9. Oil flows from port B2 of valve A9 to port P of
stakedown valve A12.
• Switch S25 sends a signal to solenoid L7, which shifts valve DV27. Oil flows to
valve DV25.
• Switch S25 also sends a signal to solenoid L9 in valve DV24, allowing pressure to
build in the load sense line and return to tank.
• Switch S27 sends no signal to solenoid L12, so valve DV25 remains in position, and
oil flows through valve to base end of cylinder CY4.
Continued on next page...

5-7
 Theory D20x22 Series II Navigator HDD Service

• Cylinder CY4 extends.

NOTE: If the stakedown function does not operate as expected, see
"Troubleshooting/Testing Stakedown Function," page 5-21.
Stakedown

5-8
D20x22 Series II Navigator HDD Service Theory

Stakedown Cylinder Right Stake Down Mode

DIVERTER/FLUID VALVE A9 CY4 CY5

FROM HYDRAULIC
L20
ENABLE S10 FROM
DV17 LEFT/
RIGHT
S27 L12
DV25
DV27
L7
L9
FROM
STAKE
FROM STAKE
LOWER
LOWER S25
S25
DV24

STAKEDOWN VALVE A9

Stakedown
Operation To operate the right stake DOWN mode:

• Seat switch S11 must be closed (operator in seat).

• Remote Lockout system must be in RUN mode.
• Hydraulic enable switch S10 must be pressed to ENABLE.
• Stakedown Left/Right switch S27 must be set to R position.
• Stakedown cylinder switch S25 must be set to DOWN position.
When required operating conditions are met:

• Oil flows from PFC pump PMP2 to diverter/drilling fluid valve A9.
• Hydraulic enable switch S10 sends a signal to solenoid L20 that activates DV17 in
diverter/drilling fluid valve A9. Oil flows from port B2 of valve A9 to port P of
stakedown valve A12.
• Switch S25 sends a signal to solenoid L7, which shifts valve DV27. Oil flows to
valve DV25.
• Switch S25 also sends a signal to solenoid L9 in valve DV24, allowing pressure to
build in the load sense line and return to the tank.
• Switch S27 sends a signal to solenoid L13, shifting valve DV25, and oil flows
through valve to base end of cylinder CY5.
Continued on next page...

5-9
 Theory D20x22 Series II Navigator HDD Service

• Cylinder CY5 extends.

NOTE: If the stakedown function does not operate as expected, see
"Troubleshooting/Testing Stakedown Function," page 5-21.
Stakedown

5-10
D20x22 Series II Navigator HDD Service Theory

Stakedown Cylinder Stake Up Mode

DIVERTER/FLUID VALVE A9 CY4 CY5

FROM HYDRAULIC
L20
ENABLE S10
DV17
L12
FROM
STAKE
LIFT DV27
S25 L8
L9

FROM STAKE
LIFT S25
DV24

STAKEDOWN VALVE A12

Stakedown
Operation To operate the left and right stake UP mode:

• Seat switch S11 must be closed (operator in seat).

• Remote Lockout system must be in RUN mode.
• Hydraulic enable switch S10 must be pressed to ENABLE.
• Stakedown cylinder switch S25 must be set to UP position.
When required operating conditions are met:

• Oil flows from PFC pump PMP2 to diverter/drilling fluid valve A9.
• Hydraulic enable switch S10 sends a signal to solenoid L20 that activates DV17 in
diverter/drilling fluid valve A9. Oil flows from port B2 of valve A9 to port P1 of
stakedown valve A12.
• Switch S25 sends a signal to solenoid L8, which shifts valve DV27. Oil flows to rod
end of cylinders.
• Switch S25 also sends a signal to solenoid L9 in valve DV24, allowing pressure to
build in the load sense line and return to the tank.
• Cylinders CY4 and CY5 retract.
NOTE: If the stakedown function does not operate as expected, see
"Troubleshooting/Testing Stakedown Function," page 5-21.

5-11
 Theory D20x22 Series II Navigator HDD Service

Stakedown Motor Left Stake In Mode

MH7

DIVERTER/FLUID VALVE A9

FROM
HYDRAULIC L20
ENABLE S10
DV17

DV26
L12 FROM
DV28 STAKE
L10 ROTATE
S26
L9
FROM STAKE
ROTATE S26
DV24

STAKEDOWN VALVE A12

Stakedown

Operation To operate the left stakedown motor STAKE IN mode:

• Seat switch S11 must be closed (operator in seat).

• Remote Lockout system must be in RUN mode.
• Hydraulic enable switch S10 must be pressed to ENABLE.
• Stakedown Left/Right switch S27 must be set to L position.
• Stakedown rotate switch S26 must be set to DOWN position.
When required operating conditions are met:

• Oil flows from PFC pump PMP2 to diverter/drilling fluid valve A9.
• Hydraulic enable switch S10 sends a signal to solenoid L20 that activates DV17 in
diverter/drilling fluid valve A9. Oil flows from port B2 of valve A9 to port P of
stakedown valve A12.
• Switch S26 sends a signal to solenoid L10, which shifts valve DV28. Oil flows to
valve DV26.
• Switch S26 also sends a signal to solenoid L9 in valve DV24, allowing pressure to
build in the load sense line and return to the tank.
• Switch S27 sends no signal to solenoid L13, so valve DV26 remains in position, and
oil flows through valve to port A of motor MH7.
Continued on next page...

5-12
D20x22 Series II Navigator HDD Service Theory

• Motor MH7 rotates clockwise (CW).

NOTE: If the stakedown function does not operate as expected, see
"Troubleshooting/Testing Stakedown Function," page 5-21.

Stakedown

5-13
 Theory D20x22 Series II Navigator HDD Service

Stakedown Motor Right Stake In Mode

MH8

DIVERTER/FLUID VALVE A9

FROM
HYDRAULIC L20 FROM
ENABLE S10 LEFT/
DV17
RIGHT
S27
L13 DV26

L10

DV28 FROM
L9
STAKE
FROM STAKE
ROTATE
ROTATE S26
S26
DV24

STAKEDOWN VALVE A12

Stakedown

Operation To operate the right stakedown motor STAKE IN mode:

• Seat switch S11 must be closed (operator in seat).

• Remote Lockout system must be in RUN mode.
• Hydraulic enable switch S10 must be pressed to ENABLE.
• Stakedown Left/Right switch S27 must be set to R position.
• Stakedown rotate switch S26 must be set to DOWN position.
When required operating conditions are met:

• Oil flows from PFC pump PMP2 to diverter/drilling fluid valve A9.
• Hydraulic enable switch S10 sends a signal to solenoid L20 that activates DV17 in
diverter/drilling fluid valve A9. Oil flows from port B2 of valve A9 to port P of
stakedown valve A12.
• Switch S26 sends a signal to solenoid L10, which shifts valve DV28. Oil flows to
valve DV26.
• Switch S26 also sends a signal to solenoid L9 in valve DV24, allowing pressure to
build in the load sense line and return to the tank.
• Switch S27 sends a signal to solenoid L13, so valve DV26 shifts position and oil
flows through valve to port A of motor MH8.
Continued on next page...

5-14
D20x22 Series II Navigator HDD Service Theory

• Motor MH8 rotates clockwise (CW).

NOTE: If the stakedown function does not operate as expected, see
"Troubleshooting/Testing Stakedown Function," page 5-21.

Stakedown

5-15
 Theory D20x22 Series II Navigator HDD Service

Stakedown Motor Stake Out Mode

DIVERTER/FLUID VALVE A9

FROM
HYDRAULIC L20
ENABLE S10
DV17

L13 FROM
STAKE
ROTATE
L11 S26
L9 DV28

FROM STAKE
ROTATE S26
DV24

STAKEDOWN VALVE A12

Stakedown

Operation To operate the stakedown motor STAKE OUT mode:

• Seat switch S11 must be closed (operator in seat).

• Remote Lockout system must be in RUN mode.
• Hydraulic enable switch S10 must be pressed to ENABLE.
• Stakedown Left/Right switch S27 may be set to L or R position.
• Stakedown rotate switch S26 must be set to UP position.
When required operating conditions are met:

• Oil flows from PFC pump PMP2 to diverter/drilling fluid valve A9.
• Hydraulic enable switch S10 sends a signal to solenoid L20 that activates DV17 in
diverter/drilling fluid valve A9. Oil flows from port B2 of valve A9 to port P of
stakedown valve A12.
• Switch S26 sends a signal to solenoid L11, which shifts valve DV28. Oil flows to
port B of both motor MH7 and MH8.
• Switch S26 also sends a signal to solenoid L9 in valve DV24, allowing pressure to
build in the load sense line and return to the tank.
• Motors MH7 and MH8 rotate counterclockwise (CCW).
NOTE: If the stakedown function does not operate as expected, see
"Troubleshooting/Testing Stakedown Function," page 5-21.

5-16
D20x22 Series II Navigator HDD Service Troubleshooting

TROUBLESHOOTING
Troubleshooting procedures are given in this chapter for each function’s operating
modes. Each procedure begins by performing a pretest inspection of the machine. See
"Pretest Inspection," page 5-17.

If nothing obvious is found during the inspection, it may be necessary to operate all
other functions of the machine to help further isolate a component problem. See
"Troubleshooting Machine Performance," page 5-19.

Pretest Inspection
Perform the following visual checks to inspect for obvious signs of failure before
troubleshooting or testing is performed.

Mechanical

Inspect the mechanical valve control handles and linkages for damage, misalignment, or
improper adjustment.

Electrical

Stakedown
Inspect electrical wiring for obvious problems. Always check the following items before
turning on switches or running the unit.

• Look for bare wires that could cause grounds or shorts.

• Look for broken, missing, corroded, or loose connections on the power wires that
supply electrical circuit components.
• Check all ground connections on the machine and chassis for tight
connections. Cleaning harness connections or ground connections can often correct
what appears to be a malfunctioning component.
• Check for overheated electrical components. They will often smell like burned
insulation.

Continued on next page...

5-17
 Troubleshooting D20x22 Series II Navigator HDD Service

Hydraulic

WARNING: Pressurized fluid can penetrate body tissue and result in serious injury or
death. Leaks can be invisible. Keep away from any suspected leak. Relieve pressure in the
hydraulic system before searching for leaks, disconnecting hoses, or performing any other
work on the system. If you must pressurize the system to find a suspected leak, use an
object such as a piece of wood or cardboard rather than your hands. When loosening a
fitting where some residual pressure may exist, slowly loosen the fitting until oil begins to
leak. Wait for leaking to stop before disconnecting the fitting. Fluid injected under the skin
must be removed immediately by a surgeon familiar with this type of injury.

Check hydraulic components for any obvious problems.

• Look for broken, kinked, loose, or leaking hoses and fittings on supply, pressure,
and return to hydraulic components.
• Check level of hydraulic fluid in hydraulic tank. Low fluid can cause erratic
operation in hydraulic circuits. Correct level is between the two lines on dipstick. If
needed, add new fluid that has been filtered through a 5-micron filter.

Also review information in the General Information chapter under "Hydraulic

Troubleshooting," page 1-12. Correct any problems found during the inspection.
Operate machine to verify the problem is fixed.
Stakedown

5-18
D20x22 Series II Navigator HDD Service Troubleshooting

Troubleshooting Machine Performance

Possible faults may occur in the stakedown function that are directly related to faults in
other functions. These other faults may not be readily apparent, because those particular
functions are not currently being operated.

Operate the machine functions and document performance of working actuators.

Note any functions not operating normally based on the normal operation given in each
chapter for that function. To help isolate a faulty component or function, compare the
notes you have taken to the normal operation given for each mode of a particular
function.

After doing the machine performance checks, if the problem is isolated to the stakedown
function, continue with troubleshooting. If multiple functions are affected, proceed with
troubleshooting based on the possible results listed below.

Possible Results 1. If all machine functions are malfunctioning, it would indicate a function or
component that is common to all the actuators is most likely malfunctioning. The
following functions and components should be investigated:
• Engine. See "Engine," page 3-6.
• Shared hydraulic components. See Chapter 4.
• Remote Lockout. See Chapter 15.

Stakedown
2. If problems are noted in the stakedown, rod greaser, rod loader, and vise functions,
and all other functions of the machine are operating normally, the hydraulic
components common to just these functions should be investigated, including:
• Diverter/Fluid Valve Assembly A9. See "Oil Supply Function," page 4-6.
• PFC pump PMP2. See "PFC Pump PMP2," page 4-6.
• Hydraulic enable circuitry. See electrical schematic in Addendum.

5-19
 Troubleshooting D20x22 Series II Navigator HDD Service

Testing Stakedown Performance

NOTE: Checking the stakedown performance requires the use of a marking device to
visually check stakedown rotation motor speed.

1. Conduct machine inspection before

proceeding. 2
1
2. If the engine has not been started, refer to
"Starting the Engine," page 2-2 and
perform before proceeding.
3. Enable Remote Lockout.
4. Press hydraulic enable push button S10 (1)
to enable stakedown hydraulic circuit.
5. Select left or right stakedown circuit using LEFT/RIGHT switch S27 (2).
NOTE: Raise the rack to its fully raised position and remove stakedown augers before
continuing.

NOTE: The performance values listed for stakedown functions are for reference
purposes only. Loaded circuit extension and retraction times experienced under working
conditions will vary from the unloaded conditions in this test. Operating conditions of
the stakedowns should not be determined by the results of these tests alone. If circuit
operation is in question, operating the stakedowns in working conditions may be
Stakedown

required.

6. Ensure chosen stakedown cylinder is at its most retracted (raised) position.

7. Press top of stakedown valve switch S25
(1) to the LOWER position. Stakedown 2
cylinder will fully extend in approximately
3 seconds. It should only take one second
if the stake is not attached.
8. Press bottom stakedown valve switch S25
(1) to the RAISE position. Stakedown
1
cylinder will fully retract in approximately
3 seconds. It should only take one second if the stake is not attached.
9. Repeat process for the opposite cylinder.
10. Press top of stakedown rotation valve switch S26 (2) to CLOCKWISE position
(CW). Measure rotation speed of motor using phototach or counting rotations for 60
seconds. Rotation speed will be approximately 20 rpm.
11. Repeat process for the opposite motor.

5-20
D20x22 Series II Navigator HDD Service Troubleshooting

Troubleshooting/Testing Stakedown Function

WARNING: Pressurized fluid can penetrate body tissue and result in serious injury or
death. Leaks can be invisible. Keep away from any suspected leaks. Relieve pressure in
the hydraulic system before searching for leaks, disconnecting hoses, or performing
any other work on the system. If you must pressurize the system to find a suspected
leak, use an object such as a piece of wood or cardboard rather than your hands. When
loosening a fitting where some residual pressure may exist, slowly loosen the fitting
until oil begins to leak. Wait for leaking to stop before disconnecting the fitting. Fluid
injected under the skin must be removed immediately by a surgeon familiar with this
type of injury.

1. Before beginning any troubleshooting or testing procedures, perform the "Pretest

Inspection," page 5-17. If nothing obvious is found continue.
2. In order to ensure the fault is isolated to the stake IN or OUT mode, the technician
should operate all the machine functions and observe the actuators as discussed in
"Troubleshooting Machine Performance," page 5-19.
If any functions other than the left or right stakedown functions are faulty, continue
troubleshooting based on the possible results given. If all other machine functions
are operating normally, continue with step 3.
3. Determine if the problem is with the right, left or both stakedowns.

Stakedown
If the problem is only with the right or left stakedown, check the function of
stakedown selector switch S27. Disconnect switch and check for continuity. If OK,
continue to step 4.
If the problem is with both stakedowns, continue to step 5.
4. Check for voltage at wire 837B of solenoid L12 and wire 837C of solenoid L13.
Expected result: 12 volts DC at wire 837B of solenoid L12 and 837C of solenoid
L13. If not, wire is faulty and should be replaced. If so, continue.
5. Test resistance of solenoid coils L7, L8, L10, L11, L12 and L13.
Expected result: Resistance should measure 4.8 ohms @ 68°F (20°C). If OK,
continue with step 5. If not, replace coil.

6. Check the function of stakedown cylinder switch S25 and stakedown motor switch
S26. Disconnect switches and check for continuity.
Expected Result: Both switches will show continuity between pins 1 and 2 when not
compressed, and between pins 1 and 3 when compressed. If not, replace faulty
switch. If so, continue.

5-21
 Troubleshooting D20x22 Series II Navigator HDD Service

7. Determine if the motors or cylinders are

operating abnormally. If motors are L12 L7 L8 L10
suspected, check for voltage at wire 835
of solenoid L10 and wire 836 of solenoid
L11. L13
Expected result: 12 volts DC at wire 835
of solenoid L10 and wire 836 of solenoid L11
L11. If not, wire is faulty and should be
replaced. If so, continue.
8. If cylinders are suspected, check for
voltage at wire 831 of solenoid L7 and
wire 832 of solenoid L8.
Expected result: 12 volts DC at wire 831
of solenoid L7 and wire 832 of solenoid
L8. If not, wire is faulty and should be replaced. If so, continue.
9. Determine if the motors or cylinders are operating abnormally. See the common
symptoms of faulty hydraulic components under "Hydraulic Troubleshooting,"
page 1-12. If only the cylinder is faulty, go to step 9. If only the motor is faulty, go
to step 10. If both are operating abnormally, go to step 11.
NOTE: Hydraulic component testing is based on volumetric efficiency. Test the
components for excessive internal leakage to determine if they are worn beyond design
specification. Refer to the Vermeer Industrial Dealerships Technician’s Shop Manual
(Vermeer P/N 105400V80) for information on how to test these components.
Stakedown

10. Test cylinder for internal cross-piston leakage. Cross-piston leakage can be caused
by damage or wear in the internal cylinder tube wall or piston seals.
Expected result: No flow should be measured when deadheading with PFC pump
PMP2 high compensator setting of 3300 psi (227 bar). If so, repair or replace
cylinder. Refer to component repair at the end of this section for information.
11. Test efficiency of motor. Excessive cross-port leakage can be caused by damage or
wear to internal components.
Expected result: Shaft speed should be 90 rpm or faster when tested with PFC
pump PMP2 high compensator setting of 3300 psi (227 bar). If not, repair or replace
motor. Refer to component repair at the end of this section for repair information.
Continued on next page...

5-22
D20x22 Series II Navigator HDD Service Troubleshooting

If one motor turns significantly slower than the other one, shut down and swap
hoses for the two motors at valve manifold A12. If the same motor still turns slower,
replace motor. If the other motor now turns slower, remove and inspect valve
cartridge associated with that motor. Refer to component repair for information.
12. If both cylinder and motor are not working properly, it may indicate a common
component to both actuators is at fault. Disassemble stakedown valve check valve
CV4 and inspect for contamination or damage to internal seals, O-rings, and internal
components. Refer to component repair in this section for information.

Test Equipment Needed

To perform the troubleshooting procedures in this chapter, the following test equipment
will be needed:

• Multimeter for continuity tests, voltage measurements, resistance

measurements in the various electrical circuits.
• Various hydraulic testing tools

NOTE: The hydraulic component test procedures discussed in this chapter will refer
the technician to the Vermeer Industrial Dealerships Technician’s Shop Manual
(Vermeer P/N 105400V80). Test procedures and equipment needed for performing

Stakedown
various tests on hydraulic components will be listed in the manual.

5-23
 Troubleshooting D20x22 Series II Navigator HDD Service

Specifications
Listed below are the electrical and hydraulic specifications for the components in this
chapter.

Electrical:

• Nominal circuit voltage - 12 volts DC

• Stakedown valve solenoid coils L7, L8, L10, L11, L12, and L13 - 7.2 ohms @ 68°F
(20°C)
Hydraulic:

• PFC Pump PMP2 normal output flow - variable to 24 gpm (90.8 L/min)
• PFC Pump PMP2 standby pressure compensator valve setting - 250 psi (17.2 bar)
• PFC Pump PMP2 high pressure compensator valve setting - 3300 psi (227.5 bar)
• Stakedown Motors MH7 and MH8 maximum speed (continuous) - 90 rpm
• Stakedown Motors MH7 and MH8 displacement - 63.9 cid (1047 cc)
• Stakedown Motors MH7 and MH8 maximum flow (continuous) - 25 gpm (94 L/
min)
• Stakedown Cylinders CY4 and CY5 maximum pressure - 3000 psi
(206.8 bar)
Stakedown

Component Repair/Replace
If troubleshooting procedures determine a component is in need of repair or
replacement, refer to the appropriate procedures at the back of the chapter or other
chapters where instructed. After repairs have been made, refer to "Hydraulic Fluid
Sampling," page 4-26 and follow instructions.

WARNING: Pressurized fluid can penetrate body tissue and result in serious injury or
death. Leaks can be invisible. Keep away from any suspected leaks. Relieve pressure in
the hydraulic system before searching for leaks, disconnecting hoses, or performing
any other work on the system. If you must pressurize the system to find a suspected
leak, use an object such as a piece of wood or cardboard rather than your hands. When
loosening a fitting where some residual pressure may exist, slowly loosen the fitting
until oil begins to leak. Wait for leaking to stop before disconnecting the fitting. Fluid
injected under the skin must be removed immediately by a surgeon familiar with this
type of injury.

5-24
D20x22 Series II Navigator HDD Service Component Repair

COMPONENT REPAIR
Stakedown Valve Assembly A7

3
2
4

Stakedown
2
1

Remove 1. Remove cover plate over stakedown valve and vise valve.
2. Label, disconnect, and cap all hydraulic hoses to fittings.
3. Disconnect wire harnesses going to solenoids.
4. Remove fittings.
5. Remove screws (1), washers (2), and nuts (3) holding stakedown valve to mounting
plate.
6. Remove control valve (4) from mounting plate.

5-25
 Component Repair D20x22 Series II Navigator HDD Service

Directional Valves DV25–DV28

Disassemble 1. Remove nuts (1) and solenoid coils (2).
1
2. Remove cartridge valve and O-rings.
3. Inspect cartridge valves and O-rings for
damage and ensure no external
contaminants are present.
2
4. Inspect valve body cavity for burrs or other
irregularities which could damage O-rings
during installation.

Assembly When assembling valve, reverse disassembly procedure. Torque solenoid coil nuts to 5
ft-lb (6.8 Nm). Torque solenoid coils to 25 ft-lb (33.9 Nm).

When installing control valve, reverse removal procedures.

Torque mounting bolts to 35 ft-lb (47 Nm).

Stakedown

5-26
D20x22 Series II Navigator HDD Service Component Repair

Stakedown Motors MH7 and MH8

Remove

Stakedown
4

1. Label, disconnect, and cap hydraulic hoses from motor.

2. Remove bolts (1), washers (2), and nuts (3) mounting motor to stakedown assembly
motor mount (4).
3. Lift motor from motor mount.
4. Remove pin (5) from coupler (6) on motor. Remove motor from coupler.

5-27
 Component Repair D20x22 Series II Navigator HDD Service

Motor Breakdown

28

8
7
23
5 27
22 26
6 25
21 9
24 14
6
15
20 16
19 17
16
15
18 14
13
12
5

3
11
Stakedown

1
29
30 4
2
10
31

10

Refer to diagram below for motor component locations. Refer to D20x22 Series II Parts
Manual for seal kit part numbers.

1. Dust seal 5. Lathe cut seal

2. Metal backup shim 6. Body seal
3. Teflon backup shim 7. Commutator seal
4. Shaft seal 8. O-ring seal
Continued on next page...

5-28
D20x22 Series II Navigator HDD Service Component Repair

9. Teflon backup seal 21. Rotor assembly

10. Hex head bolt 22. Manifold
11. Pilot ring 23. Commutator assembly
12. Roller bearing 24. End cover piston
13. Bearing spacer 25. Piston spring
14. Retaining washer 26. End cover
15. Snap ring 27. ID tag assembly
16. Roller bearing 28. Bolt
17. Thrust bearing 29. Shaft assembly
18. Rear housing bearing 30. Shaft key
19. Housing 31. Lock washer
20. Drive link

Install 1. When installing motor, reverse removal procedure. Torque mounting bolts to 90 ft-
lb (122 Nm).

Stakedown
2. Torque fitting in port A to 38 ft-lb (52 Nm).
3. Port B has two fittings, one fitted on other. Torque larger fitting into motor to 38 ft-
lb (52 Nm). Install smaller orifice fitting into larger one and torque to 19 ft-lb (26
Nm).
4. Connect hoses to fitting in ports and torque to 19 ft-lb (26 Nm).

5-29
 Component Repair D20x22 Series II Navigator HDD Service

Stakedown Cylinders CY4 and CY5

Remove 1. If needed, disconnect auger from
motor by rolling rubber O-rings out of
the way and removing two stake
keeper pins.
2. Label hoses and disconnect them
from cylinder. Cap open hose ends.
2 1
3. Remove bolt (1), washers (2), and nut 3 2
(3) holding cylinder to frame and
stakedown slide tube.
4. Lift cylinder (4) from frame.
5. If replacing cylinder, remove hose
fittings from existing cylinder and
install them in new cylinder. Torque
upper fitting to 9.5 ft-lb (12.9 Nm)
and torque lower fitting to 19 ft-lb (26
Nm).

If rebuilding cylinder, refer to

Technician’s Shop Manual for
rebuild/repair kit and use generic
Stakedown

cylinder repair instructions.

6. Reverse steps 2–5 above to install
cylinder. Torque hoses to cylinder to 4
19 ft-lb (26 Nm). Torque bolts
holding cylinder to machine to 90 ft-
lb (122 Nm).

5-30
D20x22 Series II Navigator HDD Service Overview

Chapter 6: Stabilizer

OVERVIEW
This chapter consists of the functions and components necessary for stabilizer function.

THEORY
Components
The functions covered in this section include the following components:

• Transport Valve Assembly A11, including:

• Directional Valves DV22 and DV23
• Relief Valve PV5
• Stabilizer Cylinders CY2 and CY3
• Lock Valves FV2 and FV3

Stabilizer

6-1
 Theory D20x22 Series II Navigator HDD Service

Component Locations

RIGHT STABILIZER CYLINDER CY2

LEFT STABILIZER CYLINDER CY3

STABILIZERS
Stabilizer

TRANSPORT VALVE A9

6-2
D20x22 Series II Navigator HDD Service Theory

Hydraulic Schematic
TRANSPORT VALVE A11

DIVERTER/FLUID VALVE A9

DV16

STABILIZER
CYLINDER
CY2

STABILIZER
CYLINDER
CY3

FV2 DV22

FV3 DV23

Stabilizer
PFC PUMP PMP2

OIL COOLER HE1

RETURN
MANIFOLD A17

SUCTION MANIFOLD A15

6-3
 Theory D20x22 Series II Navigator HDD Service

Hose Connections

TO HYDRAULIC
TANK RES1
TRANSPORT/RACK
VALVE A12

LEFT STABILIZER
CYLINDER CY3
Stabilizer

RIGHT STABILIZER
CYLINDER CY2 DIVERTER/FLUID VALVE A11

Shared Components
The stabilizer function shares the common hydraulic fluid distribution components,
transport valve assembly A11, as well as diverter/drilling fluid valve assembly A9. The
hydraulic fluid distribution components are shared by all functions with hydraulic
circuits. These components include:

• Hydraulic Oil Tank RES1

• Return Filters FL3 and FL4
• Oil Cooler HE1
• PFC Pump PMP2
For more information on the common hydraulic fluid distribution components and
diverter/drilling fluid valve assembly A9, refer to Chapter 4.

6-4
D20x22 Series II Navigator HDD Service Theory

Transport Valve Assembly A11

T
A
G
B
H R
C
I P
D J
E K LS
F L

Transport valve assembly A11 is a sectional manifold that consists of five manually
controlled spool sections. Each section is responsible for the control of a specific
function. When none of the functions are actuated, all valve sections are held centered
by springs.

The valve assembly has one load sense relief valve, two solenoids (for optional tether
control), and five handle inputs.

Stabilizer
The valve assembly receives oil from PFC pump PMP2 via diverter/drilling fluid valve
assembly A9 at port P. The return line at port T returns oil to oil cooler HE1 and then to
tank RES1.

Load sense line from port LS provides circuit pressure to the ‘LS’ port on the PFC pump
PMP2 after passing through load sense shuttle valve A10.

6-5
 Theory D20x22 Series II Navigator HDD Service

Stabilizer Function – Stabilizer LOWER Mode

FROM SEAT S11

L20
RIGHT
DV16
CYLINDER
CY2

DV22

DV23
LEFT
CYLINDER
CY3

Operation For the stabilizers to lower:

Stabilizer

• Operator seat switch S11 must be open (operator not in seat).

• Engine running at full throttle.
• Stabilizer handles on transport control panel must be pushed forward.
When required operating conditions are met:

• Oil flows from PFC pump PMP2 to diverter/drilling fluid valve A9.

• Seat switch S11 sends a signal to solenoid L20 in diverter/drilling fluid valve A9,
shifting DV16. Oil flows to transport valve assembly A11.

• If right stabilizer handle is pressed, valve DV22 in transport valve A11 is shifted and
oil flows to base end port of lock valve FV2 and the base end of cylinder CY2.
Cylinder CY2 extends.

• If left stabilizer handle is pressed, valve DV23 in transport valve A11 is shifted and
oil flows to base end port of lock valve FV3 and the base end of cylinder CY3.
Cylinder CY3 extends.

NOTE: If stabilizer lower mode does not operate as expected, see "Troubleshooting
Stabilizer Function," page 6-11.

6-6
D20x22 Series II Navigator HDD Service Theory

Stabilizer Function – Stabilizer RAISE Mode

FROM SEAT S11

L20
RIGHT
DV16
CYLINDER
CY2

DV22

DV23
LEFT
CYLINDER
CY3

Operation For stabilizers to raise:

Stabilizer
• Operator seat switch S11 must be open (operator not in seat).
• Engine running at full throttle.
• Stabilizer handles on transport control panel must be pulled backward.
When required operating conditions are met:

• Oil flows from PFC pump PMP2 to diverter/drilling fluid valve A9.

• Seat switch S11 sends a signal to solenoid L20 in diverter/drilling fluid valve A9,
shifting DV16. Oil flows to transport valve assembly A11.

• If right stabilizer handle is pressed, valve DV22 in transport valve A11 is shifted and
oil flows to rod end port of lock valve FV2 and the rod end of cylinder CY2.
Cylinder CY2 retracts.

• If left stabilizer handle is pressed, valve DV23 in transport valve A11 is shifted and
oil flows to rod end port of lock valve FV3 and the rod end of cylinder CY3.
Cylinder CY3 retracts.

NOTE: If stabilizer RAISE mode does not operate as expected, see "Troubleshooting
Stabilizer Function," page 6-11.
\

6-7
 Troubleshooting D20x22 Series II Navigator HDD Service

TROUBLESHOOTING
Troubleshooting procedures are given in this chapter for each function’s operating
modes. Each procedure begins by performing a pretest inspection of the machine. See
"Pretest Inspection," page 6-8.

If nothing obvious is found during the inspection, it may be necessary to operate all
other functions of the machine to help further isolate a component problem. See
"Troubleshooting Machine Performance," page 6-10.

Pretest Inspection
Perform the following visual checks to inspect for obvious signs of failure before
exhaustive troubleshooting or testing is performed.

Mechanical

Inspect the mechanical valve control handles and linkages for damage, misalignment, or
improper adjustment.

Electrical
Stabilizer

Inspect electrical wiring for obvious problems. Always check the following items before
turning on switches or running the unit.

• Look for bare wires that could cause grounds or shorts.

• Look for broken, missing, corroded, or loose connections on the power wires that
supply electrical circuit components.
• Check all ground connections on the machine and chassis for tight
connections. Cleaning harness connections or ground connections can often correct
what appears to be a malfunctioning component.
• Check for overheated electrical components.

Continued on next page...

6-8
D20x22 Series II Navigator HDD Service Troubleshooting

Hydraulic

WARNING: Pressurized fluid can penetrate body tissue and result in serious injury or
death. Leaks can be invisible. Keep away from any suspected leak. Relieve pressure in the
hydraulic system before searching for leaks, disconnecting hoses, or performing any other
work on the system. If you must pressurize the system to find a suspected leak, use an
object such as a piece of wood or cardboard rather than your hands. When loosening a
fitting where some residual pressure may exist, slowly loosen the fitting until oil begins to
leak. Wait for leaking to stop before disconnecting the fitting. Fluid injected under the skin
must be removed immediately by a surgeon familiar with this type of injury.

Check hydraulic components for any obvious problems.

• Look for broken, kinked, loose, or leaking hoses and fittings on supply, pressure,
and return to hydraulic components.
• Check level of hydraulic fluid in hydraulic tank. Low fluid can cause erratic
behavior in hydraulic circuits. Correct level is between the two lines on dipstick. If
needed, add new fluid that has been filtered through a 5-micron filter.
Also review information in the General Information chapter under "Hydraulic
Troubleshooting," page 1-12. Correct any problems found during the inspection.
Operate machine to verify the problem is fixed.

Stabilizer
Test Equipment Needed
To perform the troubleshooting procedures in this chapter, the following test equipment
will be needed:

• Multimeter for continuity tests, voltage measurements, resistance

measurements in the various electrical circuits
• Various hydraulic testing tools

NOTE: The hydraulic component test procedures discussed in this chapter will refer
the technician to the Vermeer Industrial Dealerships Technician’s Shop Manual
(Vermeer P/N 105400V80). Test procedures and equipment needed for performing the
various test on hydraulic components will be listed in the manual.

6-9
 Troubleshooting D20x22 Series II Navigator HDD Service

Troubleshooting Machine Performance

Possible faults may occur in the stabilizer function that are directly related to faults in
other functions. These other faults may not be readily apparent, because those particular
functions are not currently being operated.

Operate the machine functions and document performance of working actuators.

Make note of any functions not operating normally based on the normal operation given
in each chapter for that function. To help isolate a faulty component or function,
compare the notes you have taken to the normal operation given for each mode of a
particular function.

After doing machine performance checks, if the problem is isolated to the original
function in question, return to the troubleshooting/testing for that function. If multiple
functions are affected, proceed with troubleshooting based on the possible results listed
below.

Possible Results 1. If all machine functions are not working correctly, it would indicate a function or
component that is common to all the actuators is most likely malfunctioning. The
following functions and components should be investigated:
• Engine. See "Engine," page 3-6.
• Shared hydraulic components. See Chapter 4.
Stabilizer

• Remote Lockout. See Chapter 15.

2. If problems are noted in ground drive and stabilizer functions, as well as rod loader,
auto greaser, stakedown, drilling fluid and vise functions, and other functions of the
machine are operating normally, the hydraulic components common to just these
functions should be investigated, including:
• Diverter/Fluid valve assembly A9. See "Oil Supply Function," page 4-6.
• PFC pump PMP2. See "PFC Pump PMP2," page 4-6.
• Load sense control circuit. See "Hydraulic Schematic," page 6-3.
3. If problems are noted in the stabilizer function and all other machine functions are
operating normally, the components associated with this function should be
investigated.

6-10
D20x22 Series II Navigator HDD Service Troubleshooting

Testing Stabilizer Performance

1. Start machine.
2. Enable Remote Lockout.
3. Ensure stabilizer cylinders are fully
retracted. If necessary, move stabilizer
handles (1) to RAISE position until
stabilizer cylinders are fully retracted.
4. Simultaneously start stopwatch and move
stabilizer switch to the RAISE position.
Stop timing when stabilizer cylinders are
fully extended. Time required for stabilizer
cylinders to move from fully lowered to
1
fully raised position should be
approximately 8 seconds.
5. Simultaneously start stopwatch and move stabilizer switch to the LOWER position.
Stop timing when stabilizer cylinders are fully retracted. Time required for stabilizer
cylinders to move from fully raised to fully lowered position should be
approximately 7 seconds.

Stabilizer
Troubleshooting Stabilizer Function
The stabilizer circuit contains both electrical and hydraulic components. If the steps in
"Troubleshooting Machine Performance," page 6-10 indicate the circuit is not
operating properly, begin troubleshooting by following the general guidelines in
"Troubleshooting," page 6-8.

1. With the engine running, Remote Lockout enabled, and no operator in the seat,
operate the stabilizer function from the rear control panel. If the stabilizer will not
function, investigate the hydraulic circuit and diverter/drilling fluid valve A9.
2. Remove stabilizer valves DV22 and DV23 in transport valve A11, and check for
damaged seals or obstructions. If OK, continue.
3. Remove and inspect lock check valve cartridges FV2 and FV3 on the stabilizer
cylinders for contamination or damage. If OK, continue.
4. If cylinder CY2 or CY3 can not hold position of stabilizer steady and all solenoids
and valves have been checked, and correct voltage is being supplied to the solenoid,
replace entire cylinder/lock valve assembly.

6-11
 Troubleshooting D20x22 Series II Navigator HDD Service

Troubleshooting Transport Valve A11

If faults are noted in the rack angle, stabilizer, and ground drive functions, and all other
machine functions are normal:

1. Inspect load sense relief valve PV5 in valve assembly A11 for damage or
contamination. Relief setting is at 290 psi (20 bar). Refer to component repair
section for instructions on removal and disassembly.
2. Remove cartridge valves from manifold and inspect for obvious signs of damage or
contamination. Refer to "Transport/Rack Valve Manifold A11," page 6-14 for
disassembly steps.

Component Repair/Replace
If troubleshooting procedures determine a component is in need of repair or
replacement, refer to the appropriate procedures at the back of the chapter or other
chapters where instructed. After repairs have been made, refer to"Fluid Sample
Collection Points," page 4-28 and follow instructions.

Specifications
Stabilizer

Listed below are the electrical and hydraulic specifications for the components in this
chapter.

Electrical:

• Nominal circuit voltage - 12 volts DC

• Diverter/drilling fluid valve A9 solenoid L21 resistance - 7.2 ohms at 68°F (20°C)
Hydraulic:

• Stabilizer cylinders CY2 and CY3 maximum operating pressure - 3500 psi (241 bar)
• PFC pump PMP2 normal output flow - variable to 24 gpm (90.8 L/min)
• PFC pump PMP2 standby pressure compensator valve setting - 250 psi (17.2 bar)
• PFC pump PMP2 high pressure compensator valve setting - 3300 psi (227 bar)

6-12
D20x22 Series II Navigator HDD Service Component Repair

COMPONENT REPAIR

WARNING: Pressurized fluid can penetrate body tissue and result in serious injury or
death. Leaks can be invisible. Keep away from any suspected leaks. Relieve pressure in
the hydraulic system before searching for leaks, disconnecting hoses, or performing
any other work on the system. If you must pressurize the system to find a suspected
leak, use an object such as a piece of wood or cardboard rather than your hands. When
loosening a fitting where some residual pressure may exist, slowly loosen the fitting
until oil begins to leak. Wait for leaking to stop before disconnecting the fitting. Fluid
injected under the skin must be removed immediately by a surgeon familiar with this
type of injury.

Stabilizer

6-13
 Component Repair D20x22 Series II Navigator HDD Service

Transport/Rack Valve Manifold A11

3
Stabilizer

Remove 1. Disconnect optional tether electrical connection.

2. Open hood.
3. Remove upper shield (1). Remove access panel above valve.
4. Label, disconnect and cap all hoses and fittings.
5. Remove bolts (2) and washers (3) holding valve manifold (4) to rear panel.
6. Support valve, disengage handles from rear panel, and remove valve manifold.

Install Reverse removal procedures to install manifold.

Torque mounting bolts to 35 ft-lb (47 Nm).

6-14
D20x22 Series II Navigator HDD Service Component Repair

2
1

6 5 4 3
Disassembly 1. Remove nuts (1) and washers (2) on tie rods (3).
2. Remove end cap (4). Separate each valve section (5).
3. Remove O-rings (6) between each valve section.
4. Remove bolts (7) on ancillary blocks (8). Remove blocks.

Stabilizer
Reverse steps to assemble valve. Replace O-rings. Torque ancillary block bolts to 7 ft-lb
(9.49 Nm). Torque tie rod M6 bolts to 7 ft-lb (9.49 Nm) and
M8 bolts to 17 ft-lb (23 Nm).

6-15
 Component Repair D20x22 Series II Navigator HDD Service

Stabilizer Cylinders CY2 and CY3

5
4
3

3
5
1 2
2

Remove
Stabilizer

DANGER: Raised drill rack/stabilizer can fall and result in serious injury or death.
Never work under raised equipment unless it is adequately supported to prevent it from
falling.

WARNING: Some residual pressure may remain in cylinders equipped with lock
valve cartridges. Use extreme caution when removing cartridges. Cartridge will be
released with extreme force if residual pressure is present in cylinder. Do not stand in
front of cartridge when removing it

1. Follow "Shutdown Procedure," page 2-1.

2. Label, disconnect and cap hoses on cylinder lock valve.
3. Remove bolt (1) and washer (2). Remove pin (3) and pin lock plate (5) holding base
of cylinder (4) from stabilizer arm.
Continued on next page...

6-16
D20x22 Series II Navigator HDD Service Component Repair

4. Remove bolt (1) and nut (2). Remove pin (3) and pin lock plate (5) holding rod end
of cylinder (4) to undercarriage.
5. Remove fittings (6) from lock valve (7).
To install cylinder, reverse removal steps. Torque bolts (1) to 35 ft-lb (47 Nm).

Stabilizer

6-17
 Component Repair D20x22 Series II Navigator HDD Service

Disassembly 1. Remove cylinder. Refer to "Remove," page 6-16.

4 3

13
2
5 8 9 6 7 7 10 11 12

1
Stabilizer

REAR VIEW FRONT VIEW

2. Carefully loosen and remove lock valve cartridges (1) from valve body. Inspect
cartridge for any damages and ensure no external contaminants are present.
NOTE: Remember orientation of seals. This will be useful in installing new ones.

3. Inspect seals in lock valve. If necessary replace seals. Dip valve in clean filtered oil.
Screw valve in by hand. Torque cartridge to 30–35 ft-lb (40–47 Nm).
4. Remove gland (2).
5. With a suitable device (wrench or come-along), pull rod (3) out of cylinder body (4).
Ensure ports are open and position to direct oil into a suitable container.
Continued on next page...

6-18
D20x22 Series II Navigator HDD Service Component Repair

6. Remove nut (5) from rod (3).

IMPORTANT: Do not clamp onto unpainted portion of rod, unless it is adequately
protected by a cloth or other soft material. Scarring rod can cause premature seal failure.

7. Slide gland (2) and piston (6) off rod.

8. Remove and replace O-rings (7), wear ring (8), PSP seal (9), backup
ring (10), retaining ring (11), polypak (12), and dust seal (13).

Assembly Apply a light coat of petroleum jelly to seals before installing.

1. Set O-rings (7), backup ring (10), retaining ring (11), polypak (12), and dust seal
(13) in place around gland and rod.
2. Set O-rings (7), wear ring (8), and PSP seal (9) in place around piston.
3. Slide gland (2) and piston (6) onto rod (3) and tighten nut (5).
4. Push rod (3) into cylinder body (4).
5. Install gland into cylinder body and secure with setscrew.
6. If equipped with lock valve cartridge, fill cylinder with hydraulic oil and install lock
valve cartridge.

Stabilizer

6-19
 Component Repair D20x22 Series II Navigator HDD Service

Stabilizer

1
4
5
2
6
3

4
5
6
Stabilizer

1. Support stabilizer. Remove cylinder on stabilizer. Refer to "Stabilizer Cylinders

CY2 and CY3," page 6-16.
2. Remove bolt (6) and washer (5) on pin (2) and pin lock plate (4) holding stabilizer
arm (1) to machine. Lower stabilizer to the ground.
3. Remove bushings (3) from stabilizer arm.
4. Remove bolt (6) and washer (5) on pin (2) and pin lock plate (4) holding stabilizer
arm (1) to pad (7). Remove bushings (3).
Reverse steps above to install stabilizer. Torque bolt (6) to 35 ft-lb (47 Nm).

6-20
D20x22 Series II Navigator HDD Service Overview

Chapter 7: Rack Angle

OVERVIEW
This chapter consists of the functions and components necessary for rack angle function.

THEORY
Components
The functions covered in this section include the following components:

• Transport Valve Assembly A11, including:

• Directional Valve DV21
• Relief Valve PV5
• Rack Angle Cylinder CY1
• Lock Valve FV1

Rack Angle

7-1
 Theory D20x22 Series II Navigator HDD Service

Component Locations

TRANSPORT VALVE A11

Rack Angle

RACK ANGLE CYLINDER CY1

7-2
D20x22 Series II Navigator HDD Service Theory

Hose Connections

TRANSPORT/RACK VALVE A11

TO HYDRAULIC
TANK RES1

Rack Angle
RACK ANGLE CYLINDER CY1

DIVERTER/FLUID VALVE A9

7-3
 Theory D20x22 Series II Navigator HDD Service

Hydraulic Schematic
TRANSPORT VALVE A11

DIVERTER/FLUID VALVE A9
RACK ANGLE
DV16 CYLINDER CY1

DV21
FV1
Rack Angle

PFC PUMP PMP2

OIL COOLER HE1

RETURN MANIFOLD A17

SUCTION MANIFOLD A15

7-4
D20x22 Series II Navigator HDD Service Theory

Shared Components
The rack angle function shares the common hydraulic fluid distribution components,
transport valve assembly A11, as well as diverter/drilling fluid valve assembly A9. The
hydraulic fluid distribution components are shared by all functions with hydraulic
circuits. These components include:

• Hydraulic Oil Tank RES1

• Oil Cooler HE1
• PFC Pump PMP2
For more information on the common hydraulic fluid distribution components or
diverter/drilling fluid valve A9, refer to Chapter 4. For more information on transport
valve assembly A11, refer to Chapter 6.

Rack Angle

7-5
 Theory D20x22 Series II Navigator HDD Service

Rack Angle RAISE Mode

FROM SEAT S11

ANGLE
CYLINDER
L20 CY1

DV16 DV21

Operation For the rack angle to raise:

Rack Angle

• Operator seat switch S11 must be open (operator not in seat).

• Engine running at full throttle.
• Rack angle handle on transport control panel must be pushed forward.
When required operating conditions are met:

• Oil flows from PFC pump PMP2 to diverter/drilling fluid valve A9.

• Seat switch S11 sends a signal to solenoid L20 in diverter/drilling fluid valve A9,
shifting DV16. Oil flows to transport valve assembly A11.

• If rack angle handle is pressed, valve DV21 in transport valve A11 is shifted and oil
flows to base end port of lock valve FV1 and the base end of cylinder CY1.

• Cylinder CY1 extends.

Lock check valve CV1 keeps the cylinder from retracting when there is no circuit
pressure by locking oil in the cylinder. This ensures the cylinder will remain in the same
position when the control is released.

NOTE: If rack angle lower mode does not operate as expected, see "Troubleshooting
Rack Angle Function," page 7-11.

7-6
D20x22 Series II Navigator HDD Service Theory

Rack Angle LOWER Mode

FROM SEAT S11

ANGLE
CYLINDER
L20 CY1
DV16
DV21

Rack Angle
Operation For rack angle to lower:

• Operator seat switch S11 must be open (operator not in seat).

• Engine running at full throttle.
• Rack angle handle on transport control panel must be pulled backward.
When required operating conditions are met:

• Oil flows from PFC pump PMP2 to diverter/drilling fluid valve A9.

• Seat switch S11 sends a signal to solenoid L20 in diverter/drilling fluid valve A9,
shifting DV16. Oil flows to transport valve assembly A11.

• If rack angle handle is pressed, valve DV21 in transport valve A11 is shifted and oil
flows to rod end port of lock valve FV1 and the rod end of cylinder CY1.

• Cylinder CY1 retracts.

NOTE: If rack angle RAISE mode does not operate as expected, see
"Troubleshooting Rack Angle Function," page 7-11.
\

7-7
 Troubleshooting D20x22 Series II Navigator HDD Service

TROUBLESHOOTING
Troubleshooting procedures are given in this chapter for each function’s operating
modes. Each procedure begins by performing a pretest inspection of the machine. See
"Pretest Inspection," page 7-8.

If nothing obvious is found during the inspection, it may be necessary to operate all
other functions of the machine to help further isolate a component problem. See
"Troubleshooting Machine Performance," page 7-9.

Pretest Inspection
Perform the following visual checks to inspect for obvious signs of failure before
exhaustive troubleshooting or testing is performed.

Mechanical

Inspect the mechanical valve control handles and linkages for damage, misalignment, or
improper adjustment.

Electrical
Rack Angle

Inspect electrical wiring for obvious problems. Always check the following items before
turning on switches or running the unit.

• Look for bare wires that could cause grounds or shorts.

• Look for broken, missing, corroded, or loose connections on the power wires that
supply electrical circuit components.
• Check all ground connections on the machine and chassis for tight
connections. Cleaning harness connections or ground connections can often correct
what appears to be a malfunctioning component.
• Check for overheated electrical components.

7-8
D20x22 Series II Navigator HDD Service Troubleshooting

Hydraulic

WARNING: Pressurized fluid can penetrate body tissue and result in serious injury or
death. Leaks can be invisible. Keep away from any suspected leak. Relieve pressure in the
hydraulic system before searching for leaks, disconnecting hoses, or performing any other
work on the system. If you must pressurize the system to find a suspected leak, use an
object such as a piece of wood or cardboard rather than your hands. When loosening a
fitting where some residual pressure may exist, slowly loosen the fitting until oil begins to
leak. Wait for leaking to stop before disconnecting the fitting. Fluid injected under the skin
must be removed immediately by a surgeon familiar with this type of injury.

Check hydraulic components for any obvious problems.

• Look for broken, kinked, loose, or leaking hoses and fittings on supply, pressure,
and return to hydraulic components.
• Check level of hydraulic fluid in hydraulic tank. Low fluid can cause erratic
behavior in hydraulic circuits. Correct level is between the two lines on dipstick. If
needed, add new fluid that has been filtered through a 5-micron filter.
Also review information in the General Information chapter under "Hydraulic
Troubleshooting," page 1-12. Correct any problems found during the inspection.
Operate machine to verify the problem is fixed.

Rack Angle
Troubleshooting Machine Performance
Possible faults may occur in the rack angle function that are directly related to faults in
other functions. These other faults may not be readily apparent, because those particular
functions are not currently being operated.

Operate the machine functions and document performance of working actuators.

Make note of any functions not operating normally based on the normal operation given
in each chapter for that function. To help isolate a faulty component or function,
compare the notes you have taken to the normal operation given for each mode of a
particular function.

After doing machine performance checks, if the problem is isolated to the original
function in question, return to the troubleshooting/testing for that function. If multiple
functions are affected, proceed with troubleshooting based on the possible results listed
below.

7-9
 Troubleshooting D20x22 Series II Navigator HDD Service

Possible Results 1. If all machine functions are not working correctly, it would indicate a function or
component that is common to all the actuators is most likely malfunctioning. The
following functions and components should be investigated:
• Engine. See "Engine," page 3-6.
• Shared hydraulic components. See Chapter 4.
• Remote Lockout. See Chapter 15.
2. If problems are noted in ground drive, stabilizer, and rack angle functions, as well as
rod loader, auto greaser, stakedown, drilling fluid and vise functions, and other
functions of the machine are operating normally, the hydraulic components common
to just these functions should be investigated, including:
• Diverter/Fluid valve assembly A9. See "Oil Supply Function," page 4-6.
• PFC pump PMP2. See "PFC Pump PMP2," page 4-6.
• Load sense control circuit. See "Hydraulic Schematic," page 7-4.
3. If problems are noted in the rack angle, stabilizer, and ground drive functions, and
all other machine functions are operating normally, the component associated with
this function, namely transport valve assembly A11, should be investigated.

Testing Rack Angle Performance

Rack Angle

1. Start machine.
2. Enable Remote Lockout.
3. Ensure rack angle cylinders are fully
retracted. If necessary, move rack angle
handle (1) to RAISE position until rack
angle cylinder is fully retracted.
4. Simultaneously start stopwatch and push
rack angle handle to the RAISE position.
Stop timing when rack angle cylinder is
fully extended. Time required for rack
angle cylinder to move to fully extended
1
position should be approximately 5
seconds.
5. Simultaneously start stopwatch and push rack angle handle to the LOWER position.
Stop timing when rack angle cylinder is fully retracted. Time required for rack angle
cylinder to move to fully retracted position should be approximately 6 seconds.

7-10
D20x22 Series II Navigator HDD Service Troubleshooting

Troubleshooting Rack Angle Function

The rack angle circuit contains both electrical and hydraulic components. If the steps in
"Troubleshooting Machine Performance," page 7-9 indicate the circuit is not
operating properly, begin troubleshooting by following the general guidelines in
"Troubleshooting," page 7-8.

1. With the engine running and no operator in the seat, operate the rack angle function
from the rear control handle. If the rack angle will not function, investigate the
hydraulic circuit.
2. Remove rack angle valve DV21 in transport valve assembly A11. Check for
damaged seals or obstructions. If OK, continue.
3. Remove and inspect lock check valve cartridge FV1 on the rack angle cylinder for
contamination or damage. If OK, continue.
4. If cylinder CY1 can not hold position of rack angle steady and all valves have been
checked, replace entire cylinder/lock valve assembly.

Component Repair/Replace
If troubleshooting procedures determine a component is in need of repair or

Rack Angle
replacement, refer to the appropriate procedures at the back of the chapter or other
chapters where instructed. After repairs have been made, refer to "Hydraulic Fluid
Sampling," page 4-26 and follow instructions.

Test Equipment Needed

To perform the troubleshooting procedures in this chapter, the following test equipment
will be needed:

• Multimeter for continuity tests, voltage measurements, resistance

measurements in the various electrical circuits
• Various hydraulic testing tools

NOTE: The hydraulic component test procedures discussed in this chapter will refer
the technician to the Vermeer Industrial Dealerships Technician’s Shop Manual
(Vermeer P/N 105400V80). Test procedures and equipment needed for performing the
various test on hydraulic components will be listed in the manual.

7-11
 Component Repair D20x22 Series II Navigator HDD Service

Specifications
Listed below are the electrical and hydraulic specifications for the components in this
chapter.

Electrical:

• Nominal circuit voltage - 12 volts DC

Hydraulic:

• PFC Pump PMP2 normal output flow - variable to 24 gpm (90.8 L/min)
• PFC Pump PMP2 standby pressure compensator valve setting - 250 psi (17.2 bar)
• PFC Pump PMP2 high pressure compensator valve setting - 3300 psi (227 bar)
• Cylinder CY1 maximum operating pressure - 3000 psi (207 bar)

COMPONENT REPAIR
Rack Angle

WARNING: Pressurized fluid can penetrate body tissue and result in serious injury or
death. Leaks can be invisible. Keep away from any suspected leaks. Relieve pressure in
the hydraulic system before searching for leaks, disconnecting hoses, or performing
any other work on the system. If you must pressurize the system to find a suspected
leak, use an object such as a piece of wood or cardboard rather than your hands. When
loosening a fitting where some residual pressure may exist, slowly loosen the fitting
until oil begins to leak. Wait for leaking to stop before disconnecting the fitting. Fluid
injected under the skin must be removed immediately by a surgeon familiar with this
type of injury.

7-12
D20x22 Series II Navigator HDD Service Component Repair

Rack Angle Cylinder CY1

Remove

DANGER: Raised drill rack/stabilizer can fall and result in serious injury or death.
Never work under raised equipment unless it is adequately supported to prevent it from
falling.

WARNING: Some residual pressure may remain in cylinders equipped with lock valve
cartridges. Use extreme caution when removing cartridges. Cartridge will be released
with extreme force if residual pressure is present in cylinder. Do not stand in front of
cartridge when removing it.

Rack Angle

Continued on next page...

7-13
 Component Repair D20x22 Series II Navigator HDD Service

1. Follow steps in "Shutdown Procedure," page 2-1.

2. Use an overhead hoist to support weight of rack.
3. Remove screw (1), washer (2), and pivot pin (3) holding rod end of cylinder (4) to
rack.
4. Label hoses and disconnect them from fittings (5). Cap open hose ends.
5. Remove screw (1), washer (2), and pivot pin (3) that hold base of cylinder (4) to
frame.
6. Lift cylinder from frame.
7. If replacing cylinder, remove hose fittings from existing cylinder and install them in
new cylinder. Torque fittings to 19 ft-lb (26 Nm).

If rebuilding cylinder, refer to D20x22 Series II Parts Manual for rebuild/repair kit
and use generic cylinder repair instructions found in Technician’s Shop Manual.
Reverse steps 1–5 above to install cylinder. Torque hoses to cylinder to 19
ft-lb (26 Nm).
Rack Angle

7-14
D20x22 Series II Navigator HDD Service Component Repair

8
1 7 3 4

8
2 5 6

Disassembly 1. Release gland. Gland may be secured by retaining ring.

2. Pull rod assembly (7) out of cylinder body. Ensure ports are open and position to
direct oil into a suitable draining pan.
3. Remove nut from rod assembly.
IMPORTANT: Do not clamp onto unpainted portion of rod, unless it is adequately
protected by a cloth or other soft material. Scarring rod can cause premature seal failure.

Rack Angle
4. Slide gland and piston off rod.
5. Remove and replace seals (1, 2, 3, and 5), rod wiper (6), and backup washer (4).
Refer to D20x22 Series II Parts Manual for seal kit components and locations.
Apply a light coat of petroleum jelly to seals before installing.
6. Slide gland and piston onto rod and tighten nut.
7. Push rod assembly into cylinder body.
8. Install gland into cylinder body and secure with retaining ring.
9. Fill cylinder with hydraulic oil and install lock valve cartridge. Refer to "Rack
Angle Cylinder Lock Check Valve FV1," page 7-16.
To install cylinder, reverse removal steps.

7-15
 Component Repair D20x22 Series II Navigator HDD Service

Rack Angle Cylinder Lock Check Valve FV1

WARNING: Some residual pressure may remain in cylinders equipped with lock valve
cartridges. Use extreme caution when removing cartridges. Cartridge will be released
with extreme force if residual pressure is present in cylinder. Do not stand in front of
cartridge when removing it.

1. Unscrew and remove lock valve cartridge LOCK VALVE CARTRIDGE

from valve body.
NOTE: Make note of O-ring and backup
washer orientation.

2. Inspect valve and O-rings for damage and

ensure no external contaminants are
present.
3. Inspect valve body cavity for burrs or
other irregularities which could damage O-rings during installation.
4. Replace O-rings and backup washers if needed.
5. Dip valve in clean filtered oil.
Rack Angle

6. Screw valve in by hand until O-ring contacts valve body. Torque valve to 30 ft-lb
(40.6 Nm).

7-16
D20x22 Series II Navigator HDD Service Overview

Chapter 8: Ground Drive

OVERVIEW
The ground drive circuits consist of hydraulic and electrical components that rotate the
tracks and apply brakes.

THEORY
Components
The following components are used in the ground drive circuits:

• Transport Valve Assembly A11, including:

• Directional Valves DV19 and DV20
• Relief Valve PV5
• Torque Limiter/Loop Flush Valve Assembly A7, including:
• Directional Valve DV5

Ground Drive
• Track Motors MH5 and MH6
• 2-Speed Solenoid L34 and Switch S40

8-1
 Theory D20x22 Series II Navigator HDD Service

Component Locations

PLANETARY GEARBOX IDLER ASSEMBLY

RIGHT TRACK MOTOR MH5

TRANSPORT VALVE A11

Ground Drive

TORQUE LIMITER/LOOP FLUSH VALVE A7

8-2
D20x22 Series II Navigator HDD Service Theory

Hydraulic Schematic
TRANSPORT VALVE A11

RIGHT TRACK MH5 DV19

DV20
LEFT TRACK MH6
TORQUE LIMITER/
LOOP FLUSH VALVE A7

DV5

DIVERTER/FLUID
VALVE
A9 DV16

Ground Drive
ROTATION AND THRUST
PUMP PMP1 OIL COOLER HE1
PFC PUMP PMP2
RETURN
CHARGE FILTER FL1
MANIFOLD
A17
CHARGE PUMP PMP4

SUCTION
MANIFOLD A15

8-3
 Theory D20x22 Series II Navigator HDD Service

Electrical Schematic

A 1 L E F T H A N D J O Y S T IC K H E A D
Ground Drive

C 148 CO NTRO LLER

J1 - G R AY

J2- BLAC K

J3 - G R EEN

J4- B R O W N

8-4
D20x22 Series II Navigator HDD Service Theory

Electrical Schematic – Optional Tether

A 21 TE TH E R C O N TR O LLER

Ground Drive

8-5
 Theory D20x22 Series II Navigator HDD Service

Hose Connections
DIVERTER/FLUID VALVE A9

HYDRAULIC
TANK RES1
TRANSPORT/RACK
VALVE A12

RIGHT TRACK
MOTOR MH5 TORQUE LIMITER
VALVE A7
Ground Drive

LEFT TRACK
MOTOR MH6

8-6
D20x22 Series II Navigator HDD Service Theory

Ground Drive Function – Left Track FORWARD Mode

TO COOLER RIGHT MOTOR MH5

FROM DV5
DV19

TO COOLER LEFT MOTOR MH6

DV20
FROM DV5
FROM SEAT S11

L20

DV16

Ground Drive
Operation To operate left track FORWARD mode:

• Operator seat switch S11 must be open (operator not in seat).

• Engine running.
• Left track handle on transport control panel or switch on optional tether control must
be pushed forward.
When required operating conditions are met:

• Oil flows from PFC pump PMP2 to diverter/drilling fluid valve A9.

• Seat switch S11 sends a signal to solenoid L20 in diverter/drilling fluid valve A9,
shifting DV16. Oil flows to transport valve assembly A11.

• Oil flows through DV20 in transport valve A11, shifting the valve and allowing oil
to flow to port A of motor MH6.

Continued on next page...

8-7
 Theory D20x22 Series II Navigator HDD Service

• Motor MH6 rotates clockwise (CW).

When 2-speed rotation switch S8 on operator control panel is set to enable, solenoid L33
in torque limiter/loop flush valve A7 is energized. Solenoid L33 causes DV5 to shift,
sending oil to MH6. This causes the motor displacement to go from 1.57 to 0.765 cid,
which causes the speed of the motor to increase.

NOTE: If left track FORWARD mode does not operate as expected, see
"Troubleshooting/Testing Ground Drive Function," page 8-17.

Ground Drive Function – Right Track FORWARD Mode

Refer to schematic in "Ground Drive Function – Left Track FORWARD Mode,"
page 8-8.

Operation To operate right track FORWARD mode:

• Operator seat switch S11 must be open (operator not in seat).

• Engine running.
• Right track handle on transport control panel or switch on optional tether control
must be pushed forward.
Ground Drive

When required operating conditions are met:

• Oil flows from PFC pump PMP2 to diverter/drilling fluid valve A9.

• Seat switch S11 sends a signal to solenoid L20 in diverter/drilling fluid valve A9,
shifting DV16. Oil flows to transport valve assembly A11.

• Oil flows through DV19 in transport valve A11, shifting the valve and allowing oil
to flow to port B of motor MH5.

• Motor MH5 rotates counterclockwise (CCW).

When 2-speed rotation switch S8 on operator control panel is set to enable, solenoid L33
in torque limiter/loop flush valve A7 is energized. Solenoid L33 causes DV5 to shift,
sending oil to MH5. This causes the motor displacement to go from 1.57 to 0.765 cid,
which causes the speed of the motor to increase.

NOTE: If right track FORWARD mode does not operate as expected, see
"Troubleshooting/Testing Ground Drive Function," page 8-17.

8-8
D20x22 Series II Navigator HDD Service Theory

Ground Drive Function – Left Track REVERSE Mode

TO COOLER RIGHT MOTOR MH5

FROM DV5
DV19

TO COOLER LEFT MOTOR MH6

DV20
FROM DV5
FROM SEAT S11

L20

DV16

Ground Drive
Operation To operate left track REVERSE mode:

• Operator seat switch S11 must be open (operator not in seat).

• Engine running.
• Left track handle on transport control panel or switch on optional tether control must
be pushed forward.
When required operating conditions are met:

• Oil flows from PFC pump PMP2 to diverter/drilling fluid valve A9.

• Seat switch S11 sends a signal to solenoid L20 in diverter/drilling fluid valve A9,
shifting DV16. Oil flows to transport valve assembly A11.

• Oil flows through DV20 in transport valve A11, shifting the valve and allowing oil
to flow to port B of motor MH6.

Continued on next page...

8-9
 Theory D20x22 Series II Navigator HDD Service

• Motor MH6 rotates counterclockwise (CCW).

When 2-speed rotation switch S8 on operator control panel is set to enable, solenoid L33
in torque limiter/loop flush valve A7 is energized. Solenoid L33 causes DV5 to shift,
sending oil to MH6. This causes the motor displacement to go from 1.57 to 0.765 cid,
which causes the speed of the motor to increase.

NOTE: If left track REVERSE mode does not operate as expected, see
"Troubleshooting/Testing Ground Drive Function," page 8-17.

Ground Drive Function – Right Track REVERSE Mode

Refer to schematic in "Ground Drive Function – Left Track REVERSE Mode," page
8-10.

Operation To operate right track REVERSE mode:

• Operator seat switch S11 must be open (operator not in seat).

• Engine running.
• Right track handle on transport control panel or switch on optional tether control
must be pushed forward.
Ground Drive

When required operating conditions are met:

• Oil flows from PFC pump PMP2 to diverter/drilling fluid valve A9.

• Seat switch S11 sends a signal to solenoid L20 in diverter/drilling fluid valve A9,
shifting DV16. Oil flows to transport valve assembly A11.

• Oil flows through DV19 in transport valve A11, shifting the valve and allowing oil
to flow to port A of motor MH5.

• Motor MH5 rotates clockwise (CW).

When 2-speed rotation switch S8 on operator control panel is set to enable, solenoid L33
in torque limiter/loop flush valve A7 is energized. Solenoid L33 causes DV5 to shift,
sending oil to MH5. This causes the motor displacement to go from 1.57 to 0.765 cid,
which causes the speed of the motor to increase.

NOTE: If right track REVERSE mode does not operate as expected, see
"Troubleshooting/Testing Ground Drive Function," page 8-17.

8-10
D20x22 Series II Navigator HDD Service Troubleshooting

TROUBLESHOOTING
Troubleshooting procedures are given for each operating mode of the different functions
of this chapter. Start each procedure by performing a pretest inspection of the machine.
See "Pretest Inspection," page 8-13.

Often problems can be solved by simply doing a walk-around inspection of the machine
and looking for obvious problems.

If nothing obvious is found during the inspection, operate the other actuator functions of
the machine to help further isolate a problem. See "Troubleshooting Machine
Performance," page 8-15.

Pretest Inspection
Do the following visual checks to inspect for obvious signs of failure before any
exhaustive troubleshooting or testing is performed.

Mechanical

Inspect mechanical valve control handles and linkages for damage, misalignment, or
improper adjustment.

Ground Drive
Electrical

Always check the following items before turning on switches or running the unit.

• Look for bare wires that could cause grounds or shorts.

• Look for broken, missing, corroded, or loose connections in the power wires that
supply electrical circuit components.
• Check all ground connections on the machine and chassis for tight
connections. Cleaning harness connections or ground connections can often correct
what appears to be a malfunctioning component.
• Check for overheated components after the unit has been stopped for awhile. They
will often smell like burned insulation.

Continued on next page...

8-11
 Troubleshooting D20x22 Series II Navigator HDD Service

WARNING: Pressurized fluid can penetrate body tissue and result in serious injury or
death. Leaks can be invisible. Keep away from any suspected leak. Relieve pressure in the
hydraulic system before searching for leaks, disconnecting hoses, or performing any other
work on the system. If you must pressurize the system to find a suspected leak, use an
object such as a piece of wood or cardboard rather than your hands. When loosening a
fitting where some residual pressure may exist, slowly loosen the fitting until oil begins to
leak. Wait for leaking to stop before disconnecting the fitting. Fluid injected under the skin
must be removed immediately by a surgeon familiar with this type of injury.

Hydraulic

Check hydraulic circuits for any failures.

• Look for broken, kinked, loose, or leaking hoses and fittings on hydraulic
components.
• Check level of hydraulic oil in hydraulic tank. Low fluid can cause erratic behavior
in hydraulic circuits. Correct level is between the two lines on dipstick. Ensure fluid
being added has been filtered through a 5-micron filter.
Also review information in the General Information chapter under "Hydraulic
Troubleshooting," page 1-12. Correct any problems found during the inspection.
Operate machine to verify the fault is fixed.
Ground Drive

Test Equipment Needed

To perform the troubleshooting procedures in this chapter, the following test equipment
will be needed:

• Multimeter for continuity tests, voltage measurements, resistance

measurements in the various electrical circuits
• Pressure gauge
• Various hydraulic testing tools

NOTE: The hydraulic component test procedures discussed in this chapter will refer
the technician to the Vermeer Industrial Dealerships Technician’s Shop Manual
(Vermeer P/N 105400V80). Test procedures and equipment needed for performing the
various tests on hydraulic components will be listed in the manual.

8-12
D20x22 Series II Navigator HDD Service Troubleshooting

Troubleshooting Machine Performance

Possible faults may occur in the ground drive function that are directly related to faults
in other functions. These other faults may not be readily apparent, because those
particular functions are not currently being operated.

Operate the machine functions and document performance of working actuators.

Make note of any functions not operating normally based on the theory given in each
chapter for that function. To help isolate a faulty component or function, compare the
notes you have taken to the normal operation given for each mode of a particular
function.

After doing all the machine performance checks, if the fault is isolated to the original
function in question, return to the troubleshooting/testing for that mode. If multiple
functions are affected, proceed with troubleshooting based on the possible results listed
below.

Possible Results The possible results listed are meant to guide the service technician in a logical manner
to isolate a fault as quickly as possible.

1. If faults are noted when operating all the machine actuators, it would indicate a
circuit or component that is common to all the actuators is most likely faulty. The
following common functions and components should be investigated:

Ground Drive
• Engine. See "Engine," page 3-6.
• Shared hydraulic components. See Chapter 4.
• Remote Lockout. See Chapter 15.
2. If faults are noted in the ground drive, rack angle, and stabilizer functions, as well as
the rod loader, auto greaser, stakedown, drilling fluid, and vise functions, and all
other functions of the machine are OK, the hydraulic components common to just
these functions should be investigated, including:
• Diverter/Fluid Valve Assembly A9. See "Oil Supply Function," page 4-6.
• PFC Pump PMP2. See "PFC Pump PMP2," page 4-6.
3. If faults are noted in the ground drive, rack angle, and stabilizer functions, and all
other functions of the machine are OK, the hydraulic components common to just
these functions should be investigated, including:
• Transport Valve Assembly A11. See "Transport Valve Assembly A11," page 6-
5.

8-13
 Troubleshooting D20x22 Series II Navigator HDD Service

Testing Ground Drive Performance

This check is based on the assumption that the common hydraulic components, PFC
pump PMP2 and diverter/drilling fluid valve assembly A9 are operating normally.
Because of this assumption, it is required that all functions supplied by this pump be
evaluated.

1. Ensure "Starting Procedure," page 2-2 and engine starting and warm-up
procedures have been performed.
2. With engine running, use phototach to verify engine speed of 2400 ± 100 rpm.
3. Enable Remote Lockout.
4. Lower stabilizers all the way down using
the control switches (1) at the rear control
panel.
5. At rear control panel, operate rack angle
control lever, to lower the rack until both
tracks are completely clear of ground/
floor.
1
6. Simultaneously start stopwatch and move
track control handle (left or right track) to
maximum FORWARD position. Count revolutions of track for 60 seconds, then
release control handle. Track should rotate at approximately 8 rpm.
Ground Drive

7. Repeat step 6 for REVERSE direction of track. Track should rotate at approximately
8 rpm.
8. Return tracks to ground/floor by decreasing rack angle and raising the stabilizers.

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D20x22 Series II Navigator HDD Service Troubleshooting

Troubleshooting/Testing Ground Drive Function

Before beginning any troubleshooting or testing procedures, perform the "Pretest
Inspection," page 8-13. If nothing obvious is found, continue.

1. In order to ensure the fault is isolated to just the ground drive and rack angle
functions, the technician should operate all the machine functions and observe the
actuators as discussed in "Troubleshooting Machine Performance," page 8-15.
If any functions other than the ground drive, stabilizer and rack angle functions are
faulty, continue troubleshooting based on the possible results given. If all other
machine functions are operating normally, continue with step 3.
2. If the problem is isolated to the ground drive, stabilizer and rack angle functions, the
diverter/drilling fluid valve manifold A9, seat switch S11, and transport valve
manifold A11 should be investigated.
3. If the ground drive is operating abnormally, either the motor or transport control
valve has most likely malfunctioned. See the common symptoms of faulty hydraulic
components under "Hydraulic Troubleshooting," page 1-12 then proceed with step
4.
NOTE: Hydraulic component testing is based on volumetric efficiency. Test the
components for excessive internal leakage to determine if they are worn beyond design
specification. Refer to the Vermeer Industrial Dealerships Technician’s Shop Manual
(Vermeer P/N 105400V80), for information on how to test these components.

Ground Drive
4. Test efficiency of motor with track removed. Excessive cross-port leakage can be
caused by damage or wear to internal components.
Connect a pressure gauge to the case drain of the motor and compare the no-load
motor shaft speed against the full load speed. If volumetric efficiency is below 80%,
refer to component repair section and repair or replace motor. For efficiency
specifications, refer to "Specifications," page 8-19. If motor is OK, continue with
step 5.
NOTE: The track motors are bi-directional. To accurately determine their condition,
motors should be tested in both directions.

5. With tracks still removed, use a phototach to test the speed of the sprockets. This
will determine if motor shaft speed is appropriate. The speed of the sprockets should
be 35 rpm in low speed mode and 65 rpm in high speed mode.
6. Check tension of tracks. If the track is too tight, it could lead to excessive effort to
move the machine, especially if pump or motor condition is not good.
7. Disassemble control valve assembly A11 and inspect for contamination or damage
to internal seals, O-rings, and internal components. Refer to "Transport/Rack
Valve Manifold A11," page 6-14.

8-15
 Troubleshooting D20x22 Series II Navigator HDD Service

Towing the Machine

Conditions If the engine cannot be started, disengaging the sun gear in each track planetary gearbox
removes all motor and brake control, allowing the machine to be towed.

WARNING: Machine can move suddenly when planetary gearboxes are disengaged.
Serious injury or death is possible if struck by or run over by the machine. Always block
both tracks securely before disengaging the planetary sun gears. Securely attach the
machine to a towing machine with sufficient capacity to safely move the machine.

Procedure

3 4

1
Ground Drive

1. Thoroughly clean faces of left and right track planetary gearboxes (1). Remove two
bolts (2) and cover (3) on each gearbox.
2. Reverse covers so projections (4) are facing inward and bolt the covers in place. The
sun gears are now disengaged.
3. Tow machine to the new location.
4. Remove covers (3); reverse covers so projections (4) are facing outward as shown;
and bolt covers in place. The sun gears will engage as soon as the teeth are aligned
when the motors are powered. Operate motors slowly in forward and reverse
directions to ensure gears are fully engaged.

8-16
D20x22 Series II Navigator HDD Service Troubleshooting

Specifications
Listed below are the electrical and hydraulic specifications for the ground drive
function.

Electrical:

• Nominal circuit voltage - 12 volts DC

Hydraulic:

• PFC Pump PMP2 normal output flow - variable to 24 gpm (90.8 L/min)
• PFC Pump PMP2 standby pressure compensator valve setting - 250 psi (17.2 bar)
• PFC Pump PMP2 high pressure compensator valve setting - 3300 psi (227 bar)
• Motor MH5 and MH6 displacement 0.814 cid (13.35 cm3) or 1.57 cid (25.77 cm3)
• Motor MH5 and MH6 maximum motor speed - 3000 rpm
• Motor MH5 and MH6 maximum continuos pressure - 3045 psi (210 bar)
• Ground drive maximum ground speed - 220 ft/min (67.0 m/min) in forward high-
speed mode and 132 ft/min (40.2 m/min) in reverse or
low-speed mode

Ground Drive
Component Repair/Replace
If troubleshooting procedures determine a component is in need of repair or
replacement, refer to the appropriate procedures at the back of the chapter or other
chapters where instructed. After repairs have been made, refer to "Hydraulic Fluid
Sampling," page 4-26 and follow instructions.

WARNING: Pressurized fluid can penetrate body tissue and result in serious injury or
death. Leaks can be invisible. Keep away from any suspected leak. Relieve pressure in the
hydraulic system before searching for leaks, disconnecting hoses, or performing any other
work on the system. If you must pressurize the system to find a suspected leak, use an
object such as a piece of wood or cardboard rather than your hands. When loosening a
fitting where some residual pressure may exist, slowly loosen the fitting until oil begins to
leak. Wait for leaking to stop before disconnecting the fitting. Fluid injected under the skin
must be removed immediately by a surgeon familiar with this type of injury.

8-17
 Component Repair D20x22 Series II Navigator HDD Service

COMPONENT REPAIR
Planetary Gears

6
5

2
1
Ground Drive

Remove 1. Remove tracks. Refer to "Tracks," page 8-24.

2. Remove bolts (1) and washers (2) mounting track drive sprocket (3) on planetary
gearbox.
NOTE: Planetary assembly consists of planetary and motor.

3. Disconnect and cap hydraulic hoses on motor (4).

4. Remove bolts (6) and washers (5) mounting motor to planetary gearbox. Carefully
slide motor out of coupling from gearbox.
Install 1. Clean center face and mounting faces of motor and gearbox, checking for dents.
2. Oil center face and spread grease over motor to gearbox O-ring.
3. Check that motor shaft couples correctly with input joint of gearbox.
4. Once motor is correctly positioned, install it with bolts and washers.
Reverse remove steps above to install gear. Torque all mounting bolts to a minimum of
88.1 ft-lb (119.5 Nm) and a maximum of 107 ft-lb (145.1 Nm).

8-18
D20x22 Series II Navigator HDD Service Component Repair

Gearbox and Track Motors MH5 and MH6

6 15 20 19 24 9 17 2 10 21
7

16

13

26

18

27

12

30

23 14 25 28 29 5 11 8 22

Ground Drive
Repair Refer to diagram above for motor part locations. Refer to D20x22 Series II Parts
Manual for seal kit part number.

IMPORTANT: Cleanliness is extremely important when repairing hydraulic motors.

Work in a clean area. Clean port areas of motor thoroughly.

IMPORTANT: Inspect all parts for damage (scratches or burrs) or unusual wear
during each step of disassembly. Check condition of all mating surfaces. Do not re-use
O-rings or seals.

List of parts shown below:

1. Washer 16. External Snap Ring

2. Washer 17. External Snap Ring
3. Pad 18. External Snap Ring
4. End Cover 19. External Snap Ring
5. Output Housing 20. Internal Snap Ring
6. Hub 21. Internal Snap Ring
7. Motor 22. O-Ring
8. Planetary Carrier 23. O-Ring
9. Planetary Gear 24. Bearing

Continued on next page...

8-19
 Component Repair D20x22 Series II Navigator HDD Service

10. Planet Gear 25. Ball Bearing

11. Sun Gear 26. Neddle Bearing
12. Sun Gear 27. Shim Kit
13. Pin 28. Shim
14. Shim 29. Shim
15. Bearing 30. Plug Fitting

Install To assemble motor, replace parts that were removed.

Install motor. Refer to "Planetary Gears," page 8-20.

Install track. Refer to "Tracks," page 8-24.

Tracks
Remove 1. With a suitable lifting
device, raise machine
frame up until tracks are
clear of floor. Support
frame with jackstand.
2. Release track tension by
loosening bolt (1). 3 1 2
Ground Drive

3. Have an assistant pry

track free at idler end of track (2), while you pry track free at planetary (3).
4. Work track slowly free of planetary, gear by gear.
5. Slide track out from under track frame.

8-20
D20x22 Series II Navigator HDD Service Component Repair

Install 1. Raise machine frame and support machine with track assembly off floor.
2. Have two assistants stretch track as much as possible using pry bars, or other
appropriate tools, while you use a pry bar to engage track at planetary gears.
3. Slowly work track back under rollers, and around idler and planetary. You may need
a rubber mallet to fully work track into place.
4. Once track is in place, adjust track tension. Refer to "Track Tension Adjustment,"
page 8-27.

Track Tension Tightener

Ground Drive
Remove 1. Raise machine off ground and support with blocking to stabilize machine.
2. Remove tracks. See "Tracks," page 8-24.
3. Remove bolts holding cover on side of track assembly.
Continued on next page...

8-21
 Component Repair D20x22 Series II Navigator HDD Service

2
9
10 6
3
11
7 4

8
5

4. Loosen track tightener bolt (1). Remove restraining tab and setscrew.
5. Remove bolt (1) and washer (2).
Ground Drive

6. Remove track tightener (3).

7. Support idler assembly at front. Slide out idler assembly.
8. Remove spring (4).
9. Remove bolt (5) and nut (6).
10. Remove idler (7), idler roller (8), front idler bracket (9), bearing (10), and washer
(11).
11. Remove bearings (10) and washers (11) in idler.
Install Reverse removal procedures to install.

Torque bolt (1) to 210 ft-lb (285 Nm). Apply thread sealant to setscrew and tighten.

Torque bolts (5) to 180 ft-lb (245 Nm).

Refer to "Track Tension Adjustment," page 8-27 for tension adjustment.

8-22
D20x22 Series II Navigator HDD Service Component Repair

Track Tension NOTE: Before starting adjustment procedures, ensure tracks are clean and free of dirt
Adjustment and mud.

1. Tighten bolt to increase tension.

2. Measure distance between front and end
of spring (see figure at side).
Measurement should read 7.83" (19.9
cm). The goal is to preload spring 25%.
NOTE: You may need a flashlight to see
spring inside track assembly.
Measure
3. Replace cover on fitting.
4. Drive machine forward approximately 30 ft (10 m) and reverse 30 ft
(10 m).
5. Tighten bolt further until spring length is 7.40–7.50" (18.8–19.0 cm) and preload is
50%.
NOTE: Keep preload on the spring of 25-50%. Discard after 3.0" (7.6 cm) of track
stretch or lug is worn off.

Ground Drive

8-23
This page intentionally left blank.
D20x22 Series II Navigator HDD Service Overview

Chapter 9: Rotation

OVERVIEW
The drill rotation chapter consists of the functions/components necessary to rotate the
drill string while drilling or backreaming.

THEORY
Components
The function covered in this section includes the following components:

Rotation
• Rotation/Thrust Pump PMP1
• Rotation Valve Assembly A6, including:
• Directional Valves DV1–DV3
• Relief Valve PV1
• Torque Limiter/Loop Flush Valve Assembly A7, including:
• Check Valve CV1
• Directional Valves DV4–DV7
• Relief Valves PV2 and PV3
• Solenoids L27, L28 and L33
• Rotation Motor MH1
• Right Joystick Assembly A2, including:
• Position Sensor B7
• Switch S13
• RATT PPU B4
• Rotation Pressure Sensor B8
• Rotation Gauge E5
• Display DP-10 E7, including:
• Switches S4–S6 and S8
• Torque Limiter Valve Gauge E10

9-1
 Theory D20x22 Series II Navigator HDD Service

Component Locations

GEARBOX

ROTATION MOTOR MH1

FLUID SWIVEL
Rotation

TORQUE LIMITER/LOOP FLUSH VALVE A7

ROTATION AND THRUST PUMP PMP1

DISPLAY E10
ROTATION GAUGE E5

RIGHT JOYSTICK A2

9-2
D20x22 Series II Navigator HDD Service Theory

Hydraulic Schematic

DV1
ROTATION MOTOR A6 MH1 RIGHT TRACK MH5

PV1 DV2
LEFT TRACK MH6
DV3
TORQUE LIMITER/
LOOP FLUSH
VALVE A7 DV7
PV3

DV5

Rotation
DV6 DV4

PV2

ROTATION AND THRUST PUMP PMP1

RETURN
MANIFOLD A17
CHARGE FILTER FL1

CHARGE PUMP PMP4 SUCTION

MANIFOLD A15

9-3
 Theory D20x22 Series II Navigator HDD Service

Electrical Schematic

E 7 D IS P L A Y D P 1 0 -A

E 7 D IS P L A Y D P 1 0 -B
Rotation

A 1 L E F T H A N D J O Y S T IC K H E A D

C 148 CO NTRO LLER

J1 - G R AY

J2- B LA C K

J3 - G REEN

J4- B R O W N

9-4
D20x22 Series II Navigator HDD Service Theory

Hose Connections

Rotation and Charge Filter FL1

Thrust Pump PMP1
Thrust Valve A8

Rotation Motor MH1

Rotation
Right Track
Motor MH5

Torque Limiter/ Left Track Motor MH6

Loop Flush Valve A7

9-5
 Theory D20x22 Series II Navigator HDD Service

Rotation and Thrust Pump PMP1 Ports

Port Function Recommended Gauge Size Fitting

MA system pressure port ‘A’ 10,000 psi or 750 bar gauge 9/16”–18 O-ring fitting
MB system pressure port ‘B’ 10,000 psi or 750 bar gauge 9/16”–18 O-ring fitting
MC system pressure port ‘C’ 10,000 psi or 750 bar gauge 9/16”–18 O-ring fitting
MD system pressure port ‘D’ 10,000 psi or 750 bar gauge 9/16”–18 O-ring fitting
M3 charge pressure gauge port 1000 psi or 100 bar gauge 9/16”–18 O-ring fitting
M4 servo pressure 1000 psi or 100 bar gauge 9/16”–18 O-ring fitting
M5
L1 case pressure 100 psi or 10 bar gauge 1-1/16”–12 O-ring fitting
L2
Rotation

L3
E charge pump inlet inlet line 7/16”–20 O-ring fitting

9-6
D20x22 Series II Navigator HDD Service Theory

Operation Overview
Rotation Motor The engine drives the hydrostatic rotation pump which supplies oil to the rotation motor.
The motor is splined to a common shaft in the drill gearbox. The gearbox reduces the
speed and increases the torque available to the drive chuck.

Rotation Pump The rotation pump provides a variable output to drive the chuck at speeds ranging up to
the maximum available in each speed range. Two speed ranges may be selected by
shifting the motor into reduced displacement mode.

Charge Pump The rotation pump charge pump provides pilot oil pressure to shift the motor’s speed
and displacement. Oil from the charge pump is also supplied to the rotation closed loop
to replace leakage and to allow a percentage of the closed loop oil to be sent to the
hydraulic oil cooler by way of the shuttle valve.

Torque Limiter/Loop The torque limiter/loop flush valve on top of the gearbox incorporates the hot oil shuttle

Rotation
Flush Valve valve, the hot oil shuttle relief valve, and the torque limiting valves.

Oil from the shuttle is routed into the rotation motor case, through the return line into the
return manifold and into the tank. This oil is routed out of the circuit to remove heat
from the closed loop.

Operation Correct operation of the system requires that the engine is turning at rated RPM, oil
supply is unrestricted to the charge pump, and the charge filter is not plugged or “dirty”.
The hot oil shuttle must remove sufficient oil from the loop to keep the closed loop
operating temperature within specifications. Back pressure in the case drain line must
not exceed the maximum specified or the following may result - “blown” seals,
insufficient hot oil shuttle flow, high case temperature, high loop temperature, or erratic
operation of the speed shift function.

Shared Components
The drill rotation function shares the common hydraulic fluid distribution components,
as well as torque limiter/loop flush valve assembly A7. The hydraulic fluid distribution
components are shared by all functions with hydraulic circuits. These components
include:

• Hydraulic Tank RES1

• Oil Cooler HE1
• Rotation and Thrust Pump PMP1
For more information on the hydraulic fluid distribution components, refer to Chapter 4.

9-7
 Theory D20x22 Series II Navigator HDD Service

Charge Pump
Operation The charge pump (1) fills the loop hoses and
other components with oil during initial start-
up. It also replaces oil lost because of internal 1
leakage in circuit hydraulic components, and
oil that is routed back to the tank through the
torque limiter/loop flush valve. The charge
pump replaces hot oil shuttle flow with cooled
and filtered oil from the tank and provides
pressurized oil to position the swash plate.

The charge pump is a gerotor-type pump. Oil

is forced by atmospheric pressure through the
suction strainer in the tank, into the charge
pump, through the charge filter, and through
Rotation

the charge check valves to both sides of the

loop when the rotation pump is in neutral.
When the rotation pump is stroked, charge
pump oil flows to the low pressure side of the
loop. The remainder of the oil goes across the
charge pressure relief, into the pump case and
on to the tank.

9-8
D20x22 Series II Navigator HDD Service Theory

Pump PMP1 – High Pressure Relief Valves

Operation A high pressure relief valve is used in each closed loop port to limit the system pressure
and to allow charge oil to keep the closed loop filled.

The figure below illustrates the relationship between the high pressure relief valves and
the ports controlled by those valves.

Rotation
PORT C
PORT B

PORT D
PORT A

When the system pressure exceeds the factory setting of 3335 psi, oil is passed from the
high pressure system loop into the charge gallery, and into the low pressure system loop
via the charge check.

Each high pressure relief valve has a check valve inside which allows charge pump oil
to keep the low side of the loop filled and pressurized.

9-9
 Theory D20x22 Series II Navigator HDD Service

Pump PMP1 – Electric Displacement Control (EDC)

1

2
Rotation

Operation The EDC (1) controls the displacement of the pump.

Within the control, a pressure control pilot (PCP) proportional valve solenoids L18 and
L19 (2) receive variable electrical input from controller A5. The solenoids operate a
spring-centered 4-way servo valve. This valve ports hydraulic pressure to either side of a
dual-acting servo piston (3). The servo piston rotates the swashplate, varying the pump’s
displacement or flow, from full displacement in one direction to full displacement in the
opposite direction. The control is designed so the position of the swashplate is
proportional to the mechanical movement of the joystick. A feedback link monitors
swashplate position to shut off oil flow to the servo piston when the desired position is
reached.

9-10
D20x22 Series II Navigator HDD Service Theory

Torque Limiter/Loop Flush Valve A7

G1 GB CP
A C
T1
B T2
T

GA S1

Rotation
T3 G2
G3
G4

Torque Limiter The torque limiter circuits contain components which limit the pump pressure applied to
the rotation motor when the motor is turning the drill rod in the clockwise direction
(when looking downhole). When the front vise switch S22 is in the CLAMP position or
the 2-speed gearbox switch S8 is in the HIGH position, directional valve DV7 and relief
valve PV3 in torque limiter manifold A7 limit pressure applied to the rotation motors
when in forward (clockwise) rotation to 2000 psi (137 bar).

Loop Flush Hot oil shuttle valve DV6 shifts to allow low side flow to relief valve PV2 when
pressure is sensed on the high side. When pressure exceeds 310 psi (21.3 bar) at relief
valve PV2, oil flows to port T and then on to oil cooler HE1.

Low Speed Function When switch S8 is placed in LOW position, there is no electrical power available to
solenoid L27 in the loop flush valve manifold A7. Oil flow that comes into the manifold
is routed out of the manifold at port T3.

High Speed If front vise switch S22 is in the RELEASE position and 2-speed rotation switch S8 is
Function placed in HIGH position, electrical power is made available to solenoid L27. When
solenoid L27 is energized, valves DV4 is shifted, and oil is routed to the S port of
rotation motor MH1. This shifts the motor displacement from 1.57 to 0.765 cid,
increasing rotation speed to 184 rpm, and reducing torque.

9-11
 Theory D20x22 Series II Navigator HDD Service

Rotation Motor MH1

Rotation motor is a 30.7 cid (503 cc) motor
which is used to rotate the drill string.
Pressure at motor port Y shifts the
displacement to 2/3 of the original 30.7 cid
(503 cc). This increases drill string rotation
speed because the same amount of oil flow
from the pump will cause the motor to rotate
more revolutions.

Port F receives flow from the rotation

hydraulic circuit to flush the motor for
cooling purposes.

Port 1 allows oil flow from the pump case that drains into the rotation gearbox.
Rotation

Ports A and B receive oil from the rotation pump to rotate the drill string. Input and
output at the ports will vary depending on the position of the electric displacement
control (EDC) of the rotation pump.

9-12
D20x22 Series II Navigator HDD Service Theory

Drill Rotation Function – Drilling/Backreaming Mode

A

DV7 FROM 2-SPEED S8

TORQUE L27
LIMITER
VALVE A7 DV4
A ROTATION MOTOR MH1

Rotation
L18

ROTATION AND THRUST PUMP PMP1

Operation To operate the drill rotation drilling/backreaming mode:

• Seat switch must be closed (operator in seat).

• Remote Lockout system must be in RUN mode.
• Engine must be running at full throttle.
• Rotation joystick pushed FORWARD.
• 2-speed rotation switch S8 in HIGH or LOW position, as desired.
When required operating conditions are met:

• Rotation sensor B7 sends signal to controller A5. Controller sends signal to Rotation
EDC+ solenoid L18.
• Solenoid coil L18 of the proportional valve in pump PMP1 will be energized,
shifting it to the crossover position allowing charge flow to change the angle of the
pump’s swashplate.
• Oil will flow to torque limiter/loop flush valve A7 and motor MH1.
Continued on next page...

9-13
 Theory D20x22 Series II Navigator HDD Service

• When the pressure is in the torque limiter pressure range, oil flows to port A of
motor MH1, causing clockwise (CW) rotation speed of motor MH1.
• If 2-speed switch S8 in HIGH position, solenoid L27 in torque limiter/loop flush
valve will shift and oil will flow to Y port of motor MH1, causing reduced
displacement and higher speed.
NOTE: The rotation pressure gauge on the control panel measures pressure at the
torque limiter/loop flush valve. The rotation speed on the display screen comes from
rotation sensor B7 at the gearbox.

NOTE: If drilling/backreaming mode does not operate as expected, see "Hydrostatic

Closed-Loop Troubleshooting," page 9-18.
Rotation

9-14
D20x22 Series II Navigator HDD Service Theory

Drill Rotation Function – Rod Uncoupling Mode

A

DV7 FROM 2-SPEED S8

TORQUE L27
LIMITER
VALVE A7 DV4
ROTATION MOTOR MH1

Rotation
L19

ROTATION AND THRUST PUMP PMP1

Operation To operate the drill rotation rod uncoupling mode:

• Seat switch must be closed (operator in seat).

• Remote Lockout system must be in RUN mode.
• Engine must be running at full throttle.
• Rotation handle pulled BACKWARD.
When required operating conditions are met:

• Rotation sensor B7 sends signal to controller A5. Controller sends signal to Rotation
EDC- solenoid L19.
• Solenoid coil L19 of the proportional valve in pump PMP1 will be energized,
shifting it to the crossover position allowing charge flow to change the angle of the
pump’s swashplate.
• Oil will flow to torque limiter/loop flush valve A7 and motor MH1.
Continued on next page...

9-15
 Troubleshooting D20x22 Series II Navigator HDD Service

• When the pressure is in the torque limiter pressure range, oil flows to port B of
motor MH1, causing counterclockwise (CCW) rotation speed of motor MH1.
• If 2-speed switch S8 is in HIGH position, solenoid L27 in torque limiter/loop flush
valve will shift and oil will flow to Y port of motor MH1, causing reduced
displacement and higher speed.
NOTE: The rotation pressure gauge on the control panel measures pressure at the
torque limiter/loop flush valve. The rotation speed on the display screen comes from
rotation sensor B7 at the gearbox.

NOTE: If rod uncoupling mode does not operate as expected, see "Hydrostatic
Closed-Loop Troubleshooting," page 9-18.

TROUBLESHOOTING
Rotation

Troubleshooting procedures are given for each operating mode of the different functions
of this chapter. Begin each procedure by performing a pretest inspection of the machine.
See "Pretest Inspection," page 9-17.

Often problems can be solved by doing a walk-around inspection of the machine

looking for obvious problems.

If nothing is found during the pretest inspection, continue by operating all other actuator
functions of the machine to help further isolate problems. See "Troubleshooting
Machine Performance," page 9-24.

9-16
D20x22 Series II Navigator HDD Service Troubleshooting

Pretest Inspection
If a problem develops in the rotation circuits and machine performance indicates the
machine is not operating within specifications, begin by visually checking for any
obvious failures. Broken, kinked, or loose hoses and fittings on supply, pressure, and
return to hydraulic components will affect function performance.

• Ensure there are no broken, missing, corroded, or loose connections on ground and
power wires that supply electrical circuit components. If any are found, repair or
replace them.
• Refer to the Hydraulic Fluid Distribution chapter and ensure fluid conditioning
components are operational. If OK, continue. If not, correct any problems found.

WARNING: Pressurized fluid can penetrate body tissue and result in serious injury or
death. Leaks can be invisible. Keep away from any suspected leak. Relieve pressure in

Rotation
the hydraulic system before searching for leaks, disconnecting hoses, or performing any
other work on the system. If you must pressurize the system to find a suspected leak, use
an object such as a piece of wood or cardboard rather than your hands. When loosening a
fitting where some residual pressure may exist, slowly loosen the fitting until oil begins
to leak. Wait for leaking to stop before disconnecting the fitting. Fluid injected under the
skin must be removed immediately by a surgeon familiar with this type of injury.

9-17
 Troubleshooting D20x22 Series II Navigator HDD Service

Hydrostatic Closed-Loop Troubleshooting

The hydrostatic drive components are precision-built to very close tolerances and
operate at high pressures. Cleanliness is extremely important when performing any of
the following:
• When setting or checking pressure, oil temperature should be near normal operating
temperature 120°F (49°C).
• Clean components and immediate area before servicing. Use only filtered hydraulic
oil and a clean funnel when adding oil to the system.
• Unless specified in the instructions, tighten all bolts and fittings according to the
recommended torque values provided in the Vermeer Technician’s Shop Manual.
• When installing pumps and motors, coat drive splines with anti-seize compound.
• Whenever replacing charge filters, engine must be cranked without starting to ensure
adequate charge pressure is available. See filter change procedure found in D16x20
Rotation

Series II/D20x22 Series II Maintenance Manual.

IMPORTANT: Never bypass neutral start lockouts to start machine. Internal pump
damage can occur if the engine is started and the pumps are not in NEUTRAL.

• Label hoses for location before disconnecting them. Plug all hoses and cap all fittings
when disconnecting them to prevent contamination of the hydraulic system.
• All components (tank, hoses, and fittings) must be clean before installation. Hoses
and fittings should be rinsed with clean solvent filtered through a 5-micron filter and
dried with air before installation.
• Filter closed loop systems whenever they have been opened and exposed to
contamination, such as when replacing a hose or component.
• When replacing a closed loop high pressure hose: Ensure engine is shut off, and wait
approximately 5–10 minutes before carefully removing old hose.
• Do not run a new motor over half speed until the motor is under full hydraulic
pressure. Run approximately 5 minutes to ensure air is out of the system.
Continued on next page...

9-18
D20x22 Series II Navigator HDD Service Troubleshooting

Unless the problem is obvious, investigate these fundamental hydraulic-related

questions:

1. Ensure pump is delivering correct flow. Is the inlet restricted? Is the pump worn
out? Is the electric displacement control (EDC) correctly controlling pump stroke?
2. Ensure pump (EDC) is functioning correctly. Is the pump neutral set correctly? Is
the circuit relief set correctly?
3. Ensure circuit is delivering correct pressure to the actuator. Are the actuators
original equipment or correct replacements?
4. Ensure there is pressure and flow at the motors. Correct pressure and flow at the
motor ports will rotate the motors unless they are severely worn, defective, or
incorrect replacements.
5. Ensure motors are receiving flow from the control valve.

Rotation
6. Ensure there is no abnormal mechanical resistance to actuator function. Pressure in
a hydraulic system comes only from “line” (“system”) resistance or from “load”
(“actuator”) resistance. Any change from normal will result in changed
performance.
NOTE: A dramatic change in operation between cold conditions and warmed up
conditions indicates pump or motor wear, because hot oil flows more easily through a
worn pump or motor.

9-19
 Troubleshooting D20x22 Series II Navigator HDD Service

Indicators Used For Troubleshooting Closed Loops

Five primary clues combined with four measurements reveal most problems found in
closed loops hydraulic circuits.

The five clues are observed during normal operation of the machine. The five clues are:

• noise
• temperature
• movement
• control
• torque

The four measurements can be taken when troubleshooting the thrust/pullback hydraulic
loop. The four measurements are:
Rotation

• inlet restriction
• charge pressure
• system pressure
• case pressures

Pump Noise Shrieking noises from the pump or charge pump indicate cavitation or pseudo-
cavitation. Shut down until the situation is remedied.

Cavitation will be indicated by high inlet restriction.

Pseudo-cavitation will be indicated by foam in the oil tank, which is usually caused by a
hole or loose fitting in the suction line between the charge pump inlet and the tank.

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D20x22 Series II Navigator HDD Service Troubleshooting

Fluid Temperature The temperature of the hydraulic oil should not exceed 180°F (82°C) for an extended
length of time. High heat indicates a malfunctioning component in a hydraulic system.
Either the oil cooling circuit is not functioning efficiently and the normal heat due to
work is building up, or excess heat is being generated by oil passing over a relief valve
or excessive internal leakage in a component.

Causes of high heat include:

• low oil level in the tank— add clean, filtered oil if needed
• clogged oil cooler—hot oil bypassing directly to the tank
• excessively dirty fins on the oil cooler—preventing heat exchange—clean fins
• low charge pressure—charge pump pushing cool oil out over charge pressure relief
• low setting on high pressure relief valves—heat is added to oil when crossing relief
valves and lower settings allow more oil to cross at a lower pressure.

Rotation
• high system pressure—increased workload, due to failed mechanical components
such as bearings or linkages, increase the working pressure of the circuit.
• excessive internal leakage in pump and motors

Required Test Equipment

• Pressure
• Phototach
• Flow Meter
• Needle Valve
• Flow Meter, Needle Valve, Pressure Gauge Combination
• Pyrometer
• Digital Multimeter

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 Troubleshooting D20x22 Series II Navigator HDD Service

Pressure Check
Rotation circuit pressure can be checked at the pressure gauge in the control panel.

1. Start engine and set engine speed to full throttle. Verify engine speed at
approximately 2350 rpm.
2. Engage Remote Lockout.
3. Move rotation gearbox to the most forward position and clamp drill into vise.
4. Place rotation speed switch to LOW setting.
5. With propel lever in NEUTRAL, the rotation pressure gauges on control panel
should read 0.
6. Push propel handle to FORWARD so pressure increases in the high pressure side of
the closed circuit to the pressure limiter setting. The pressure limiter setting is
Rotation

reached when pressure stops increasing and remains steady as shown on rotation
pressure gauge.
Expected result: The pressure gauges should measure approximately 6000 psi (413
bar). If not, return pump to its NEUTRAL setting and inspect high pressure relief
valves for damage or contamination. Repair, replace, or adjust as necessary.

Oil Sampling
A closed-loop system should not be opened when testing so that contamination is not
introduced into the system. Therefore, before installing any test equipment to determine
component wear, the first step would be to obtain an oil sample from the closed loop.

Oil sampling systems can analyze the oil without interrupting machine operation or
opening the system. Oil sampling can determine oil viscosity, temperature, contaminate
particle size, type, and concentration.

If oil sample test is not within the acceptable range, and machine performance is within
specifications, replace hydraulic oil as instructed in the D16x20 Series II/D20x22 Series
II Maintenance Manual.

Continued on next page...

9-22
D20x22 Series II Navigator HDD Service Troubleshooting

IMPORTANT: The pressure and flow ratings of the test equipment used to conduct
the following hydraulic test procedures must be equal to or greater than the pressure and
flow ratings of the circuit being tested.

The tolerances associated with a given specification are values indicating the nominal,
operating parameters.

High internal leakage (usually associated with pumps and motors) will cause system
overheating and/or a decline in actuator speed. The amount of leakage is influenced by
four factors:

• pressure difference across internal clearances

• oil viscosity
• temperature
• size of internal clearances

Rotation
NOTE: Clearance-related problems are generally viscosity sensitive. Increased
leakage will be less obvious when the fluid temperature is low and will increase as the
fluid temperature increases.

Internal leakage is externally drained from the pump case by a separate drain line which
returns directly to the oil tank.

The rotation motors are drained internally directly into the rotation gearbox.

The most common symptoms associated with excessive pump and motor leakage
are:

• a loss of rotation speed as the fluid temperature increases

• a moderate to high increase in the operating temperature of the fluid
• drill rotation stalling at low pump speed
• increase in pump case pressure which could result in shaft seal leakage.
NOTE: If leakage in a motor or pump approaches or exceeds 30% of the theoretical
(no-load) flow at full-load (maximum-rated pressure), it should be replaced.

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 Troubleshooting D20x22 Series II Navigator HDD Service

Troubleshooting Machine Performance

Possible faults may occur in the drill rotation function that are directly related to faults
in other functions. These other faults may not be readily apparent, because those
particular functions are not currently being operated.

Operate the machine functions and document performance of working actuators.

Make note of any functions not operating normally based on the theory given in each
chapter for that function. To help isolate a faulty component or function, compare the
notes you have taken to the normal operation given for each mode of a particular
function.

After checking the performance of all functions, if the problem is isolated to the original
function in question, return to the troubleshooting/testing for that mode. If multiple
functions are affected, proceed with troubleshooting based on the possible results listed
Rotation

next.

Possible Results The possible results listed are meant to guide the service technician in a logical manner
to isolate a fault as quickly as possible.

1. If faults are noted when operating all machine actuators, it would indicate a function
or component that is common to all the actuators is most likely faulty. The following
common functions and components should be investigated:
• Engine. Refer to "Engine," page 3-6.
• Remote Lockout. Refer to Chapter 15.

2. If faults are noted in the drill rotation function, as well as the ground drive function,
and all other functions are OK, the hydraulic components common to just these
functions should be investigated, including:
• Rotation/Thrust pump PMP1. See "Rotation and Thrust Closed-Loop Pump
PMP1," page 4-8 and this chapter.
• Torque limiter/loop flush valve A7. See "Torque Limiter/Loop Flush Valve A7,"
page 9-11.
3. If faults are noted in only the drill rotation and thrust/pullback functions, and all
other functions are OK, the hydraulic components common to just the vises should
be investigated:
• Rotation/Thrust pump PMP1. See "Rotation and Thrust Closed-Loop Pump
PMP1," page 4-8 and this chapter.
• Torque limiter/loop flush valve A7. See "Torque Limiter/Loop Flush Valve A7,"
page 9-11.

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D20x22 Series II Navigator HDD Service Troubleshooting

Testing Drill Rotation Performance

Before beginning any troubleshooting or testing procedures, perform the "Pretest
Inspection," page 9-17. If nothing obvious is found, continue.

1. Ensure switches listed in "Starting the Engine," page 2-2, are in correct positions.
2. If pretest inspection has not been performed, conduct inspection before proceeding.
3. Start the engine.
4. Enable Remote Lockout.
5. Push forward on right joystick.
6. Press 2-speed control switch S8 (1) to HIGH.
1
7. Push forward on right joystick.

Rotation
8. Press 2-speed control switch S8 to LOW.
9. Pull backward on right joystick.
10. Press 2-speed control switch S8 to HIGH.
11. Pull backward on right joystick.
12. Press 2-speed control switch S8 to LOW.
13. Press AutoDrill rotation cruise switch S6. Set parameters as suggested in D16x20
Series II/D20x22 Series II Operator’s Manual.

Troubleshooting/Testing Rotation and Thrust Pump PMP1

1. If electrical problems are suspected, refer to the table below.

Troubleshoot Possible Effect Action

Control operates EDC coil failure. Measure resistance at coil pins.

pump in one direction Resistance should be 3.66 ohms at
only. 70°F (20°C).
Pump does not No power to EDC.
Restore power to EDC.
function.
Pump functions Electrical connection to pump is bad. Disconnect connection, check wires,
erratically. reconnect wires.

Continued on next page...

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 Troubleshooting D20x22 Series II Navigator HDD Service

2. If there is excessive noise or vibration associated with the pump, refer to the table
below.

Troubleshoot Possible Effect Action

Check fluid level in Low hydraulic oil level can cause

Fill hydraulic oil to correct level.
tank. cavitation.
Check for air in Air in system decreases efficiency of
Purge air and tighten fittings. Check
system. units and controls. Air in system is
inlet for leaks, proper size and
indicated by excessive noise in pump,
restrictions.
foaming in oil, and hot oil.
Check oil If oil is cold, it may be too viscous for Allow system to warm up to its normal
temperature. proper function and pump will cavitate. operating temperature with engine at
idle speed.
Check pump inlet Improper inlet conditions will cause Look for restrictions in inlet line. Check
pressure. Check for erratic behavior and low outlet flow. inlet line size. Check filter and bypass
Rotation

vacuum. switch.
Inspect charge/system Unusual noise may indicate sticking Clean/replace valves and test
relief valves. valves. Possible contamination. pump.Noise may be a normal
condition.

Continued on next page...

9-26
D20x22 Series II Navigator HDD Service Troubleshooting

3. If the pump sounds normal, but there is excessive heat generated by the drill rotation
or drill fluid circuits, refer to "Pump Test Procedure," page 9-30 for further
testing instructions.

Troubleshoot Possible Effect Action

Check fluid level in Insufficient volume of hydraulic fluid Fill hydraulic oil to correct level.
tank. will not meet cooling demands of
system.
Inspect oil cooler. Insufficient flow or high input Clean, repair or replace oil cooler as
temperature will not meet cooling required.
demands of the system.
Measure charge Low charge pressure will overwork Inspect and adjust or replace charge
pressure. system. relief valve. Inspect and repair or
replace charge pump.
Check charge pump High inlet vacuum adds heat to the Correct inlet pressure conditions.

Rotation
inlet pressure for system.
vacuum.
Check system relief If the system relief valves are worn, Adjust relief valve setting. Refer to
valve pressure setting. contaminated or valve settings are too "Specifications," page 9-44. Replace
low, the relief valves will be valves as necessary.
overworked.
Measure system Frequent or long term operation over If pressure is too high, reduce loads.
pressure. system relief setting will create heat in
system.

4. If neutral position is difficult or impossible to find, refer to the table below.

Troubleshoot Possible Effect Action

Check electrical input Input to EDC module is operating Disconnect input and check to see if
to EDC. improperly. pump comes back to neutral. If yes,
troubleshoot machine controller and
connection.
Verify pump control Neutral is set improperly in EDC. Shunt ports M4 and M5 together with
neutral is set. external hose and see if pump comes
back to neutral. If no, perform
"Adjusting Pump Neutral Setting,"
page 9-35. If you still cannot set
neutral, replace control.

Continued on next page...

9-27
 Troubleshooting D20x22 Series II Navigator HDD Service

5. If drill rotates or thrust motors move in one direction only, refer to the table below.

Troubleshoot Possible Effect Action

Check electrical input Input to EDC module is operating Check input. Repair or replace as
to EDC. improperly. necessary.
Check control orifices. Control may not operate correctly if Clean orifices.
orifice is blocked.
Check EDC control Control may not operate correctly if Clean screen.
screen. screen is blocked.
Interchange high Problem could be related to the If the rotation or thrust changes
pressure relief valves. malfunction of one valve. direction, replace the faulty valve.
Check servo pressure. Servo pressure could be low or Check for damaged servo seals.
decaying. Replace and retest. Only a Sauer-
Danfoss Global Service Partner may
remove the servo piston without
Rotation

voiding the warranty.

6. If drill will not rotate in either direction or thrust motors move in neither direction,
refer to the table below.

Troubleshoot Possible Effect Action

Check fluid level in Insufficient volume of hydraulic fluid Fill hydraulic oil to correct level.
tank. will not meet cooling demands of
system.
Check control orifices. Control may not operate correctly if Clean orifices.
orifice is blocked.
Check EDC control Control may not operate correctly if Clean screen.
screen. screen is blocked.
Measure charge Low charge pressure insufficient to If pressure is low, troubleshoot charge
pressure with pump in recharge system loop. relief valve.
neutral.
Check charge relief A pump charge relief valve that is Adjust or replace charge relief valve as
valve. leaky, contaminated or set too low will necessary.
depressurize the system.
Inspect charge pump A clogged filter will under supply Replace if necessary.
inlet filter. system loop.
Check charge pump. A malfunctioning charge pump will Repair or replace the charge pump.
provide insufficient charge flow.
Measure pump Low system pressure does not provide If low, troubleshoot high pressure relief
system pressure. enough power to move load. valves.
Interchange high Defective high pressure relief valves Replace the faulty valve.
pressure relief valves. cause system pressure to be low.
Check electrical input Input to EDC module is operating Check input. Repair or replace as
to EDC. improperly. necessary.
Continued on next page...

9-28
D20x22 Series II Navigator HDD Service Troubleshooting

7. If machine function response is sluggish, refer to the table below.

Troubleshoot Possible Effect Action

Check fluid level in Insufficient volume of hydraulic fluid Fill hydraulic oil to correct level.
tank. will not meet cooling demands of
system.
Interchange high Incorrect pressure settings will affect Replace the faulty valve.
pressure relief valves. system reaction time.
Check engine speed. Low engine speed will reduce system Troubleshoot engine.
performance.
Measure charge and Incorrect pressures will affect system Adjust charge and control valves.
control pressures. performance.
Check for air in Air in system will produce sluggish Fill tank to proper level. Cycle system
system. system response. slowly for several minutes to remove
air from system.

Rotation
Check EDC control Control may not operate correctly if Clean orifices
orifices. orifice is blocked.
Check EDC control Control may not operate correctly if Clean screen.
screen. screen is blocked.
Check pump inlet High inlet vacuum reduces system Measure charge inlet vacuum. Inspect
pressure for vacuum. pressure. line for proper sizing. Replace filter.
Confirm proper bypass operation.

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 Troubleshooting D20x22 Series II Navigator HDD Service

Pump Test Procedure

NOTE: The circuit schematics, in the following hydraulic troubleshooting tests, show
where to install testing equipment to perform a particular test and the procedure used to
perform the tests. In some cases it may not be easy to access the component or clearance
may be limited. Therefore, it is up to the discretion of the technician how to apply the
procedure.

IMPORTANT: Ensure any hoses or fittings that are added to the test equipment are
the same size and rating as hoses and fittings installed in the hydraulic circuit.
Mismatched hose or fitting sizes can result in erroneous pressure readings. Mismatched
pressure ratings can result in leakage or personal injury.

When troubleshooting a closed loop hydrostatic circuit, the following measurements can
be used to diagnose malfunctions:
Rotation

• Charge Pressure
• Rotation Circuit Pressure
• Pump or Motor Case Pressure
• Charge Pump Inlet Restriction
• Rotation Circuit Flow
Refer to "Specifications," page 9-44 for specifications and tolerances.

Continued on next page...

9-30
D20x22 Series II Navigator HDD Service Troubleshooting

Case Drain Pressure 1. Follow "Shutdown Procedure," page 2-1.

Test
2. Turn ground disconnect switch to the
DISABLE position.
3. Disconnect hose from case drain port
(port L3) (1).
4. Install T-fitting, diagnostic fitting, and
connect 100 psi (7 bar) pressure gauge at
port L3 (1) to indicate pump case drain
pressure.
5. Turn ground disconnect switch to the
ENABLE position. Start engine and 1
inspect test equipment connections for
leaks.

Rotation
6. Turn on Remote Lockout and select RUN
mode.
NOTE: If catastrophic failure is suspected,
do not operate pump for any longer than is
absolutely necessary to determine its
condition. If metal fragments are found in the
hydraulic lines, outlet port of pump, charge or
return filters, and/or tank, Do not operate
pump. Filter system before testing pump or
motor.

7. Set engine speed to full throttle. Verify

engine speed at tachometer. The engine
must be able to maintain full throttle to
achieve desired pump flow.
8. Allow hydraulic oil to warm up to approximately 130°F (54°C). If needed, cycle a
machine function to aid in warming the oil.
9. Actuate rotation control to full displacement position for clockwise rotation and
pump case pressure indicated on gauge (5).
NOTE: During test, do not allow case pressure to exceed 40 psi (2.7 bar). If it reaches
40 psi (2.7 bar), discontinue test. During cold start the pressure is allowed to reach 75
psi (5.1 bar) intermittent.

10. Shut down engine and analyze test results.

11. At conclusion of test procedure, remove test equipment, reconnect hydraulic lines
and tighten connections.
12. Start engine and check connections for leaks.
Continued on next page...

9-31
 Troubleshooting D20x22 Series II Navigator HDD Service

Analyzing Case Pump and motor wear is caused by hydraulic system contamination and degradation of
Pressure Test the oil. Since the pump and motor in closed loop circuits continuously cycle the same
Results oil, the pump and motors will normally wear at the same rate. If the test reveals that the
pump is worn and should be replaced, the motors may also be worn and need
replacement.

The pump is considered worn beyond limits when the case drain flow reaches or
exceeds 10% of the no-load flow. Refer to "Specifications," page 9-44 to determine
minimum output flow requirements.

If the case pressure exceeds 40 psi (3.0 bar), there appears to be excessive leakage
across ports of the pump. The pump should be replaced.
Rotation

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D20x22 Series II Navigator HDD Service Troubleshooting

Pump Case
Pressure Test
Test Objective To determine if pump case pressure exceeds specifications, indicating either a restriction
in case drain line or some condition causing excess flow to the pump case.

Special Tools and • 1000 psi (70 bar) pressure gauge

Materials • diagnostic fitting with 1-1/16–12 thread to install in pump case pressure port
Conditions Testing may be done initially with cold oil but must conclude with oil tank temperature
at normal working temperature, (at least 100°F (40°C)). Verify oil temperature with a
non-contact thermometer.

IMPORTANT: This procedure requires specialized training. Do not perform this test
if you are not trained in the use of flow meters on high pressure systems.

IMPORTANT: Never test case pressure by removing the drain line and plugging the

Rotation
case with a pressure gauge. This can lead to pump case failure and does not provide an
accurate test.

Procedure 1. Remove fitting from case drain port L3

1
(1).
2. Install T-fitting, diagnostic fitting, and
connect pressure gauge.
3. Load a drill rod into the machine and
clamp the front vise on it. Operate
machine at full throttle with rotation
joystick control in full FORWARD;
observe and record pressure on the gauge
and on the rotation gauge at the operators
panel.
4. Ensure rotation pressure gauge at operator station shows approximately 2000 psi
(torque limiter setting). If gauge shows pump case pressure above 20 psi (1.4 bar)
after system warms up, or 70 psi (4.8 bar) while cold, there is a restriction in the
case drain circuit or there is a condition causing excessive flow to the pump case.
Check case drain hose for restriction, if restriction is not found, check case drain
flow.

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 Troubleshooting D20x22 Series II Navigator HDD Service

Inspect Electric Disconnect electrical cable from the connector on the pump and check for neutral
Displacement operation. Disconnecting the control handle should allow the pump to return to neutral.
Control (EDC) If operation is satisfactory with the control disconnected, inspect control handle at
operator station for free movement.

If operation is not satisfactory with control handle disconnected, the pump neutral
setting may be out of adjustment.

NOTE: Before proceeding with pump control adjustment, inspect internal linkage,
torsion spring, and O-rings.

Remove cap screws while holding the control in place, and swing it away from the
housing and remove. Visually inspect for broken or missing linkages, torsion spring, and
O-rings. Inspect for missing, plugged, or damaged orifice.
Rotation

Inspect Charge When the rotation motors are not functioning properly in one direction, interchange
Check/High valve cartridges to determine if the problem changes to the other side of the circuit. If so,
Pressure Relief replace the faulty valve.
Valves
Pressure setting for these valves should be 3335 psi (230 bar).

9-34
D20x22 Series II Navigator HDD Service Troubleshooting

Adjusting Pump Neutral Setting

WARNING: Entanglement in rotating drill chuck and drill rod can result in death or
serious injury. Stay away from rotating equipment. Do not wear loose clothing that
could catch on rotating equipment.

1. Install a 1000 psi (70 bar) gauge in each Adjusting Screw

of the two displacement control cylinder Lock Nut
gauge ports (M4 and M5). Ensure
rotation joystick is in NEUTRAL
position. Disconnect the electrical
connections to EDC module. Start engine
and operate at normal idle speed.
2. Use a 4 mm Allen wrench to hold the
M5

Rotation
neutral adjusting screw stationary while
loosening the lock nut with a 13 mm
wrench. M4
NOTE: Adjustment of the EDC is very
sensitive. Be sure to hold the hex wrench steady while loosening the lock nut. Total
adjustment is less than 120 degrees.

3. Observe pressure gauges. If necessary, turn adjusting screw to reduce any pressure
differential.
4. Rotate the neutral adjusting screw Solenoid Shaft
clockwise until the pressure increases on Control Spool
the gauge. Note the angular position of
the wrench. Then rotate the neutral
adjusting screw counterclockwise until
the pressure increases by an equal
amount on the other gauge. Again note
the angular position of the wrench.
5. Rotate the neutral adjusting screw
clockwise half the distance between the
wrench positions shown above. The
gauges should read the same pressure, Adjusting
indicating that the control is in its Screw Cam
Feedback Pin
NEUTRAL position.
NOTE: A small pressure differential of 22 Less than 120°
psi (1.5 bar) or less is acceptable. Zero
differential is usually not possible.

Continued on next page...

9-35
 Troubleshooting D20x22 Series II Navigator HDD Service

6. Hold the neutral adjusting screw stationary. Tighten lock nut to 7 ft-lb (10 Nm). Do
not overtorque the nut.
7. Once NEUTRAL position is set, stop engine, remove gauges, and install gauge port
plugs. Connect electrical connections to EDC.
Rotation

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D20x22 Series II Navigator HDD Service Troubleshooting

Charge Pressure Relief Valve Check and Adjustment

WARNING: Pressurized fluid can penetrate body tissue and result in serious injury
or death. Leaks can be invisible. Keep away from any suspected leak. Relieve
pressure in the hydraulic system before searching for leaks, disconnecting hoses, or
performing any other work on the system. If you must pressurize the system to find a
suspected leak, use an object such as a piece of wood or cardboard rather than your
hands. When loosening a fitting where some residual pressure may exist, slowly
loosen the fitting until oil begins to leak. Wait for leaking to stop before disconnecting
the fitting. Fluid injected under the skin must be removed immediately by a surgeon
familiar with this type of injury.

NOTE: Cleanliness is extremely important when servicing hydrostatic systems. Refer

to "Returning System to Service," page 9-45 whenever a hydrostatic component is
replaced.

Rotation
1. Install a 1000 psi (50 bar)
pressure gauge at charge pressure
port M3 (1). 1

2. Install a 100 psi (10 bar) pressure 3

gauge at case pressure port L1 (2). 4
3. Turn on Remote Lockout and select RUN
mode.
4. Put rotation handle in NEUTRAL.
5. Start engine and set engine throttle to
normal speed.

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 Troubleshooting D20x22 Series II Navigator HDD Service

6. The acceptable charge pressure range is 313 psi (21.5 bar) ± 21.8 psi (1.5 bar). This
pressure assumes 1800 rpm pump speed and a pump reservoir temperature of 120°F
(50°C) and are referenced to case pressure.
7. Loosen lock nut (3) and rotate the adjusting screw (4) clockwise to increase the
setting or counterclockwise to decrease it. Subtract the case pressure reading to
compute the actual charge pressure.
NOTE: Change in pressure per turn is dependent on charge flow entering pump.

8. While holding the adjusting screw, torque lock nut to 13 ft-lb (17 Nm).
9. When you achieve the desired charge pressure setting, shut off engine and remove
the gauges and install the fittings and hoses.
Rotation

9-38
D20x22 Series II Navigator HDD Service Troubleshooting

Rotation Motor Case Drain Flow Test

This test provides information on rotation motor condition by measuring the case drain
flow for excessive leakage.

IMPORTANT: Ensure any hoses or fittings that are added to the test equipment are
the same size and rating as hoses and fittings installed in the hydraulic circuit.
Mismatched hose or fitting sizes can result in erroneous pressure indications.
Mismatched pressure ratings can result in leakage or personal injury.

The test procedure shown can be used to measure the case drain flow from each motor.

Rotation
1

1. Disconnect case drain line (1) from the rotation motor and install it to the inlet of a
20 gpm flow meter. Ensure meter flow direction arrow is pointing away from the
gearbox.
2. Add a short hose (2) from the outlet of the flow meter to the drain lines for the thrust
motors.
3. Turn ground disconnect switch to the ENABLE position. Start engine and inspect
test equipment connections for leaks.
4. Allow system to warm up to approximately 130°F (54°C). If needed, cycle a
machine function to aid in warming the oil.
5. Set engine speed to full throttle (2350 rpm). Place rotation speed range switch in
LOW.
6. Actuate rotation control to full FORWARD and record case drain measurement.

9-39
 Troubleshooting D20x22 Series II Navigator HDD Service

Analyzing Motor Test Results

The case drain flow should measure between 1.5 gpm (5.5 L/min) nominal, to 5.5 gpm
(21 L/min) maximum. If the measurement approaches or exceeds the maximum
allowable leakage, it is considered worn beyond its useful life.

IMPORTANT: Motor wear is caused by contamination and degradation of the oil.

Since the pump and motor in the closed loop continuously recycle the same oil, the
pump and motor wear at the same rate. If leakage in a motor approaches or exceeds the
maximum, it is highly recommended that the motor and pump be replaced.

Flushing the Rotation System

General Guidelines
Rotation

Hydrostatic drive components are precision-built to very close tolerances and operate at
When Servicing very high pressures. Cleanliness is extremely important, when servicing a hydrostatic
Hydrostatic Circuits system. Use care to avoid allowing dirt, dust or debris to enter the hydraulic system.
Contaminated oil will ruin the pump and motor in a short amount of time.

Before Repair (opening the circuit):

• Clean dirt from hose connections and around pump and motor ports before
loosening any connection.
• Use clean plugs to plug disconnected hoses and manifolds. If clean plugs are not
available, place plastic bags (such as sandwich bags) over the ends of hoses and
hold them in place with rubber bands. Also use new clean caps to cap off fittings.
The hydrostatic system can be easily damaged by contamination or lack of oil during
start-up. After repairing a hydrostatic system, use the following procedure to assure
there is an adequate supply of filtered oil to each part of the circuit:

• All oil supply components (tank, hoses, tubes, fittings) must be clean. If possible,
use a foam projectile cleaning system, part number 307480001 to clean hoses.
Otherwise, rinse all components with clean solvent (solvent must be filtered through
a 5-micron filter), and dried with filtered air before installation.
• Replace charge filter and return filters in circuit being serviced.
Continued on next page...

9-40
D20x22 Series II Navigator HDD Service Troubleshooting

• Fill oil tank with the recommended hydraulic oil. If replacing a pump or motor, fill
case with oil before starting the machine. Filter oil with a
5-micron oil filter as it is added to the tank, pump, or motor. Do not reuse old
hydraulic oil.
• Fill all disconnected hoses with new filtered oil during reassembly.
• Install filter assembly in the circuit using the proper fittings. Install filter assembly
in the return side of the circuit being flushed. Ensure flow arrow indicates correct
flow direction when the function is activated. Do not reverse oil flow direction when
flushing the circuit. Refer to "Procedure," page 9-41 to determine oil flow
direction and hose connections.

FROM PUMP ‘A’ PORT

FROM PUMP ‘B’ PORT

Rotation
A

DIRECTION OF
OIL FLOW

Special Tools • torque wrench capable of producing 90 ft-lb (122 Nm)

Procedure IMPORTANT: Do not start the machine after installing a new pump, motor, hose or
tube until the filter kit is installed. If installing a new hydrostatic pump or motor, fill the
case with filtered oil prior to starting the engine.

1. The drill rack should be level and the gearbox should be at the rear of the rack.
2. Follow "Shutdown Procedure," page 2-1.
3. Thoroughly clean top of the gearbox.
Oil the threads and 4. Label and remove ‘A’ port hose and ‘B’ port hose on motor, capping the fittings.
seats of the hoses or
fittings to achieve IMPORTANT: Note orientation of the arrow showing oil flow direction, and connect
correct torque values. hoses to the filter kit. Refer to figure above. Torque hose to 88 ft-lb (119 Nm).
Continued on next page...

9-41
 Troubleshooting D20x22 Series II Navigator HDD Service

5. Install a 600 psi (40 bar) pressure gauge on the charge pressure diagnostic port
connected to the oil filter.
IMPORTANT: Push emergency stop button down to prevent the engine from starting
before charge pressure is established. Pump damage will result if the engine starts before
the hydrostatic system is properly filled with oil.

NOTE: Do not crank engine for more than 30 seconds at a time to prevent the starter
from overheating. Allow starter to cool for several minutes between attempts to build
charge pressure.

6. Crank engine until the charge pressure is 25–50 psi (1.7–3.4 bar).
7. Pull emergency stop button out. Start engine and run it at the lowest possible RPM
until charge pressure is at least 290 psi (20 bar).
IMPORTANT: To avoid internal damage to the pump, never attempt to start the
Rotation

machine unless the pump is in neutral.

8. Pull left joystick back and flush circuit for 10 minutes at half throttle.
IMPORTANT: To prevent reintroducing contaminants, do not push the joystick
forward while the flushing filter is installed.

Oil the threads and 9. Follow "Shutdown Procedure," page 2-1. Remove filter kit, and connect ‘A’ port
seats of the hoses or hose and ‘B’ port hose to motor, being careful not to get contaminants into the
fittings to achieve circuit. Torque hoses to 88 ft-lb (119 Nm).
correct torque values.
10. Take an oil sample. Ensure oil sample test results reflect IS0 18/16/13 cleanliness
standard.
Continued on next page...

9-42
D20x22 Series II Navigator HDD Service Troubleshooting

Filter Components

1
2
8

5
7
6 6
7 4
3

Rotation
5 2

Filter Assembly Components

Number Part Number Description Quantity

(1) 82923-001 Fitting-16M JIC x 16/62 90° SH Ref 2

(2) 72895-001 O-ring-Sq. #16 Flange 2
(3) 235718-001 Bolt-1/2-13 x 2" GR8 Hex Zinc PLT 8
(4) 485-025 Washer-1/2” Flat Hardened Zinc 8
(5) 75351-001 Split Flange 2
(6) 75350-001 Spacer 2
(7) 72896-001 O-ring-Sq. #20 Flange 2
(8) 71927-001 Filter Assembly 1
71928-001 Element-Filter 1
75353-001 Seal Kit 1
71927-005 Indicator-Visual 1
71927-007 Glass-Visual Indicator 1

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 Troubleshooting D20x22 Series II Navigator HDD Service

Specifications
Listed below are the electrical and hydraulic specifications for the components in this
chapter.

Electrical:

• Nominal circuit voltage - 12 volts DC

• Torque limiter/loop flush valve solenoid coils L27 and L33 - 9.8 ohms @ 68°F
(20°C)
• Torque limiter/loop flush valve solenoid coil L28 - 7.2 ohms @ 68°F (20°C)
Hydraulic:

• Rotation and Thrust pump PMP1 normal output flow - 33 gpm (125 L/min) @ 2400
engine rpm
Rotation

• Rotation and Thrust pump PMP1 displacement - 3.2 cid (52.4 cc)
• Rotation and Thrust pump PMP1 charge pressure relief valve setting - 313 psi (21.5
bar)
• Rotation and Thrust pump PMP1 high pressure relief valve setting - 3335 psi (230
bar)
• Rotation and Thrust pump PMP1 maximum vacuum at inlet - 5 in. Hg
• Rotation motor MH1 maximum speed (high speed) - 279 rpm
• Rotation motor MH1 displacement - 30.7 cid (116.2 cc)
• Rotation motor MH1 maximum flow (continuous) - 32.8 gpm (124 L/min)
• Rotation motor MH1 maximum torque (continuous) - 1652 ft-lb
(2240 Nm)
• Rotation motor MH1 maximum case drain flow - high speed forward 3.6 gpm (13.6
L/min), low speed forward 3.5 gpm (13.2 L/min), and reverse 3.15 gpm (11.9 L/
min)
• Torque limiter relief valve PV3 pressure setting - 2000 psi (138 bar).
• Loop flush relief valve PV2 pressure setting - 450 psi (31 bar)

9-44
D20x22 Series II Navigator HDD Service Troubleshooting

Returning System to Service

The hydrostatic systems can be easily damaged by contaminants or by lack of oil. After
repairing a hydrostatic system, use the following procedure to assure an adequate supply
of oil to each part of the system.

• Fill the tank with the recommended hydraulic fluid. Filter the oil with a 5-micron oil
filter as it is added to the tank. Do not reuse hydraulic fluid.
• If replacing a hose, fill it with filtered oil before starting the machine.
• If replacing a pump or motor, fill the case with filtered oil before starting the
machine.

NOTE: Whenever the drilling fluid swivel has been removed from gearbox, the
gearbox has been removed, or any service work is done at rear side of gearbox, perform
the “Rotation Sensor Phase – Adjust” procedure in D16x20 Series II/D20x22 Series II
Maintenance Manual before returning the machine to service.

Rotation
IMPORTANT: Hydrostatic components can be destroyed if not filled with oil before
the engine is started.

9-45
 Component Repair D20x22 Series II Navigator HDD Service

COMPONENT REPAIR

WARNING: Pressurized fluid can penetrate body tissue and result in serious injury or
death. Leaks can be invisible. Keep away from any suspected leak. Relieve pressure in the
hydraulic system before searching for leaks, disconnecting hoses, or performing any other
work on the system. If you must pressurize the system to find a suspected leak, use an
object such as a piece of wood or cardboard rather than your hands. When loosening a
fitting where some residual pressure may exist, slowly loosen the fitting until oil begins to
leak. Wait for leaking to stop before disconnecting the fitting. Fluid injected under the skin
must be removed immediately by a surgeon familiar with this type of injury.
Rotation

9-46
D20x22 Series II Navigator HDD Service Component Repair

Rotation and Thrust Pump PMP1

Rotation
5 1

Removal

WARNING: Contamination can damage internal components and void the manufacturer’s
warranty. Take precautions to ensure system cleanliness when removing and installing system
lines.

1. Thoroughly clean all dirt and grime from outside of pump.

2. Label, disconnect and cap all hoses. Cap all fittings.
3. Attach a suitable hoist strap to pumpstack assembly.
4. Remove mounting bolts (1).
5. Use hoist to remove pump assembly.
NOTE: Be careful. Do not damage solenoids and electrical connections when using
straps or chains to support pump.

6. Remove bolts (2) and nuts (3) holding pump support plate (4) to pump support
weldment (5) and to rotation and thrust pump.

9-47
 Component Repair D20x22 Series II Navigator HDD Service

Ensure work surface and surrounding area are clean and free of contaminants, such as
dirt and grime.

Inspect system for contamination.

Look at hydraulic fluid for signs of system contamination, oil discoloration, foam,
sludge, or metal particles in oil.

Before replacing pump, replace all filters and drain hydraulic system. Flush system lines
and fill hydraulic tank with correct, filtered hydraulic fluid.

Install 1. Fill pump with clean, filtered hydraulic fluid. Use a 5-micron filter.
2. Attach pump to pump drive. Torque mounting bolts to 180 ft-lb (245 Nm).
3. Attach all hoses. Ensure charge inlet line is filled with fluid.
Rotation

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D20x22 Series II Navigator HDD Service Component Repair

EDC Module
Removal

Rotation
4

1. Using a 5 mm internal hex wrench, remove six cap screws (1).

2. Remove control module (2) and gasket (3). Discard gasket.
3. Disconnect electrical connection. Remove three cap screws (4) on each solenoid
using a 4 mm internal hex wrench.
4. Remove solenoid (5) and O-ring (6). Discard O-ring.
5. If necessary, remove coil using a 12-point 26 mm socket.

9-49
 Component Repair D20x22 Series II Navigator HDD Service

EDC Module 1. Lubricate new O-ring using petroleum jelly. Install O-ring.
Assembly
2. Install solenoids with three cap screws using a 4 mm internal hex wrench. Torque
screws to 4 ft-lb (5 Nm).
3. Install coil using a 12-point 26 mm socket. Torque coil nut to 3.7 ft-lb
(5 Nm).
4. Inspect machined surfaces on control and top of pump. If you find any nicks or
scratches, replace component.
NOTE: Remove plug on top of control to ensure swashplate feedback pin is properly
positioned in center of control module when installing control.

5. Install dowel pins in housing before installing control.

6. Install a new gasket.
7. If you removed screen, install a new one. Ensure screen has mesh facing outward.
Rotation

8. Install control module and six cap

screws. Torque screws in pattern shown. 2 1
Torque to 10 ft-lb (13.5 Nm).
9. Connect electrical connections and test
pump for proper operation. 6 5

4 3

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D20x22 Series II Navigator HDD Service Component Repair

Shaft, Seal and

Bearing Removal

1
2
3
4
5
6

Rotation
1. Unwind spiral ring (1) from housing to release shaft/seal/bearing subassembly.
2. Pry on lip of seal carrier (2) to remove it from pump. Remove seal carrier. Remove
and discard O-ring (3).
3. Press seal (4) out of carrier and discard seal.
4. Pull shaft (7) with bearing (6) out of pump. If necessary, tap lightly on shaft to
dislodge it from cylinder block.
IMPORTANT: Exercise caution. Do not damage housing bore, shaft, or bearing when
removing shaft and bearing.

5. Remove retaining ring (5) using retaining ring pliers. Press bearing off of shaft.

9-51
 Component Repair D20x22 Series II Navigator HDD Service

Shaft, Seal and 1. Inspect shaft journals for wear, scratches and pits. Check splines for fretting.
Bearing Assembly Replace if damaged.
2. Rotate bearing. If it does not rotate smoothly, replace it.
3. Press bearing onto shaft and replace retaining ring. Ensure retaining ring diameter is
less than 1.53" (38.9 mm) when installed on shaft.
4. Install shaft/bearing assembly into pump.
5. Lubricate and install a new O-ring onto
2 1
seal carrier. Press a new seal (1) into
seal carrier. Press seal until it is flush
within 0.005" (0.12 mm) or -0.0028" (-
0.72 mm) of inside lip (2) of carrier.
6. Cover shaft with a protective sleeve
while installing seal carrier. Hand press seal carrier into housing. Ensure seal carrier
Rotation

clears spiral ring groove in housing. Remove protective sleeve.

7. Wind spiral ring into housing. Ensure inside diameter of spiral ring is greater than
2.677" (68 mm) after installation.

9-52
D20x22 Series II Navigator HDD Service Component Repair

High Pressure
Relief/Charge Check
Valves

WARNING: Pressurized fluid can penetrate body tissue and result in serious injury or
death. Leaks can be invisible. Keep away from any suspected leaks. Relieve pressure in
the hydraulic system before searching for leaks, disconnecting hoses, or performing
any other work on the system. If you must pressurize the system to find a suspected
leak, use an object such as a piece of wood or cardboard rather than your hands. When
loosening a fitting where some residual pressure may exist, slowly loosen the fitting
until oil begins to leak. Wait for leaking to stop before disconnecting the fitting. Fluid
injected under the skin must be removed immediately by a surgeon familiar with this
type of injury.

1. Using an 8 mm internal hex wrench, remove valve seat plugs.

Continued on next page... Rotation

9-53
 Component Repair D20x22 Series II Navigator HDD Service

2. Carefully lift valve and spring assemblies from center sections using a magnet.
3. Inspect valves and mating seats in valve seat plugs for damage or foreign material.
4. Lubricate and install new O-rings and backup ring on valve seat plug.
5. Verify that conical springs are properly retained on check relief valves. Install valve
assemblies into center section. Torque to 59 ft-lb (80 Nm).
6. Operate machine through full range of controls to ensure proper operation. Check
for leaks.

Charge Pressure 1. Using a 1" wrench, remove

Relief Valve charge pressure relief valve.
Discard O-rings.
Rotation

2. Inspect sealing surfaces of

pump and relief valve for nicks
or scratches. Replace
components as necessary.
3. Lubricate and install new O-
rings.
4. Install relief valve. Torque to
30–35 ft-lb (41–47 Nm).
5. Operate machine through full
range of controls to ensure
proper operation.

9-54
D20x22 Series II Navigator HDD Service Component Repair

Charge Pump PMP3

1

1
2

Rotation
1. Label, disconnect and cap both hoses to charge pump.
2. Provide a support for diverter/fluid valve assembly.
3. Remove bolts (1) holding charge pump and valve bracket to PFC pump.
4. Remove bracket with diverter/fluid valve.
5. Disengage PFC pump shaft from charge pump.
6. Remove fittings (2).
To install, reverse steps above. Torque bolts to 35 ft-lb (47 Nm).

9-55
 Component Repair D20x22 Series II Navigator HDD Service

Torque Limiter/Loop Flush Valve Assembly A7

2
6 7
1
5

8
Rotation

Removal 1. Label, disconnect and cap all hoses.

2. Disconnect wiring connections to solenoids.
3. Remove bolts (1), washers (2), and nuts (3) holding valve (4) to bracket (5).
4. Support valve while removing it.
5. Remove fittings.
6. Remove bolt (8) holding wire harness clip to bracket (5).
7. Remove bolts (6) and washers (7) holding bracket (5) to pump drive.
To install valve, reverse steps above. Torque bolts (6) to 83 ft-lb (112.5 Nm). Torque
bolts (1) and (8) to 35 ft-lb (47 Nm).

9-56
D20x22 Series II Navigator HDD Service Component Repair

Directional Valves DV4–DV7 and Relief Valves PV2 and PV3

1 3

2 4

Rotation
5
Disassembly 1. Remove nut (1) and solenoid coil (2).
2. Remove nut (3) and solenoid coil (4).
3. Remove cartridge valves and O-rings.
4. Inspect cartridge valves and O-rings for damage and ensure no external
contaminants are present.
5. Remove relief valves (5).
6. Inspect relief valve for damage.
7. Inspect valve body cavity for burrs or other irregularities which could damage O-
rings during installation.
Assembly When assembling valve, reverse disassembly procedure.

Torque solenoid coil nuts (1) and (3) to 5 ft-lb (6.8 Nm). Torque solenoid coil (2) to 35
ft-lb (47 Nm). Torque solenoid coil (4) to 20 ft-lb (27.1 Nm). Torque relief valves to 25
ft-lb (33.9 Nm).

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 Component Repair D20x22 Series II Navigator HDD Service

Replace Drive Chuck

Special Tools and • torque wrench capable of producing 90 ft-lb (122 Nm)
Materials

1. Remove six bolts and washers. Remove drive chuck. Remove screen if rotation
shaft is so equipped.
2. Cap or plug end of rotation shaft to keep bore clean.
3. Always use a new O-ring (1) and rubber washer during re-
assembly. Lightly lubricate them before installation. Seat 1
O-ring in drive chuck groove and rubber washer against
screen lip.
4. Mount drive chuck on rotation shaft. Use a gradual cross
pattern tightening sequence to evenly seat drive chuck
Rotation

against rotation shaft. Torque bolts to 90 ft-lb (122 Nm) in

a cross pattern sequence.

Drive Chuck Sub-Saver Installation/Removal

Special Tools and • acetylene heating torch
Materials • wire brush
• Formula “C” BAKERLOCK, or Plusco 170 Thread Locking Compound (Vermeer
P/N 235804-001)
Thread Locking Thread locking compound has a shelf life of three years as long as the hermetically
Compound sealed containers are not opened. Prolonged storage at temperatures above 100°F (38°C)
Considerations may cause some settling of fillers and require thorough mixing for best results. Freezing
has no detrimental affects on the components.

The optimum drive chuck casing temperature for applying mixed compound to threads
is 70°–150°F (21°–66°C). The compound will not cure at temperatures below 40°F
(4°C).

Once the compound has been mixed, it has a limited usable life—apply as soon as
possible.

Temperature Usable Life Full Strength Cure Time

70°F (21°C) 90 minutes 48 hours
100°F (38°C) 40 minutes 17 hours
120°F (50°C) --- 6 hours
150°F (65°C) --- 2 hours

9-58
D20x22 Series II Navigator HDD Service Component Repair

Install Sub-Saver 2

1. Clean all threads on sub-saver (1) and drive chuck (2) with solvent and rinse with
water. Remove all grease, moisture, and foreign matter. Remove any rust with a wire
brush.
2. Thoroughly mix can of thread locking compound with applicator. Shake vial of

Rotation
hardener and add to compound. Mix until completely blended and no streaks are
visible in mixture.
3. Apply compound to entire circumference of first 2/3 of drive chuck threads.
4. Clamp sub-saver in rear rod vise and make up joint with maximum torque (gearbox
set to LOW).
IMPORTANT: Do not put sub-saver into use until thread locking compound has
cured to full strength.

Remove Sub-Saver
To prevent damage to 1. Clamp sub-saver in rear rod vise.
the drive chuck, do not
apply heat directly to its 2. Using an acetylene heating torch, evenly and quickly
surface. apply heat to threaded joint to loosen threads. Apply heat
only to box end of sub-saver. Thread locking compound
will release at
500°–600°F (260°–315°C).
3. Quickly back drive chuck out of sub-saver before heat
transfers to drive chuck.

9-59
 Component Repair D20x22 Series II Navigator HDD Service

Gearbox Removal/Installation
Special Tools and • torque wrench capable of producing 30 ft-lb (40 Nm) and 90 ft-lb (122 Nm)
Materials • wire brush
• pipe sealant
NOTE: Whenever the drilling fluid swivel has been removed from gearbox, the
gearbox has been removed, or any service work is done at rear side of gearbox, perform
the “Rotation Sensor Phase – Adjust” procedure in D16x20 Series II/D20x22 Series II
Maintenance Manual before returning the machine to service.
Rotation

9-60
D20x22 Series II Navigator HDD Service Component Repair

Rotation Gearbox
Replace

1
5

Rotation
2

4
3

1. Move gearbox forward (far enough to allow work space).

2. Label, disconnect, and cap hydraulic hoses and fittings at rotation motor. Remove
motor. Refer to "Rotation Motor MH1," page 9-66.
3. Attach suitable lifting device to support gearbox (1).
4. Remove bolts (2) and washers (3) from the rotation gearbox base.
5. Remove bushings (4) and bar rollers (5).
6. Hoist gearbox (1) off of carriage.
7. Position gearbox over suitable container and drain oil by removing drain and check
plugs.
8. When installing gearbox, reverse rotation gearbox removal steps. Torque nuts to 300
ft-lb (405 Nm). To install motor, refer to "Rotation Motor MH1," page 9-66.

9-61
 Component Repair D20x22 Series II Navigator HDD Service

Gearbox 1. Ensure gearbox and components are clean.

Disassembly
2. Remove motor from gearbox assembly. Refer to "Rotation Motor MH1," page 9-
66.
3. Remove rotation gearbox (1) from machine. Refer to "Rotation Gearbox," page 9-
61.

2 4
3 5

7
Rotation

20

24
23
19 22
18 21
16
14
12
1
10
8 17
15
13
11
9
4. Remove bolts (2), washers (3), breather vent (4), fitting (5), lid plate (6), and gasket
(7) from gearbox.
Continued on next page...

9-62
D20x22 Series II Navigator HDD Service Component Repair

5. Remove fitting (9) from fluid swivel (8). Remove swivel (8).
6. Remove jam nut (10).
7. Bend tang on lock washer (11) out of lock nut (12). Remove lock washer and lock
nut.
8. Remove seal (15).
9. Slide seal sleeve (13) with O-ring seal (14) off shaft.
10. Support shaft and remove bearing cone (16), bearing cup (17), and spacer (18).
11. Support shaft (24) and simultaneously remove gear (20) and snap ring (21) by
sliding shaft out of gearbox.
12. Remove seal (22), and bearing cone (23). Remove bearing cone from bearing cup
(17).

Rotation

9-63
 Component Repair D20x22 Series II Navigator HDD Service

Gearbox Assembly

2 4
3 5

20

24
Rotation

23
19 22
18 21
16
14
12
1
10
8 17
15
13
11
9
1. Ensure gearbox interior is clean.
2. Remove sealant residue from seal bores.
3. Apply oil and install bearing cup (23) and bearing cone (22). Drive cup into bore
until it bottoms out against step.
4. Insert shaft (24) through bearing assembly.
Continued on next page...

9-64
D20x22 Series II Navigator HDD Service Component Repair

5. Apply gasket sealant to seal (15) and seal mounting surface. Position seal with seal
lip to inside of gearbox and install until flush.
6. Lower gear (20) and expanded snap ring (21) into gearbox and align with shaft (24).
Apply a light coating of oil to shaft and slide into gearbox and through snap ring and
gear.
7. Engage snap ring in shaft groove from inside of gearbox.
8. Support shaft and install spacer (18) with step facing toward outside of gearbox.
9. Support shaft and install bearing cone (16) and bearing cup (17).
10. Apply oil to O-ring (14) and install inside seal sleeve (15).
11. Install seal sleeve (15) with step on outside and seat against bearing.
12. Apply gasket sealer to outside of sleeve seal (13) and seal mounting surface before
installation. Seat until seal is flush with mounting tube.

Rotation
13. Install jam nut (12) with chamfer on nut to the outside and torque to
87.5 ft-lb (119 Nm).
14. Rotate shaft several revolutions and repeat torque process.
15. Repeat this process several times until torque remains same after shaft rotation.
16. Install lock washer (11) and align tang with slot in nut. If slot in nut and tang do not
align, it may be necessary to tighten nut slightly. Do not loosen nut to achieve
alignment.
17. Install outer nut (10) and torque to 87.5 ft-lb (119 Nm). Align lock washer tang with
nut. If necessary, tighten nut slightly to align.
18. Bend lock washer tab into first nut and second nut.
19. Install gearbox drain plug.
20. Fill gearbox to the check plug. Use oil that conforms to API GL5 or
MIL-L-2105D specifications.
-20° to 100°F (-30° to 40°C): 80W-90
20° to 120°F (-10° to 50°C): 85W-140
21. Apply gasket sealant to gearbox and install gasket (7), cover (6), washers (3), and
bolts (2).

9-65
 Component Repair D20x22 Series II Navigator HDD Service

Motor Replacement
Special Tools and • torque wrench capable of producing 180 ft-lb (244 Nm)
Materials • tubing wrenches
• thread sealant

Rotation Motor MH1

Rotation

5
6
8
3 9
11

7
10
2

1
The following material is from Eaton Corporation.

Removal 1. Mark all hoses to aid in hookup once repair is complete.

2. Label and disconnect all hoses from fittings on motor. Cap hoses.
3. Remove bolts (1) and washers (2) which secure motor (3) to gearbox (4).
4. Remove motor from gearbox and take to work area.
5. Remove bolt (5) and washer (6) which secures gear (7) and support bearing (8) to
motor shaft. Replace washers (9), spacer (10), and gasket (11) if necessary.
To install, reverse steps above. Torque gear retention bolt (5) to 35 ft-lb
(47 Nm). Torque motor mounting bolts (1) to 90 ft-lb (120 Nm).

9-66
D20x22 Series II Navigator HDD Service Component Repair

Disassembly 1. Remove motor. Drain oil from motor

before disassembly.
2. Place motor in a vise in a vertical
position. Remove nine cap screws on end
cap.
3. Remove O-ring from end cap and seal.
4. Remove valve plate and seal.
5. Remove geroler, being careful to not
disturb balls in geroler.
6. Remove seal and balance plate assembly.
7. Remove drive, drive spacer, and seal.
8. Remove backup rings, O-ring, and seal

Rotation
from bearing housing.
9. Disassemble bearing housing. Remove
shaft sub-assembly, shaft seal, O-ring,
and front retainer. Using snap ring pliers,
remove retaining ring from front retainer.
NOTE: Do not disassemble shaft sub-
assembly.

10. Check all mating surfaces. To reduce

chance of leakage, replace any parts that
have scratches or burrs. Wash all metal
parts in clean solvent. Blow them dry
with pressurized air. Do not wipe parts
dry with paper towels or cloth as lint in a
hydraulic system will cause damage.

9-67
 Component Repair D20x22 Series II Navigator HDD Service

Assembly NOTE: Lubricate all seals with clean

petroleum jelly. A good service policy is to
replace all old seals with new ones.

1. Install shaft face seal into bearing

housing. Use installation tool (No.
606138-000, available from Eaton) as
shown. Lubricate seal with petroleum
jelly.

2. Lightly lubricate seal with petroleum

jelly. Install in groove on front retainer.
Rotation

3. Lightly lubricate seal lip of shaft pressure

seal with petroleum jelly. Place seal on
assembly tool (No. 606175-000,
available from Eaton), and press into bore
of front retainer. Press until seal makes
positive stop with front retainer shoulder.
Protect inside diameter shaft seal area
from damage.
4. Install shaft and bearing assembly in
bearing housing. You may need a press to
install bearing shaft and bearing
assembly.
5. Before installing retainer, place a
protective sleeve of bullet (available from
Eaton) over shaft. Grease inside diameter
of shaft seal. To prevent damage to seal,
install front retainer over shaft with a
twisting motion. Damage to shaft seal
will cause external leakage.

Continued on next page...

9-68
D20x22 Series II Navigator HDD Service Component Repair

6. Install square cut seal into large face

groove of bearing housing.
7. Install seal and backup ring into
groove of bearing housing.
8. Install seal and backup ring into small
face groove of bearing housing.
9. Install drive spacer into output shaft
spline.
10. Install drive with longest spline length
(if asymmetric) into output shaft
spline.
11. Install balance plate onto bearing
housing. Align shuttle flow cavity of

Rotation
balance plate with shuttle flow cavity
of bearing housing.
12. Grease two seals and install into face
grooves of geroler.
13. Place two steel balls into seats of star
(one per seat). Grease sufficiently to
retain balls when geroler is assembled.
14. Install geroler by mating internal
spline with external spline of drive.
Align shuttle flow cavity of geroler
with shuttle flow cavity of balance
plate.
15. Install valve plate on geroler, ensure
necessary shuttle flow holes are
aligned.
16. Grease seal and install into groove of
end cap.
17. Grease seal and install into small face groove of end cap.
18. Carefully invert end cap and install on valve plate.
Continued on next page...

9-69
 Component Repair D20x22 Series II Navigator HDD Service

19. Place nine screws into end cap (screw

threads are to be lubricated with
hydraulic oil), through valve plate,
geroler, outer balance plate and into 9 1
flange. Verify screw alignment and 6 4
torque to 75–85 ft-lb (102–115 Nm).

3 7

8 2
5
Rotation

9-70
D20x22 Series II Navigator HDD Service Overview

Chapter 10: Thrust/Pullback

OVERVIEW
The thrust and pullback functions utilize rack and pinion gearing to move the rotation
gearbox carriage up and down the rack to add and remove drill rods, as well as apply
thrust and pullback pressure during operation.

THEORY
Components
• Rotation and Thrust Pump PMP1
• Thrust/Pullback Valve Assembly A8, including:
• Directional Valves DV12–DV14

Thrust/Pullback
• Solenoid L29
• Thrust/Pullback Motors MH2–MH4
• Left Joystick Assembly A1, including:
• Position Sensor B6
• Thrust/Pullback Pressure Sensor B5
• Thrust Gauge Light E4
• Thrust/Pullback Pressure Gauge E11
• Switches S9, S31, S32, S34 and S35

10-1
 Theory D20x22 Series II Navigator HDD Service

Component Locations

SWITCHES S34 AND S35

SWITCHES S31 AND S32

Thrust/Pullback

TORQUE LIMITER/LOOP FLUSH VALVE A7

ROTATION AND THRUST PUMP PMP1

THRUST/PULLBACK PRESSURE GAUGE E11

LEFT JOYSTICK A1

10-2
D20x22 Series II Navigator HDD Service Theory

THRUST MOTOR MH2

THRUST MOTOR MH3

THRUST MOTOR MH4

THRUST VALVE A8

Thrust/Pullback

10-3
 Theory D20x22 Series II Navigator HDD Service

Hydraulic Schematic
FRONT THRUST MOTOR MH2

CENTER THRUST MOTOR MH3

REAR THRUST MOTOR MH4

TORQUE LIMITER/LOOP FLUSH VALVE A7
DV38
DV13
THRUST VALVE A8

DV12 DV14
DV4
Thrust/Pullback

DV10

DV11

ROTATION AND THRUST PUMP PMP1

CHARGE FILTER FL1

CHARGE PUMP PMP4 RETURN

MANIFOLD
SUCTION A17
MANIFOLD A15

10-4
D20x22 Series II Navigator HDD Service Theory

Electrical Schematic

E 7 D IS P L A Y D P 1 0 -A

E 7 D IS P L A Y D P 1 0 -B

A 1 L E F T H A N D J O Y S T IC K H E A D

C 148 CO N TR O LLER

Thrust/Pullback
J1 - G R A Y

J2- B LA C K

J3 - G REEN

J4- B R O W N

10-5
 Theory D20x22 Series II Navigator HDD Service

Hose Connections

FRONT THRUST MIDDLE THRUST

MOTOR MH2 MOTOR MH3

REAR THRUST
MOTOR
MH4

ROTATION AND THRUST

PUMP PMP1
Thrust/Pullback

THRUST VALVE A8

CHARGE FILTER FL1

TORQUE LIMITER
VALVE A7

10-6
D20x22 Series II Navigator HDD Service Theory

Operation Overview
Rotation and Thrust The Rotation and Thrust Pump PMP1 is a closed-loop hydrostatic pump that provides a
Pump variable output to drive the motors. A charge pump supplies charge oil to the thrust/
pullback closed loop to replace internal leakage in components.

The right joystick control lever provides an electrical signal to the pump EDC, which
provides a hydraulic pressure signal that operates a servo piston to “stroke” the pump
(change the swashplate angle). The angle of the swashplate in either direction from zero
(neutral) determines pump output and flow direction. When system pressure exceeds the
factory setting, oil is passed from the high pressure system loop into the charge gallery,
and into the low pressure system loop via the charge check. For more information, refer
to Chapters 4 and 9.

Thrust Limiter AutoDrill mode and optional R.A.T.T. mode allow the user to set a thrust limit. This
limit must stay within the operational limit of the machine. The thrust pressure stays at
or below this limit by controller signal to the pump EDC.

Anti-Crash and The slowdown/anti-crash switches send signals to the controller which affects the thrust/
Slowdown Switches pullback EDC control. Based on inputs from the front and rear slowdown and stop
switches, the controller slows down the carriage at each end of its travel, then cuts the

Thrust/Pullback
circuit at the appropriate travel limit to prevent overtravel.

2-Speed Solenoid The 2-speed solenoid shifts the thrust motors into low displacement (HIGH speed)
whenever the 2-speed switch is on.

Shared Components
The thrust/pullback function shares the common hydraulic fluid distribution
components, as well as rotation and thrust pump PMP1 and charge pump PMP3. The
hydraulic fluid distribution components are shared by all functions with hydraulic
circuits. These components include:

• Hydraulic Tank RES1

• Oil Cooler HE1
• Return Manifold A17
For more information on the hydraulic fluid distribution components and rotation and
thrust pump PMP1, refer to Chapter 4.

10-7
 Theory D20x22 Series II Navigator HDD Service

Thrust Function
A THRUST MOTOR MH2
A THRUST MOTOR MH3
LOOP FLUSH VALVE A7
A
FROM THRUST MOTOR MH4
2-SPEED
S9 DV12
FROM THRUST VALVE A8
CONTROLLER L29
A5
DV6
Thrust/Pullback

Operation To move the carriage to the front of the rack:

• Seat switch must be closed (operator in seat).

• Remote Lockout system must be in RUN mode.
• Engine must be running at full throttle.
• Thrust/pullback joystick must be pushed FORWARD.
• 2-speed thrust switch S9 must be in HIGH or LOW position, as desired.
When required operating conditions are met:

• Thrust joystick sensor B6 sends signal to controller A5. Controller sends signal to
Thrust EDC+ solenoid L14.
• Solenoid L14 of the proportional valve in pump PMP1 will be energized, shifting it
to the crossover position allowing charge flow to change the angle of the pump’s
swashplate.
Continued on next page...

10-8
D20x22 Series II Navigator HDD Service Theory

• Oil will flow to thrust valve A8, loop flush valve A7, and motors MH2 and MH4.
• Oil flows to port A of motors MH2, MH3, and MH4, causing clockwise (CW)
rotation of motors.
• If 2-speed switch S9 is in LOW position, solenoids L29 and L31 in thrust valve will
energize. Valves DV12 and DV14 will shift and oil will not flow to motor MH3.
Solenoid L30 will also energize, shifting valve DV13 so that pressure equalizes
between port A and B of motor MH3.
When the carriage passes front slowdown switch S35, switch S35 sends a signal to
controller A5 which sends a signal to the pump EDC. Flow to the valve and motors is
reduced.

When the carriage passes front stop switch S34, switch S34 sends a signal to controller
A5 which sends a signal to the pump EDC. Flow to the valve and motors is stopped.

NOTE: The thrust pressure gauge on the control panel measures pressure at the loop
flush valve. The thrust speed on the display screen comes from thrust sensor B5 at the
gearbox.

Thrust/Pullback

10-9
 Theory D20x22 Series II Navigator HDD Service

Pullback Function
THRUST MOTOR MH2
B
LOOP FLUSH VALVE A7 THRUST MOTOR MH3
B
FROM B THRUST MOTOR MH4
2-SPEED DV12
S9
FROM THRUST VALVE A8
CONTROLLER L29

DV6 A5
Thrust/Pullback

Operation To move the carriage to the rear of the rack:

• Seat switch must be closed (operator in seat).

• Remote Lockout system must be in RUN mode.
• Engine must be running at full throttle.
• Thrust/pullback joystick must be pulled BACKWARD.
• 2-speed thrust switch S9 must be in HIGH or LOW position, as desired.
When required operating conditions are met:

• Thrust joystick sensor B6 sends signal to controller A5. Controller sends signal to
Thrust EDC- solenoid L15.
• Solenoid L15 of the proportional valve in pump PMP1 will be energized, shifting it
to the crossover position allowing charge flow to change the angle of the pump’s
swashplate.
Continued on next page...

10-10
D20x22 Series II Navigator HDD Service Troubleshooting

• Oil will flow to thrust valve A8, loop flush valve A7, and motors MH2 and MH4.
• Oil flows to port B of motors MH2, MH3, and MH4, causing counterclockwise
(CCW) rotation of motors.
• If 2-speed switch S9 is in LOW position, solenoids L29 and L31 in thrust valve will
energize. Valves DV12 and DV14 will shift and oil will not flow to motor MH3.
Solenoid L30 will also energize, shifting valve DV13 so that pressure equalizes
between port A and B of motor MH3.
When the carriage passes rear slowdown switch S32, switch S32 sends a signal to
controller A5 which sends a signal to the pump EDC. Flow to the valve and motors is
reduced.

When the carriage passes rear stop switch S31, switch S31 sends a signal to controller
A5 which sends a signal to the pump EDC. Flow to the valve and motors is stopped.

NOTE: The thrust pressure gauge on the control panel measures pressure at the loop
flush valve. The thrust speed on the display screen comes from thrust sensor B5 at the
gearbox.

Thrust/Pullback
TROUBLESHOOTING
Troubleshooting procedures are given for each operating mode of the different functions
of this chapter. Begin each procedure by performing a pretest inspection of the machine.
See "Pretest Inspection," page 10-12.

Often problems can be solved by doing a walk-around inspection of the machine

looking for obvious problems.

If nothing is found during the pretest inspection, continue by operating all other actuator
functions of the machine to help further isolate problems. See "Troubleshooting
Machine Performance," page 10-13.

10-11
 Troubleshooting D20x22 Series II Navigator HDD Service

Pretest Inspection
If a problem develops in the thrust circuits and machine performance indicates the
machine is not operating within specifications, begin by visually checking for any
obvious failures. Broken, kinked, or loose hoses and fittings on supply, pressure, and
return to hydraulic components will affect function performance.

Ensure there are no broken, missing, corroded, or loose connections on ground and
power wires that supply electrical circuit components. If any are found, repair or replace
them.

Refer to the Hydraulic Fluid Distribution chapter and ensure fluid conditioning
components are operational. If OK, continue. If not, correct any problems found.

WARNING: Pressurized fluid can penetrate body tissue and result in serious injury or
death. Leaks can be invisible. Keep away from any suspected leak. Relieve pressure in
the hydraulic system before searching for leaks, disconnecting hoses, or performing any
other work on the system. If you must pressurize the system to find a suspected leak, use
an object such as a piece of wood or cardboard rather than your hands. When loosening a
Thrust/Pullback

fitting where some residual pressure may exist, slowly loosen the fitting until oil begins
to leak. Wait for leaking to stop before disconnecting the fitting. Fluid injected under the
skin must be removed immediately by a surgeon familiar with this type of injury.

10-12
D20x22 Series II Navigator HDD Service Troubleshooting

Troubleshooting Machine Performance

Possible faults may occur in the thrust/pullback function that are directly related to
faults in other functions. These other faults may not be readily apparent, because those
particular functions are not currently being operated.

Operate the machine functions and document performance of working actuators.

Make note of any functions not operating normally based on the theory given in each
chapter for that function. To help isolate a faulty component or function, compare the
notes you have taken to the normal operation given for each mode of a particular
function.

After checking the performance of all functions, if the problem is isolated to the original
function in question, return to the troubleshooting/testing for that mode. If multiple
functions are affected, proceed with troubleshooting based on the possible results listed
next.

Possible Results The possible results listed are meant to guide the service technician in a logical manner
to isolate a fault as quickly as possible.

Thrust/Pullback
1. If faults are noted when operating all machine actuators, it would indicate a function
or component that is common to all the actuators is most likely faulty. The following
common functions and components should be investigated:
• Engine. See "Engine," page 3-6.
• Remote Lockout. See Chapter 15.

2. If faults are noted in only the drill rotation and thrust/pullback functions, and all
other functions are OK, the hydraulic components common to just the vises should
be investigated:
• Rotation and thrust pump PMP1. See "Rotation and Thrust Closed-Loop
Pump PMP1," page 4-8 and "Rotation and Thrust Pump PMP1 Ports," page
9-6.
• Torque limiter/loop flush valve A7. See "Torque Limiter/Loop Flush Valve A7,"
page 9-11.

10-13
 Troubleshooting D20x22 Series II Navigator HDD Service

Testing AutoDrill Mode

Before beginning any troubleshooting or testing procedures, perform the "Pretest
Inspection," page 10-12. If nothing obvious is found, continue.

1. Ensure switches listed in "Starting the Engine," page 2-2, are in correct positions.
2. Start the engine.
3. Turn on Remote Lockout and select RUN mode.
4. Sit in operator’s seat to select drilling mode.
5. Move and hold Rotation and Thrust/
Pullback Handles to obtain the desired
rotation and thrust/pullback motion for
the current drilling conditions.
6. Press AutoDrill Button (1) for two
seconds. Then immediately release the
button and Rotation and Thrust/Pullback 1
Handles. When the AutoDrill Button (1)
Thrust/Pullback

is pressed, the present thrust/pullback and

rotation pressure set points are stored.
7. The controller will drive the rotation and thrust/pullback pump outputs to maintain
the pressures at which this mode was initiated.
8. Use Rotation and Thrust Trim Switches (2 & 3)
3 2
to increase or decrease the pressure settings in
10 psi (70 kPa) increments. Holding the Trim
Switches for 2 seconds initiates a process of
ramping pressure up or down.

Continued on next page...

10-14
D20x22 Series II Navigator HDD Service Troubleshooting

If the trim switches are not used for 3 seconds, the display automatically returns to show
the previous display screen. If the optional R.A.T.T. mode has been activated, then the
display will show the current oscillating degree setting.

NOTE: The rotation and thrust/pullback set points can only be adjusted while the
AutoDrill mode has been enabled.

9. View the display. The first input from the Rotation Trim Switch or the Thrust/
Pullback Trim Switch (2) should change the display screen (3) to show the current
thrust/pullback or rotation set point.
NOTE: Set points are stored until the engine is shut off. When the engine is started,
the initial set points are zero.

10. Move either Rotation or Thrust/Pullback Handles to stop drill string motion and
pause AutoDrill.

Testing Pressure Limit Selector in R.A.T.T. Manual Mode

Thrust/Pullback
Before beginning any troubleshooting or testing procedures, perform the "Pretest
Inspection," page 10-12. If nothing obvious is found, continue.

1. Ensure switches listed in "Starting the Engine," page 2-2, are in correct positions.
2. Start the engine.
3. Turn on Remote Lockout and select RUN
mode.
4. Press (1) once to enable both Thrust/
Pullback and Rotation limits; rotation and
thrust/pullback lights on the display will
1
be ON.
5. Press (1) a second time to disable
Rotation limit, Thrust/Pullback limit
enabled; rotation light OFF, thrust/pullback light ON.
6. Press (1) a third time to disable both Thrust/Pullback and Rotation limits; rotation
and thrust/pullback lights are OFF.

10-15
 Troubleshooting D20x22 Series II Navigator HDD Service

Troubleshooting the Thrust/Pullback Function

The thrust/pullback function contains both electrical and hydraulic components. If the
steps in "Testing AutoDrill Mode," page 10-14 or a general test of the thrust/pullback
function indicate the circuit is not operating properly, begin troubleshooting by
following the general guidelines below.

1. Verify that Remote Lockout is not in Lockout mode.

2. Inspect and clean proximity switches S31, S32, S34 and S35. Verify switch arm
position. The switch sensor should have 0.25" (1 cm) clearance below the rack.
3. Disconnect wire 759 from thrust valve solenoid L29. Use multimeter to check for
voltage.
Expected result: When switch is pushed, 12 volts will be present at wire 759 of
solenoid L29.

If not, check components in circuit for voltage. If voltage is found at 2-speed switch
S9, check continuity of wire 759 to solenoid L29. Replace wire section if faulty. If
so, continue.
4. Check wire 346 at solenoid L29 for continuity to ground. If continuity is found, go
Thrust/Pullback

on to the next step. If not, repair wire segment.

5. Inspect thrust valve A8 for damage or contaminants. Refer to repair section of this
chapter.
6. Troubleshoot pump PMP1. Refer to "Hydrostatic Closed-Loop
Troubleshooting," page 9-18.
7. Perform "Charge Pressure Measurement," page 10-20.
NOTE: Hydraulic component testing is based on volumetric efficiency. Test the
components for excessive internal leakage to determine if they are worn beyond design
specification. Refer to the Vermeer Industrial Dealerships Technician’s Shop Manual
(Vermeer P/N 105400V80), for information on how to test these components.

8. Test efficiency of thrust motors. Excessive cross-port leakage can be caused by

damage or wear to internal components.
Connect a pressure gauge to the return port of the motor and compare the no-load
motor shaft speed against the full load speed. If volumetric efficiency is below 80%,
refer to component repair section and repair or replace motor. For efficiency
specifications, refer to "Specifications," page 10-23.
If the machine is experiencing the symptoms described in the following sections, follow
the troubleshooting steps described there as well.

10-16
D20x22 Series II Navigator HDD Service Troubleshooting

Movement—One Inspect the electrical circuits that apply, and troubleshoot circuits involved directly with
Direction Only operating the malfunctioning motors.

1
2

Thrust/Pullback
2

Possible causes include:

• Faulty EDC module – If voltage output to the EDC changes in response to joystick
movement, the joystick is supplying voltage but the EDC is not responding.
• Failed high pressure relief valve – On the pump are four valves called the high
pressure relief valves. Valves (1) control thrust, and valves (2) control pullback.
Shut down the machine and swap the two relief valves and see if the non-functioning
direction changes. If so, remove and clean the malfunctioning relief valve or replace it.

10-17
 Troubleshooting D20x22 Series II Navigator HDD Service

Movement—Neither Determine if only the thrust/pullback motors are affected. If they are, suspect the pump
Direction and continue below. Otherwise, review interlocks that apply, and troubleshoot circuits
involved directly with operating the malfunctioning motor(s).

Possible causes include:

• Joystick output not reaching the EDC – Verify output from joystick.
• Faulty pump EDC module
• Insufficient charge pressure – Check in neutral, forward, and reverse. See "Charge
Pressure Measurement," page 10-20. If low only in neutral (or neutral and
forward/reverse), replace charge pressure relief valve in the pump. If charge
pressure remains low, replace charge pump.
• Faulty high pressure relief valves not allowing sufficient pressure to build to operate
the motors – Observe pressure gauge for thrust/pullback on the console. Maximum
pressure indicated should be 3100 psi (213 bar) in thrust mode and 4900 psi (337
bar) in pullback. Otherwise, replace relief valves.
• Internal leakage in pump and motor not allowing sufficient circuit pressure to build
to do the work – Conduct case pressure tests ("Function Pressure Measurement,"
page 10-21) and replace pump and motor if needed.
Thrust/Pullback

Movement— If a motor continues to move slowly when the control handles are centered:
Gearbox Creeps in
Stop 1. Follow "Shutdown Procedure," page 2-1 and unplug EDC at harness connection
from the pump.
2. Restart engine and use the manual controller on the EDC to attempt to find
NEUTRAL.
If you can start and stop the motors with the manual control lever, the pump is OK and
the problem lies in the EDC or the signal from the joystick to the EDC. Test the joystick.
If the joystick is OK, null the EDC (see "Adjusting Pump Neutral Setting," page 9-
35).

If you cannot stop the creep with the manual control lever, the pump needs to be
replaced.

10-18
D20x22 Series II Navigator HDD Service Troubleshooting

Control—Response If the motors react slowly to control inputs:

is Sluggish
1. Follow "Shutdown Procedure," page 2-1 and unplug the EDC on PMP1.
2. Restart engine, and have an operator sit in the seat to put machine in DRILL mode.
3. Use a lever on the manual controller on the EDC to adjust pump output.
4. Operate thrust/pullback motors.
If the motors’ speed and direction react normally to inputs from the manual control, the
problem lies in the joystick controller or the EDC. Check joystick output to the EDC
controller on the pump.

If the motors react sluggishly to the manual control, the problem is hydraulic. Test the
motor and pump.

Motor Torque

Thrust/Pullback
Motor torque is a function of amount of pressure in the high side of the loop minus the
pressure in the low side of the loop.

Pressure on the high side of the loop is a result of resistance provided by the work being
done. For this function, the work is moving the gearbox carriage back and forth.

The pressure on the low side of the loop is the charge pump minimum pressure setting,
313 psi (21.5 bar). Check charge pressure (see "Charge Pressure Measurement,"
page 10-20).

If torque is suspected to be less than acceptable, visually inspect to find a reason. Is there
leakage at shaft seals?

If no visual reason is apparent, it may be that the moving parts in the pump and motors
are worn to the point that there is excessive internal leakage. Internal leakage in a pump
or motor can be assessed with a case drain test on that component when circuit is at
maximum pressure.

10-19
 Troubleshooting D20x22 Series II Navigator HDD Service

Charge Pressure Measurement

Minimum charge pressure should be 313 psi ± 10 psi (21.5 bar ± 0.5 bar). If higher,
replace charge filter and check pressure relief valve. If lower, review reasons below.

• The charge pump may be producing inadequate flow, possibly due to an inlet
restriction, or wear in the pump.
• The charge pressure relief valve may be opening at a lower pressure.
• There may be cross port leakage in the valves in the rotation and thrust pump,
allowing charge pump flow to drain to tank.

The following procedure measures the charge pressure and helps determine possible
cause of low pressure.

1. With the machine shut down, attach a 600 psi test gauge to the diagnostic port G4 on
the torque limiter/loop flush valve A7.
2. Have an assistant sit in the operator’s seat and start the machine, following the
normal starting procedure. Run the engine at idle while you inspect and verify that
there are no leaks where the test gauge is connected to the diagnostic port.
Thrust/Pullback

3. Run engine at 2200 rpm. Charge pressure should read 313 psi, ± 10 psi (21.5 bar, ±
0.5 bar). Needle may drop very briefly, but it must recover to this range.

If not, troubleshoot by measuring inlet restriction to the charge pump. If the inlet
restriction is within limits, replace pump.

10-20
D20x22 Series II Navigator HDD Service Troubleshooting

Function Pressure Measurement

A gauge is provided on the machine to
measure system pressure for the hydraulic
circuit. The thrust/pullback pressure gauge 1
(1) is mounted on the drill operator’s control
console.

If pressure exceeds 3335 psi (229.9 bar)

during thrust, remove, inspect, and clean or
replace high pressure relief valve at port A.

If pressure exceeds 4900 psi (337 bar) during pullback, remove, inspect, and clean or
replace high pressure relief valve at port B.

WARNING: Pressurized fluid can penetrate body tissue and result in serious injury or
death. Leaks can be invisible. Keep away from any suspected leaks. Relieve pressure in
the hydraulic system before searching for leaks, disconnecting hoses, or performing
any other work on the system. If you must pressurize the system to find a suspected
leak, use an object such as a piece of wood or cardboard rather than your hands. When

Thrust/Pullback
loosening a fitting where some residual pressure may exist, slowly loosen the fitting
until oil begins to leak. Wait for leaking to stop before disconnecting the fitting. Fluid
injected under the skin must be removed immediately by a surgeon familiar with this
type of injury.

For information on high pressure relief valve removal and installation, see "Charge
Pressure Relief Valve Check and Adjustment," page 9-37.

10-21
 Troubleshooting D20x22 Series II Navigator HDD Service

Testing Proximity Switches

1. Position gearbox midway on the rack so the faces of proximity switches S31, S32,
S34 and S35 are visible.
2. Pass a metal block over the switches. If the LED does not illuminate, continue to the
next step. If the LED does illuminate, continue to step 5.
3. Disconnect switch from the harness, and measure voltage from pin 4 to pin 3 in the
harness jack.
Expected result: 12 volts DC, ± 1.2 vDC. If so, continue below. If not, test
continuity on harness segments from pin to the ground and pin 4 to fuse F6. Repair
or replace faulty harness segment.

4. Test continuity on the switch plug from pin 4 to pin 3 while closing the switch.
Expected result: Continuity when switch closes. Open when switch is released. If
so, continue below.

If not, replace defective switch.

Thrust/Pullback

5. The fault appears to be in the harness from the switch connection to the controller.
Consult schematic and test harness segments for the wire leading from switch.
Repair or replace the defective harness segment.

Adjusting Proximity To adjust a proximity switch, do the following:

Switch
1. Loosen retaining bolts.
2. Move target surface (gearbox carriage) used by this switch over the switch.
3. While testing continuity across the switch, adjust retaining bolts to move the face of
the switch below the carriage to close the switch.

10-22
D20x22 Series II Navigator HDD Service Component Repair

Specifications
Listed below are the electrical and hydraulic specifications for the components in this
chapter.

Electrical:

• Nominal circuit voltage - 12 volts DC

• Thrust valve solenoid coil L29 - 7.2 ohms @ 68°F (20°C)
Hydraulic:

• Rotation and Thrust pump PMP1 normal output flow - 33 gpm (125 L/min) @ 2400
engine rpm
• Rotation and Thrust pump PMP1 displacement - 3.2 cid (52.4 cc)
• Rotation and Thrust pump PMP1 charge pressure relief valve setting - 313 psi (21.5
bar)
• Rotation and Thrust pump PMP1 high pressure relief valve setting - 3335 psi (230
bar)

Thrust/Pullback
• Thrust motors MH2, MH3 and MH4 maximum speed - 277 rpm
• Thrust motors MH2, MH3 and MH4 displacement - 20.6 cid (337.6 cc)
• Thrust motors MH2, MH3 and MH4 maximum pressure (continuous) - 3500 psi
(241 bar)
• Loop flush relief valve PV8 pressure setting - 450 psi (31 bar)

COMPONENT REPAIR

WARNING: Pressurized fluid can penetrate body tissue and result in serious injury or
death. Leaks can be invisible. Keep away from any suspected leak. Relieve pressure in
the hydraulic system before searching for leaks, disconnecting hoses, or performing any
other work on the system. If you must pressurize the system to find a suspected leak, use
an object such as a piece of wood or cardboard rather than your hands. When loosening a
fitting where some residual pressure may exist, slowly loosen the fitting until oil begins
to leak. Wait for leaking to stop before disconnecting the fitting. Fluid injected under the
skin must be removed immediately by a surgeon familiar with this type of injury.

Continued on next page...

10-23
 Component Repair D20x22 Series II Navigator HDD Service

Thrust Valve Assembly A8

5
4

3
Thrust/Pullback

Remove 1. Disconnect electrical connections from solenoid coil (1).

2. Label and disconnect tubes from fittings.
3. Remove fittings.
4. Remove bolts (2),washers (3) and nuts (4) from valve (5).
5. Hoist valve assembly from carriage.
6. Remove fittings.
To install valve, reverse steps above. Torque mounting bolts to 35 ft-lb
(47 Nm).

10-24
D20x22 Series II Navigator HDD Service Component Repair

Directional Valves DV12–DV14

3 1

Disassembly 1. Loosen and remove hex nut (1) on coil (2).

2. Remove coil from valve and replace if necessary.

Thrust/Pullback
3. Remove cartridge valves (3) and O-rings from manifold and check for damage or
contamination. If necessary, replace.
To assemble valve, torque cartridge valves to 24–26 ft-lb (32.5–35.3 Nm). Torque coil
nut to 5–7 ft-lb (6.8–9.5 Nm).

10-25
 Component Repair D20x22 Series II Navigator HDD Service

Thrust Motors MH2, MH3, and MH4

6
Thrust/Pullback

Removal 1. Label, disconnect, and cap tubes and fittings on motors and manifold.
2. Remove bolts (1) and washers (2).
3. Remove mounting bolts (3), washers (4), and gears (5).
4. Hoist motors (6) from carriage.
Reverse removal process to install motors.

Apply thread sealant grade 272 to motor mounting bolts (1) and torque to
90 ft-lb (122.4 Nm).

Apply thread sealant grade 271 to gear retaining bolt (3) and torque to 195 ft-lb
(265 Nm).

10-26
D20x22 Series II Navigator HDD Service Component Repair

Disassembly NOTE: Do not disassemble motor unless warranty has expired. Warranty will be
voided if motor is disassembled while warranty is still in effect.

VALVE
SEAL PLATE
SPLINED
WEAR DRIVE GEROLER
BEARING AND PLATE
SHAFT SEAL
ASSEMBLY SHAFT
FACE SEAL

SHAFT
SEAL
SEAL VALVE
DRIVE
BEARING
HOUSING
VALVE HOUSING

OUTER
FACE
SEAL
VALVE

Thrust/Pullback
SEAL

BACKUP
WASHER SPRING
DUST SEAL INNER
BALANCE FACE
RING SEAL

Continued on next page...

10-27
 Component Repair D20x22 Series II Navigator HDD Service

1. Place motor in a vise with output shaft down. Clamp across edge of mounting
flange, not on housing. Excessive clamping pressure will cause distortion. When
clamping, use some protective device on the vise jaws, such as soft jaws or pieces of
hard rubber or wood.
2. Remove 4 bolts from valve housing (1).

1
Thrust/Pullback

3. Lift valve housing straight up. If done carefully,

springs and balance ring subassembly will remain 1
in valve housing for easy removal.
4. Carefully remove following from valve housing: 2
6
4
• seal, 3.24 inch ID (2)
• case drain port seal, 0.35 inch ID (3) 7
5
5. Remove balance ring springs (4).
6. Remove balance ring (5).
3 8
7. Remove inner (6) and outer (7) face seals from
balance ring.
8. Lift off valve (8).

Continued on next page...

10-28
D20x22 Series II Navigator HDD Service Component Repair

9. Remove valve plate (1).

10. Remove 3.49 inch ID seal (2) from valve plate. 2 1

11. Remove valve drive (3). 3

4
12. Remove case drain port O-ring (4).

13. Remove geroler (5). Retain rollers in outer geroler

5
ring if they are loose.
14. Remove case drain port seal (6) from geroler.
2
15. Remove drive (7).
16. Remove 3.49 inch ID seal (2) from wear plate (8). 7
6
17. Remove wear plate (8) from bearing housing (9).
8

Thrust/Pullback
9
18. Remove shaft face seal from wear plate (8).
8
19. Remove seal (2) from bearing housing (9).

2
9

20. Position motor in vise with output shaft facing up.

Support bearing housing (10), from below and remove
screws (11), washers (discard washers as they are not 11
required for reassembly), and mounting flange.

10

Continued on next page...

10-29
 Component Repair D20x22 Series II Navigator HDD Service

1 3
5 6 7
4 2

21. Remove O-ring seal (1), shaft seal (2), backup ring (3) (if supplied), and dust seal
(4) from flange (5). Use a small screwdriver to remove dust seal. Do not damage
bore of flange.
22. Remove shaft and bearing assembly (6). You may need a press to remove shaft and
Thrust/Pullback

bearing assembly.
23. Remove shaft face seal (7) from bore of bearing housing (8). Do not damage bore of
bearing housing.

Assembly 1. Check all mating surfaces. Replace any parts that have scratches or burrs that could
cause leakage or damage O-rings. Clean all metal parts with solvent and blow dry
with air. Do not wipe with cloth or paper towel because lint or other contaminants
could get into hydraulic system and cause damage. Do not use coarse grit papers/
cloth or grind motor parts.
NOTE: Lubricate all seals with petroleum jelly before assembly. Use new seals when
assembling motor.

2. Place wear plate (1) on flat surface with largest open end of housing up. Apply
petroleum jelly to shaft face seal (2). Install seal in seal seat. Seat seal properly in
groove. A damaged or improperly installed shaft face seal could cause internal
lubrication loss and subsequent parts wear.
Continued on next page...

10-30
D20x22 Series II Navigator HDD Service Component Repair

4
5

7
8

Thrust/Pullback
3. Install shaft and bearing assembly (1) in bearing housing (2). Do not damage seal in
bore of housing. It may be necessary to use a press to install shaft and bearing
assembly.
4. Apply petroleum jelly to seal (3). Install seal in seal groove of bearing housing (2).
5. Use a small press, if available, to install dust seal (4) in retainer (5). Metal side of
dust seal must face toward flange, as shown. If a press is not available, use a plastic
or rubber hammer to tap dust seal in place.
6. Install backup ring (6), and shaft seal (7) in retainer. Flat or smooth side of shaft seal
must face toward retainer as shown in illustration. Apply petroleum jelly to inside
diameter of shaft seal (after installing seal in retainer).
7. Grease inside diameter of dust and shaft seals. To prevent damage to seals, install
retainer over shaft with a twisting motion. Do not cut or distort shaft seal. Damage
to shaft seal will cause external leakage.
8. Lubricate threads of cap screws (8) with a light film of oil. Install and finger tighten
screws.
Continued on next page...

10-31
 Component Repair D20x22 Series II Navigator HDD Service

9. Clamp bearing housing in vise. Torque screws to 50 in-lb (6 Nm) in sequence

shown. Then torque to 300 in-lb (34 Nm) in sequence.
10. Reposition motor in vise with output shaft down. Clamp across edges of retainer
plate.
11. Pour a small amount of clean hydraulic oil inside the output shaft.
12. Apply a light film of petroleum jelly on 3.49 inch ID seal. Install seal in bearing
housing.
13. Install drive into output shaft (insert longer splined end of drive first).
14. To help in the reassembly procedure, it is recommended using two alignment studs
diagonally opposed in two of the four bolt holes of bearing housing.
15. Apply petroleum jelly to two 0.25 inch ID O-ring seals. Install seals in O-ring
grooves at case drain holes on each side of geroler.
NOTE: Installation at this point involves 3 steps in timing the motor. Timing
determines output shaft rotation direction.

VALVE
Thrust/Pullback

CASE DRAIN
GEROLER HOLE

ROTATE VALVE
CLOCKWISE 1/2
TOOTH TO ENGAGE
SPLINE

VALVE
PLATE

PRESSURE
RELIEF HOLE
1 LARGEST
OPEN POCKET
Timing Step No. 1 - Locate largest open pocket in geroler (1). Then mark location of
pocket on outside edge of geroler.

16. Align case drain hole and pressure relief hole in geroler with case drain hole and
pressure relief hole in bearing housing. Install geroler on bearing housing. Retain
rollers in outer geroler ring if they are loose.
Continued on next page...

10-32
D20x22 Series II Navigator HDD Service Component Repair

17. Install valve drive in geroler.

18. Apply light film of petroleum jelly on 3.49 inch ID seal. Install seal in valve plate.
19. Align case drain hole in valve plate with case drain hole in geroler. Install valve
plate (seal toward geroler) on geroler.
Timing Step No. 2 - Locate slot opening in valve plate which is in-line with largest open
pocket of geroler.

20. Use the following procedure for installing valve on valve plate.
Timing Step No. 3 - Locate any side opening of valve that goes through to face of valve.
Line up this side opening in valve with open slot of valve plate that is in-line with largest
open pocket of geroler. Rotate valve clockwise (1/2 spline tooth) to engage valve with
valve drive spline, alignment reference shown.

21. Apply clean grease on balance ring assembly springs (1). Install springs in 2 holes
located inside bore face of valve housing (2).

Thrust/Pullback
1

4
3

22. Apply a light film of petroleum jelly on 0.35 inch ID seal (3). Install seal in case
drain groove of valve housing.
Continued on next page...

10-33
 Component Repair D20x22 Series II Navigator HDD Service

23. Apply a light film of petroleum jelly on 3.24 inch ID seal (4). Install seal in outside
seal groove of valve housing.
24. Apply petroleum jelly on inner (5)
and outer (6) face seals. Install 5 6
seals on balance ring (7) as shown.
IMPORTANT: Install face seals in
positions shown in figure, or motor
will not operate properly. Do not force
or bend these face seals. Any damage
to these seals will affect operation of
motor.
7
25. Align two pins of balance ring
with two spring holes in valve housing. Install balance ring in valve housing.
26. Insert a finger through port of housing. Apply pressure to side of balance ring
assembly. Hold ring in position until valve housing is in place. Align case drain hole
in housing with case drain hole in valve plate.
NOTE: After installing valve housing on valve plate, check between body parts of
Thrust/Pullback

motor for unseated seals.

27. Install and finger-tighten two bolts opposite

alignment studs if used. Remove alignment studs
and install remaining bolts. Torque bolts to 750 4 1
in-lb (85 Nm) in sequence shown.
28. Install two check plug assemblies, also install
case drain plug with seal.

2 3

10-34
D20x22 Series II Navigator HDD Service Component Repair

Returning System to Service

The hydrostatic systems can be easily damaged by contaminants or by lack of oil. After
repairing a hydrostatic system, use the following procedure to assure an adequate supply
of oil to each part of the system.

• Fill tank with the recommended hydraulic fluid. Filter oil with a 5-micron oil filter as
it is added to the tank. Do not reuse hydraulic fluid.
• If replacing a hose, if possible, fill it with filtered oil before starting the machine.
• Fill motor or pump case with oil before starting the machine.

IMPORTANT: Hydrostatic components can be destroyed if not filled with oil before
the engine is started.

Carriage
Special Tools • 90 ft-lb (120 Nm) torque wrench
Remove

Thrust/Pullback
2
1

3
5 6
4

1. Disconnect and cap hoses (1) and (2) to thrust valve A8.
2. Remove four nuts (3), washers and bolts attaching thrust valve to carriage.
3. Remove bolts holding hose carrier (4) to carriage. Support hose carrier and lift it
back from carriage.
4. Remove thrust/pullback motors (5). Refer to "Thrust Motors MH2, MH3, and
MH4," page 10-24.
5. Remove rotation gearbox (6). Refer to "Gearbox Removal/Installation," page 9-
60.
Continued on next page...

10-35
 Component Repair D20x22 Series II Navigator HDD Service

5
1

2
3
4

WARNING: Clamp or block the thrust/pullback carriage to lock it in place, preventing the
carriage from moving if the rack is inclined. Serious injury may occur if struck by moving
carriage.
Thrust/Pullback

6. Remove bolts and washers (1). Remove guide rollers (2) on each side of rack.
7. Loosen four nuts (3) (bottom rollers only) on each side of rack.
8. Remove bolts (4) and washers holding sides of carriage to top plate (5). Support
sides as you lift them away with top and bottom rollers still attached.
9. Remove bolts and washers on rollers. Remove rollers and inspect for wear or
damage.
10. Install a suitable lifting sling onto carriage top plate (5) so it will be balanced when
slid off rack. Attach an adequate lifting device to sling, and lift enough to remove
weight of carriage from rack.
11. Slide carriage from rack.

10-36
D20x22 Series II Navigator HDD Service Component Repair

2 6
5
1

Install 1. Install top rollers to sides of carriage, using bolts and washers (1).
2. Loosely bolt bottom rollers (2) on sides of carriage.
Torque to all bolts on 3. Install thrust motors (3). Refer to "Thrust Motors MH2, MH3, and MH4," page

Thrust/Pullback
carriage to 90 ft-lb 10-24.
(120 Nm).
4. Lift carriage top plate (4) onto rack. Attach sides, using bolts and washers (5).
5. Insert roller guides (6) through holes in side plates. Loosely bolt in place.
6. Tighten bolts (2) on bottom rollers to correct torque level.
7. Install gearbox. Refer to "Gearbox Removal/Installation," page 9-60.
8. Install thrust valve. Refer to repair section of this chapter.
9. Hoist hose carrier in position on carriage. Install bolts, washers and nuts holding
hose carrier to carriage.
10. Clamp a rod in rear vise. Verify that drive chuck correctly engages rod end. If
adjustment is required, loosen nuts on each side of rack. Use adjustment bolts to
shift carriage from side to side, centering drive chuck to rod end.
11. Once drive chuck is centered, set a clearance of 1/16" (2 mm) between guide roller
(6) and rack plate edge on each side. Tighten bolts on guide rollers.

10-37
 Component Repair D20x22 Series II Navigator HDD Service

Stop and Slowdown Switches

1
2

The front stop switch is 1. Move carriage to middle of rack to allow clearance.
on the front of the rack
Thrust/Pullback

near the vises. The front 2. Disconnect switches from electrical harness.
slowdown switch is
directly behind it.
3. Remove screws holding switch assemblies to rack.

The rear stop switch is 4. Position front slowdown switch (1) and front stop switch (2) so carriage travels
on the rear of the rack directly over circles stamped into switch housing. Then attach switches to rack with
near the fuel tank. The screws.
rear slowdown switch is
directly in front of it. 5. Position rear slowdown switch (3) and rear stop switch (4) so that carriage travels
directly over circles stamped into switch housing. Then attach switches to rack with
screws.
6. Connect switches to electrical harness.
NOTE: Switches may be tested by passing a piece of metal over circles stamped into
switch housing. If light in corner of switch goes on, contact was made.

10-38
D20x22 Series II Navigator HDD Service Overview

Chapter 11: Rod Loader

OVERVIEW
The rod loader circuits control loading and unloading drill rod from the drill string.

THEORY
Components
The functions covered in this section include the following components:

• Rod Loader Valve Assembly A14, including:

• Directional Valves DV34 and DV35
• Check Valve CV8–CV12
• Solenoids L2–L5
• Rod Lift Cylinders CY10–CY11
• Rod Loader Motor MH9
• Switches S17–S20, S33 and S36

Rod Loader

11-1
 Theory D20x22 Series II Navigator HDD Service

Component Locations

ROD LOADER VALVE A14

ROD LOADER LIFT

FRONT LIFT AND ANTI-CRASH ROD LOADER MOTOR MH7
CYLINDER CY10 SWITCHES S33 AND S36
REAR LIFT CYLINDER CY11
Rod Loader

ROD LOADER ARM

RIGHT JOYSTICK A2

11-2
D20x22 Series II Navigator HDD Service Theory

Hose Connections
REAR ROD LIFT
CYLINDER CY11 ROD LOADER
VALVE A14
VISE VALVE A13

FRONT ROD LIFT

CYLINDER CY10

TO TANK

Rod Loader
ROD LOADER MOTOR MH9 DIVERTER/FLUID
VALVE A9

11-3
 Theory D20x22 Series II Navigator HDD Service

Electrical Schematic

E 7 D IS P L A Y D P 1 0 -A

E 7 D IS P L A Y D P 1 0 - B

A 2 R IG H T H A N D J O Y S T IC K H E A D
Rod Loader

C 148 C O N TR O LLER

J1 - G R AY

J2- B LAC K

J3 - G R EEN

11-4
D20x22 Series II Navigator HDD Service Theory

Hydraulic Diagram
VISE VALVE A13

DV17

REAR ROD LIFT

FRONT ROD LIFT CYLINDER CY11
CYLINDER CY10 ROD LOADER
MOTOR MH9

DIVERTER/FLUID CV9 CV10 CV11

VALVE A9 CV8

CV12

Rod Loader
DV34 DV35

ROD LOADER
VALVE A14

PCF PUMP PMP2

RETURN MANIFOLD A17

SUCTION MANIFOLD A15

11-5
 Theory D20x22 Series II Navigator HDD Service

Shared Components
The rod loader function shares the common hydraulic fluid distribution components, as
well as diverter/drilling fluid valve assembly A9. The hydraulic fluid distribution
components are shared by all functions with hydraulic circuits. These components
include:

• Hydraulic Tank RES1

• Oil Cooler HE1
• PFC Pump PMP2
For more information on the hydraulic fluid distribution components and diverter/
drilling fluid valve assembly A9, refer to Chapter 4.

Rod Loader Valve Assembly A14

LIFT CYLINDER
SOLENOIDS L4 & L5

MOTOR
SOLENOIDS L2 & L3
Rod Loader

ROD LOADER
MANIFOLD
A14

ROD END T
LIFT CYLINDER
P

BASE END
LIFT CYLINDER

LS

The rod loader valve assembly A14 contains four solenoid valves, two directional
valves, and load sense check valves to control rod loader operation. A hydraulic load
sense line runs from the rod loader manifold to PFC pump PMP2.

Pressurized oil flows into the valve at port P. Return oil flows out at port T, which
connects with the return line from the vise valve and stakedown valve before returning
to tank RES1.

11-6
D20x22 Series II Navigator HDD Service Theory

Rod Loader Function – Rod Lifter Lower Mode

DIVERTER VALVE A9
CY10 CY11
TO VISE
L20 VALVE
FROM
HYDRAULIC
DV17
ENABLE S10

FROM
ROD
LOWER L5
S20

DV34
ROD LOADER
VALVE A14

Operation To operate rod lifter LOWER mode:

• Seat switch S11 must be closed (operator in seat).

Rod Loader
• Remote Lockout system must be in RUN mode.
• Hydraulic enable switch S10 must be pressed to ENABLE.
• Rod lower switch S20 on right joystick must be pressed.
When required operating conditions are met:

• Oil flows from PFC pump PMP2 to diverter/drilling fluid valve A9.
• Hydraulic enable switch S10 sends a signal to solenoid L20 that activates DV17 in
diverter/drilling fluid valve A9. Oil flows from port B of valve A9 to port P of rod
loader valve A14.
• Rod lower switch S20 sends a signal to solenoid L5 that activates valve DV34 in
assembly A14. Oil flows to rod end of lift cylinders CY10 and CY11.
NOTE: If the rod lift function does not operate as expected, see "Troubleshooting
Rod Loader Lift Function," page 11-17.

11-7
 Theory D20x22 Series II Navigator HDD Service

Rod Loader Function – Rod Lifter Raise Mode

DIVERTER VALVE A9
CY10 CY11

TO VISE
L20 VALVE
FROM
H HYDRAULIC
ENABLE S10 DV17

FROM
ROD
RAISE L4
S19
DV34

ROD LOADER
VALVE A14

Operation To operate rod lifter RAISE mode:

• Seat switch S11 must be closed (operator in seat).

• Remote Lockout system must be in RUN mode.
Rod Loader

• Hydraulic enable switch S10 must be pressed to ENABLE.

• Rod raise switch S19 on right joystick must be pressed.
When required operating conditions are met:

• Oil flows from PFC pump PMP2 to diverter/drilling fluid valve A9.
• Hydraulic enable switch S10 sends a signal to solenoid L20 that activates DV17 in
diverter/drilling fluid valve A9. Oil flows from port B of valve A9 to port P of rod
loader valve A14.
• Rod raise switch S19 sends a signal to solenoid L4 that activates valve DV34 in
assembly A14. Oil flows to base end of lift cylinders CY10 and CY11.
NOTE: If the rod lift function does not operate as expected, see "Troubleshooting
Rod Loader Lift Function," page 11-17.

11-8
D20x22 Series II Navigator HDD Service Theory

Rod Loader Function – Rod Selector Retract Mode

DIVERTER VALVE A9
MH9
TO VISE
L20 VALVE
FROM
HYDRAULIC DV17
ENABLE S10

L3

DV35
ROD LOADER
VALVE A14
FROM ROD RETRACT S18 &
CONTROLLER A5
Operation To operate rod selector RETRACT mode:

• Row selector lever must be set to desired row.

Rod Loader
• Seat switch S11 must be closed (operator in seat).
• Remote Lockout system must be in RUN mode.
• Hydraulic enable switch S10 must be pressed to ENABLE.
• Rod arm retract switch S18 on right joystick must be pressed.
When required operating conditions are met:

• Oil flows from PFC pump PMP2 to diverter/drilling fluid valve A9.
• Hydraulic enable switch S10 sends a signal to solenoid L20 that activates DV17 in
diverter/drilling fluid valve A9. Oil flows from port B of valve A9 to port P of rod
loader valve A14.
• Rod arm retract switch S18 sends a signal to Display DP-10 which sends the signal
on to controller C148. The controller sends a signal to solenoid L3 that activates
valve DV35 in assembly A14. Oil flows to port B of motor MH9.
• The motor rotates counterclockwise (CCW) causing the rod arm to retract towards
the rod box until it is stopped by the row selector bar.
NOTE: If the rod selector function does not operate as expected, see
"Troubleshooting the Rod Loader Load Function," page 11-15.

11-9
 Theory D20x22 Series II Navigator HDD Service

Rod Loader Function – Rod Selector Extend Mode

DIVERTER VALVE A9
MH9

TO VISE
L20 VALVE
FROM
HYDRAULIC
ENABLE S10 DV17

L2

DV35
ROD LOADER
VALVE A14
FROM ROD EXTEND S17 &
CONTROLLER A5
Operation To operate rod selector EXTEND mode:

• Row selector lever must be set to desired row.

Rod Loader

• Seat switch S11 must be closed (operator in seat).

• Remote Lockout system must be in RUN mode.
• Hydraulic enable switch S10 must be pressed to ENABLE.
• Rod arm extend switch S17 on right joystick must be pressed.
When required operating conditions are met:

• Oil flows from PFC pump PMP2 to diverter/drilling fluid valve A9.
• Hydraulic enable switch S10 sends a signal to solenoid L20 that activates DV17 in
diverter/drilling fluid valve A9. Oil flows from port B of valve A9 to port P of rod
loader valve A14.
• Rod arm extend switch S17 sends a signal to Display DP-10 which sends the signal
on to controller C148. The controller sends a signal to solenoid L2 that activates
valve DV35 in assembly A14. Oil flows to port A of motor MH9.
• The motor rotates clockwise (CW) causing the rod arm to extend until it returns to
the drill string.
NOTE: If the rod selector function does not operate as expected, see
"Troubleshooting the Rod Loader Load Function," page 11-15.

11-10
D20x22 Series II Navigator HDD Service Troubleshooting

TROUBLESHOOTING
Troubleshooting procedures are given for each operating mode of the different functions
of this chapter. Begin each procedure by performing a pretest inspection of the machine.
See "Pretest Inspection," page 11-11.

Often problems can be solved by doing a walk-around inspection of the machine

looking for obvious problems.

If nothing is found during the pretest inspection, continue by operating all other actuator
functions of the machine to help further isolate problems. See "Troubleshooting
Machine Performance," page 11-13.

Pretest Inspection
Visually check to inspect for obvious signs of failure before any exhaustive
troubleshooting or testing procedures are performed.

Mechanical

Inspect mechanical linkages, cables, and connectors from joystick controllers and
control valves for:

Rod Loader
• damage, misalignment, or improper adjustment

Electrical

Inspect electrical circuits for clues to malfunction. Always check the following items
before turning on switches or running the machine.

• Look for bare wires that could cause grounds or shorts.

• Look for broken, missing, corroded, or loose connections in the power wires that
supply electrical circuit components.
• Check all ground connections on the machine and chassis for tight
connections. Cleaning harness connections or ground connections can often correct
what appears to be a malfunctioning component.
Continued on next page...

11-11
 Troubleshooting D20x22 Series II Navigator HDD Service

• Check for overheated components after the unit has been stopped for awhile. They
will often smell like burned insulation.

WARNING: Pressurized fluid can penetrate body tissue and result in serious injury or
death. Leaks can be invisible. Keep away from any suspected leak. Relieve pressure in the
hydraulic system before searching for leaks, disconnecting hoses, or performing any other
work on the system. If you must pressurize the system to find a suspected leak, use an
object such as a piece of wood or cardboard rather than your hands. When loosening a
fitting where some residual pressure may exist, slowly loosen the fitting until oil begins to
leak. Wait for leaking to stop before disconnecting the fitting. Fluid injected under the skin
must be removed immediately by a surgeon familiar with this type of injury.

Hydraulic

Check hydraulic circuits for any failures.

• Look for broken, kinked, loose, or leaking hoses and fittings on supply, pressure,
and return to hydraulic components.
• Check level of hydraulic fluid in hydraulic tank. Low fluid levels can cause erratic
behavior in hydraulic circuits. Correct level is between the two lines on dipstick. If
needed, add new fluid that has been filtered through a 5-micron filter.

Also review information in the General Information chapter under "Hydraulic

Rod Loader

Troubleshooting," page 1-12. Correct any problems found during the inspection.
Operate machine to verify the fault is fixed.

Test Equipment Needed

To perform the troubleshooting procedures in this chapter, the following test equipment
will be needed:

• Multimeter for continuity tests, voltage measurements, resistance

measurements in the various electrical circuits.
• Various hydraulic testing tools.

NOTE: The hydraulic component test procedures discussed in this chapter will refer
the technician to the Vermeer Industrial Dealerships Technician’s Shop Manual
(Vermeer P/N 105400V80). Test procedures and equipment needed for performing the
various tests on hydraulic components will be listed in the manual.

11-12
D20x22 Series II Navigator HDD Service Troubleshooting

Troubleshooting Machine Performance

Possible faults may occur in the rod loader function that are directly related to faults in
other functions. These other faults may not be readily apparent, because those particular
functions are not currently being operated.

Operate the machine functions and document performance of working actuators.

Note functions not operating normally, based on the theory given in that function
chapter. To help isolate a faulty component or function, compare the notes you have
taken to the normal operation given for each mode of a particular function.

After doing all machine performance checks, if the fault is isolated to the original
function in question, return to the troubleshooting/testing for that mode. If multiple
functions are affected, proceed with troubleshooting based on the possible results listed
below.

Possible Results 1. If faults are noted when operating all the machine actuators, it would indicate a
function or component that is common to all the actuators is most likely faulty. The
following common functions and components should be investigated:
• Engine. See "Engine," page 3-6.
• Shared hydraulic components. See Chapter 4.
• Remote Lockout. See Chapter 15.

Rod Loader
2. If faults are noted in the rod loader, stakedown, vises, and auto greaser functions, as
well as the stabilizer and ground drive functions and all other functions are OK, the
following components should be investigated:
• PFC pump PMP2. See "PFC Pump PMP2," page 4-6.
• Diverter/drilling fluid valve assembly A9. See "Oil Supply Function," page 4-6.
3. If problems are noted only in the rod loader function, and all other functions are OK,
troubleshoot the rod loader electrical circuit first.

11-13
 Troubleshooting D20x22 Series II Navigator HDD Service

Testing Rod Loader Performance

Before beginning any troubleshooting or testing procedures, perform the "Pretest
Inspection," page 11-11. If nothing obvious is found, continue.

1. Ensure switches listed in "Starting Procedure," page 2-2, are in correct positions.
2. Start the engine.
1
3. Turn on Remote Lockout and select RUN
mode.
4. Press hydraulic enable switch S10 (1) to enable
rod loader circuits.
NOTE: The performance values listed for the rod
loader circuit are for reference purposes only. All
cylinder functions should require about one second
for completion. Due to these short time frames, operational conditions of these circuits
should not be determined by the results of these tests alone. If circuit operation is in
question, refer to "Troubleshooting the Rod Loader Load Function," page 11-15 or
"Troubleshooting Rod Loader Lift Function," page 11-17.

Completion time of one second assumes the cylinder is at room temperature. If the
cylinder is in hot or cold environment, the time will vary.
Rod Loader

5. Push rod lift switch S19 (2). Rod lift cylinders

will extend in approximately 2 seconds. The LED
above the switch will light while the rod lifter is
in the lowered position. 4

6. Push rod lower switch S20 (3). Rod lift cylinders

will retract in approximately 2 seconds. 5
2 3
7. Push loader arm extend switch S17 (4). Loader
arms will move to the drill string in
approximately 2 seconds. The LED will remain
lit while the button is being pressed.
8. Press loader arm retract switch S18 (5) to RETRACT position. Loader arms will
move toward the rod box in approximately 2 seconds.

11-14
D20x22 Series II Navigator HDD Service Troubleshooting

Troubleshooting the Rod Loader Load Function

The rod loader load function contains both electrical and hydraulic components. If the
steps in "Troubleshooting Machine Performance," page 11-13, indicate the circuit is
not operating properly, begin troubleshooting by following the general guidelines below.

1. If the loader arms will not extend, remove rod loader valve manifold cover.
2. With engine running, seat switch closed, and Remote Lockout enabled. Push
hydraulic enable button S10. Ensure gearbox carriage is fully retracted (rear stop
switch S31 is closed).
3. Disconnect wire 739 from rod loader power solenoid L20. Use multimeter to check
for voltage.
Expected result: When switch is pushed, 12 volts will be present at wire 739 of
solenoid L20.

If not, check components in circuit for voltage. If voltage is found at hydraulic

enable switch S10, check continuity of wire 739 to solenoid L20. Replace wire
section if faulty. If so, continue.
4. Check wire 332 at solenoid L20 for continuity to ground. If continuity is found, go
on to the next step. If not, repair wire segment.
5. Push loader arms extend switch S17. Use multimeter to check for voltage at wire
803 of solenoid L3.

Rod Loader
Expected result: When switch is pushed, 12 volts will be present at wire 803.

If not, check components in circuit for voltage. If voltage is found at switch S17,
check continuity of wire 803 to solenoid L3 (1). Replace wire section if faulty. If so,
continue.
6. Disconnect wire harness from solenoid L3. Use multimeter to check resistance of
coil L3.
Expected result: Coil resistance should measure 7.2 ohms @ 68°F (20°C). If not
replace coil. If so, troubleshoot the hydraulic circuit.
Continued on next page...

11-15
 Troubleshooting D20x22 Series II Navigator HDD Service

7. Push loader arms retract switch S18. Use

multimeter to check for voltage at wire 804 of
solenoid L2.
Expected result: When switch is pushed, 12
volts will be present at wire 804. 1

If not, check components in circuit for voltage.

If voltage is found at switch S18, check
continuity of wire 804 to solenoid L2 (1).
Replace wire section if faulty. If so, continue.
8. Test solenoid coil L2 for magnetism when
switch is activated. If so, also test coil
resistance. It should have a resistance of 7.2
ohms @ 68°F (20°C). If so, troubleshoot
hydraulic circuit.
9. Inspect rod loader valve A14. If OK, continue.
Rod Loader

11-16
D20x22 Series II Navigator HDD Service Troubleshooting

Troubleshooting Rod Loader Lift Function

The rod loader select function contains both electrical and hydraulic components. If the
steps in "Troubleshooting Machine Performance," page 11-13 indicate the circuit is
not operating properly, begin troubleshooting by following the general guidelines below.

1. If the rod loader lift cylinders will not extend, and other rod loader functions are
working correctly, remove rod loader valve manifold cover.
2. With the engine running, and the operator seat switch closed, ensure Remote
Lockout is functioning properly and that the rotation gearbox is in the retracted
position. Push hydraulic enable button S10. This activates rod loader power valve
solenoid L20, supplying hydraulic oil to rod loader valve A14.
3. Disconnect wire 801 from solenoid L4.
4. Push rod lift switch S19. Use multimeter to
L5
check for voltage at wire 801.
Expected result: When switch is pushed, 12
L6
volts will be present.
If not, check components in the electrical
circuit for voltage. If voltage is not found at
switch, check continuity of wire 801 at the
right joystick 12-pin connector to solenoid
L4. Replace wire section if faulty. If so,

Rod Loader
continue.
5. Test the resistance of coil L4. It should have a
resistance of 7.2 ohms @ 68°F (20°C). If so,
the solenoid is faulty. If not, troubleshoot the
hydraulic system.
6. Push rod lower switch S20. Use multimeter
to check for voltage at wire 802.
Expected result: When switch is pushed, 12 volts will be present.
If not, check components in the electrical circuit for voltage. If voltage is not found
at switch, check continuity of wire 802 at the right joystick 12-pin connector to
solenoid L5. Replace wire section if faulty. If so, continue.
7. Inspect rod loader valve A14. If OK, continue.
8. Test cylinders CY10 and CY11 for cross piston leakage. Refer to the Vermeer
Industrial Dealerships Technician’s Shop Manual.

11-17
 Component Repair D20x22 Series II Navigator HDD Service

Specifications
Listed below are electrical and hydraulic specifications for rod loader functions.

Electrical:

• Nominal circuit voltage - 12 volts DC

• Rod loader valve solenoid coils L2, L3, L4, and L5 - 7.2 ohms @ 68°F (20°C)
Hydraulic:

• Rod Loader Motor MH9 maximum speed - 308 rpm @ 20 gpm flow
• Rod Loader Motor MH9 displacement - 14.9 cid (244 cc)
• Rod Loader Motor MH9 maximum case drain flow under full load -
0.75 gpm (2.84 L/min)
• Rod Lift Cylinders CY10 and CY11 maximum pressure - 3000 psi
(207 bar)
• PFC Pump PMP2 normal output flow - variable to 24 gpm (90.8 L/min)
• PFC Pump PMP2 standby pressure compensator valve setting - 250 psi (17.2 bar)
• PFC Pump PMP2 high pressure compensator valve setting - 3300 psi (227.5 bar)
Rod Loader

Component Repair/Replace
If troubleshooting procedures determine a component is in need of repair or
replacement, refer to the appropriate procedures at the back of the chapter or other
chapters where instructed. After repairs have been made, refer to"Hydraulic Fluid
Sampling," page 4-26 and follow instructions.

COMPONENT REPAIR

WARNING: Pressurized fluid can penetrate body tissue and result in serious injury or
death. Leaks can be invisible. Keep away from any suspected leak. Relieve pressure in
the hydraulic system before searching for leaks, disconnecting hoses, or performing any
other work on the system. If you must pressurize the system to find a suspected leak, use
an object such as a piece of wood or cardboard rather than your hands. When loosening a
fitting where some residual pressure may exist, slowly loosen the fitting until oil begins
to leak. Wait for leaking to stop before disconnecting the fitting. Fluid injected under the
skin must be removed immediately by a surgeon familiar with this type of injury.

11-18
D20x22 Series II Navigator HDD Service Component Repair

Rod Loader Valve Assembly A14

2
3

Removal 1. Remove cover at rear of rod box to access valve.

2. Label, disconnect and cap all hoses and fittings.

Rod Loader
3. Remove bolts (2) and washers (3) holding valve manifold (1) to mounting plate.
To install valve, reverse steps above. Torque bolts (2) to 35 ft-lb (47 Nm).

11-19
 Component Repair D20x22 Series II Navigator HDD Service

Directional Valves DV34 and DV35

2 1

1. Disconnect electrical connection from solenoid.

2. Remove nut (1) and solenoid coils (2) from valve.
Rod Loader

3. Unscrew and remove cartridge valve from valve manifold.

NOTE: Make note of O-ring and backup washer orientation.

4. Inspect valve and O-rings for damage and ensure no external contaminants are
present.
5. Inspect valve body cavity for burrs or other irregularities which could damage O-
rings during installation.
6. Replace O-rings and backup washers if needed.
7. Dip valve in clean filtered oil.
8. Screw valve in by hand until outer O-ring contacts valve body. Torque valve to 25
ft-lb (33.9 Nm). Torque solenoid nut to 5 ft-lb (6.8 Nm).

11-20
D20x22 Series II Navigator HDD Service Component Repair

Check Valve CV8

1. Remove check valve (1) from base of
valve manifold.
NOTE: Make note of O-ring and backup
washer orientation.

2. Inspect valve and O-ring for damage and

ensure no external contaminants are 1
present.
3. Inspect valve body cavity for burrs or
other irregularities which could damage
O-ring during installation.
4. Replace O-ring and backup washer, if needed.
5. Dip valve in clean filtered oil.
6. Screw valve in by hand until O-ring contacts valve body. Torque valve to 20 ft-lb
(27.1 Nm).

Check Valves CV9–CV12

Rod Loader
1. Remove check valve cartridge (1) from
valve manifold.
1
NOTE: Make note of O-ring and backup
washer orientation.

2. Inspect valve and O-rings for damage and

ensure no external contaminants are
present.
3. Inspect valve body cavity for burrs or
other irregularities which could damage
O-rings during installation.
4. Replace O-rings if needed.
5. Dip valve in clean filtered oil.
6. Screw valve in by hand until O-ring contacts valve body. Torque valve to 27 ft-lb
(36.5 Nm).

11-21
 Component Repair D20x22 Series II Navigator HDD Service

Rod Lift Cylinders CY10 and CY11

8 2

3 8

1
6
7

1
7
3

5 3
Rod Loader

4
7

Removal 1. Label, disconnect, and cap all hoses and fittings.

2. Remove cotter pin (7) from pin (4) at base end of cylinder.
3. Remove pin (4) and washer (3) from base end of cylinder.
4. Remove cotter pin (7) from pin (8) at rod end of cylinder.
5. Remove pin (8) and washer (3) from rod end of cylinder.
To install cylinder, reverse removal steps.

11-22
D20x22 Series II Navigator HDD Service Component Repair

Disassembly

5 6 12 8 9
2
11

4 7 8 1 5 3 10

1. Place cylinder on a clean surface.

2. Clamp cylinder body (1) into a vise. Do not apply excessive clamping force to
cylinder body.
3. Remove cap and internal head gland (2) with spanner wrench.
4. Pull rod assembly (3) out of cylinder body. Ensure ports are open and positioned to
direct oil into a suitable container.
5. Remove lock nut (4) from rod assembly.

Rod Loader
IMPORTANT: Do not clamp onto unpainted portion of rod. Scarring rod can cause
premature seal failure.

6. Slide gland (2) and piston (12) off rod.

7. Remove loaded U-cup (10) and rod wiper (9).
8. Remove and replace seals (5, 6, 7, 8 and 9). Refer to the D20x22 Series II Parts
Manual for seal kit components. Apply a light coat of petroleum jelly to seals
before installation.
Assembly 1. Slide gland and piston onto rod and tighten nut.
2. Push rod assembly into cylinder body.
3. Install head gland into cylinder body and secure.
4. Install cylinder.

11-23
 Component Repair D20x22 Series II Navigator HDD Service

Rod Loader Motor MH9

5
4
Rod Loader

1. Label, disconnect and cap all hoses and fittings (3).

2. Use a drill with a very long 3/8" socket bit to remove four bolts (2).
3. Remove retaining bolt (5) on gear (4).
4. Support motor and disengage shaft of motor (1) from gear (4).
Reverse steps above to install motor. Torque bolts to 90 ft-lb (120 Nm).

11-24
D20x22 Series II Navigator HDD Service Component Repair

Rod Box
Remove

WARNING: Falling load can crush. Never lift rod box over people.

Do not stand or work under raised rod box.

WARNING: Pinch points can result in serious crushing injuries. Keep hands and
feet away from pinch points of rod loader. Keep shields in place and properly
secured.

Rod Loader
3
1
4

1. If rod box is not empty, raise rod box cylinders to push rods into rod box.
2. Shut off engine.
3. Install bottom rod support tubes (3) and keeper pins (2). Lower rod box cylinders
and shut off engine.
4. Connect hoist chain to all four lift eyes (1).
5. Lift rod box by top lift eyes only.
6. Remove lower rod box keeper pins (4).
7. Remove rod box.

11-25
 Component Repair D20x22 Series II Navigator HDD Service

Install 1. Connect hoist chain to all four lift eyes.

IMPORTANT: Lift rod box by top lift eyes
4
only.

2. Carefully lower rod box between guide

plates. 1
2
NOTE: Install rod box with male threads to 3
front.

3. Install two lower rod box keeper pins (3).

4. Remove hoist chain.
5. Raise rod box cylinders to push rods into box.
6. Shut off engine.
7. Remove bottom rod keeper tubes (2) and support bars (1) and place in storage
position (4) before drilling.
Rod Loader

11-26
D20x22 Series II Navigator HDD Service Rod Arm Extend and Lift Limit Switches

ROD ARM EXTEND AND LIFT LIMIT SWITCHES

Replacement

1
2 4
3

Limit switches are 1. Fully retract rod loader arms (1) so they are under first row of rod.
located on the rear rod
loader. 2. Disconnect switches (2) from electrical harness.
3. Remove two screws holding each switch on mounting bracket. Remove and discard
switches.
4. Loosely tighten two screws (3) holding lift switch on mounting bracket. Lift
cylinder switch S36 is beside lift cylinder. Adjust placement on mounting bracket so
that switch clicks as arm moves up. Tighten two screws.
5. Loosely tighten two screws (4) holding anti-crash switch on mounting bracket.

Rod Loader
Anti-crash switch S33 is across from lift switch. Adjust placement on mounting
bracket so that switch clicks as arm retracts. Tighten two screws.
6. Verify correct lift switch operation by raising and lowering arm and noting whether
LED in corner of switch is lit. Verify correct anti-crash switch operation by
extending arm into drill string and retracting arm and noting whether LED is lit.

11-27
This page intentionally left blank.
D20x22 Series II Navigator HDD Service Overview

Chapter 12: Vises

OVERVIEW
This chapter is comprised of information about circuits and components necessary for
rear and front vise clamping and vise rotation.

The operator uses the vises along with the rod loader to add or remove rods from drill
string. The vise valve assembly A13 is connected to three cylinders: CY7, CY8, and
CY9.

All the solenoids in A13 are controlled by inputs from controller A5. The controller
respond to inputs from operator controlled switches.

THEORY
Functions
The following functions are included in this chapter:

Vises
• Rear Vise Clamp
• Front Vise Clamp
• Rear Vise Rotate

Components
The functions covered in this section include the following components:

• Vise Valve Assembly A13, including:

• Directional Valves DV29–DV33
• Solenoids L22–L26
• Check Valves CV5–CV7
• Pressure Relief Valve PV6
• Front Vise Cylinder CY7
• Rear Vise Cylinder CY8
• Rear Vise Rotation Cylinder CY9
• Switches S21 and S22

12-1
 Theory D20x22 Series II Navigator HDD Service

Component Locations

REAR VISE CYLINDER CY8

FRONT VISE CYLINDER CY7

REAR VISE ROTATION

CYLINDER CY9
Vises

RIGHT JOYSTICK A2

VISE VALVE A13

12-2
D20x22 Series II Navigator HDD Service Theory

Hose Connections
AUTO GREASER VALVE A16 FRONT VISE
CYLINDER CY7

AUTO GREASER
CYLINDER CY12 REAR VISE
CYLINDER CY8

VISE
VALVE A13

REAR VISE

Vises
ROTATION
CYLINDER CY9 STAKEDOWN VALVE A12

DIVERTER/FLUID VALVE A9

12-3
 Theory D20x22 Series II Navigator HDD Service

Hydraulic Schematic
FRONT VISE ROTATION
CYLINDER CY7 CYLINDER CY9
AUTO GREASER REAR VISE
DIVERTER/FLUID CYLINDER CY12 CYLINDER CY8
VALVE A9
AUTO GREASER
VALVE A16

DV29 DV30
DV17
DV31 DV33

DV32
PV6
VISE VALVE A13

PFC PUMP PMP2

Vises

RETURN
MANIFOLD A17

SUCTION
MANIFOLD A15

12-4
D20x22 Series II Navigator HDD Service Theory

Electrical Schematic

E 7 D IS P L A Y D P 1 0 - A

E 7 D IS P L A Y D P 1 0 - B

A 2 R IG H T H A N D J O Y S T IC K H E A D

C 148 C O N TRO LLER

J1 - G R AY

Vises
J3 - G R EEN

J4- B R O W N

12-5
 Theory D20x22 Series II Navigator HDD Service

Shared Components
The vise functions share the common hydraulic fluid distribution components, as well as
diverter/drilling fluid valve assembly A9. The hydraulic fluid distribution components
are shared by all functions with hydraulic circuits. These components include:

• Hydraulic Tank RES1

• Oil Cooler HE1
• PFC Pump PMP2
For more information on the hydraulic fluid distribution components and diverter/
drilling fluid valve assembly A9, refer to "Oil Supply Function," page 4-6.
Vises

12-6
D20x22 Series II Navigator HDD Service Theory

Vise Valve Assembly A13

Operation Flow from PFC pump PMP2 enters vise valve assembly A13, where it is directed to
vises based on operator inputs. Directing this flow is accomplished by directional valves
DV31, DV32, and DV33. Valves DV29 and DV30 hold pressure to cylinders CY3 and
CY4 when the vise is clamped.

These valve cartridges are solenoid controlled and direct flow, based on operator inputs.
As the operator provides inputs into the switches on the right joystick, a signal is sent to
controller A5, which then relays the signal to the vise valve assembly.

FRONT VISE
FRONT VISE
CLAMP L22
RELEASE L23
REAR VISE
CLAMP L25
REAR VISE
RELEASE L24
REAR VISE ROTATE
CLAMP L26
A1

Vises
LS A2
B1
T B3 B2
P
A3
When solenoids are not energized, oil from PMP2 flows to the rod end of cylinders
CY7, CY8, and CY9, holding them in the retracted position.

12-7
 Theory D20x22 Series II Navigator HDD Service

Front Vise CLAMP Mode

FRONT VISE
CYLINDER CY7
L20

FROM
HYDRAULIC DV17
ENABLE
S10

L22
DV31
FROM
CONTROLLER
A5
DIVERTER/FLUID VALVE A9
VISE VALVE A13

Operation To operate front vise CLAMPING mode:

• Remote Lockout system must be in RUN mode.

• Seat switch S11 must be in the closed position (operator in seat).
Vises

• Operator must press top of front vise switch S22 on right joystick.
When required operating conditions are met:

• Switch S22 sends signal to controller A5 via display DP-10.

• PFC pump PMP2 sends oil to diverter/drilling fluid valve A9.
• Hydraulic enable solenoid L20 in diverter/drilling fluid valve A9 is energized and
shifts DV17, allowing oil to reach vise valve assembly A13.
• Controller A5 sends a signal to solenoid L22 in vise valve A13 and shifts DV31,
sending oil to the base end of cylinder CY7.
• CY7 extends and clamps onto end of drill string.
The check valve in DV29 maintains the cylinder in the clamped position, even though
no oil is flowing to the cylinder.

NOTE: If the front vise clamp function does not operate as expected, see
"Troubleshooting/Testing the Front Vise," page 12-19.

12-8
D20x22 Series II Navigator HDD Service Theory

Front Vise UNCLAMP Mode

FRONT VISE
CYLINDER CY7
L20
FROM
HYDRAULIC
ENABLE DV17
S10

L23

FROM L22
CONTROLLER
A5 DV31

DIVERTER/FLUID VALVE A9

VISE VALVE A13

Operation • Remote Lockout system must be in Run mode.

• Seat switch S11 must be in the closed position (operator in seat).

Vises
• Operator must press bottom of front vise switch S22 on right joystick.
When required operating conditions are met:

• Switch S22 sends signal to controller A5 via display DP-10.

• PFC pump PMP2 sends oil to diverter/drilling fluid valve A9.
• Hydraulic enable solenoid L20 in diverter/drilling fluid valve A9 is energized and
shifts DV17, allowing oil to reach vise valve assembly A13.
• Controller A5 sends a signal to solenoid L22 in vise valve A13 and returns DV31 to
the de-energized position, sending oil to the rod end of cylinder CY7.
• Controller A5 sends a signal to solenoid L23 in vise valve A13 and shifts DV29,
allowing oil to return from the base end of CY7.
• CY7 retracts.
The de-energized valve position in vise valve A13 maintains the cylinder in the
unclamped (open) position.

If problems occur during unclamping, see "Troubleshooting/Testing the Front Vise,"

page 12-19.

12-9
 Theory D20x22 Series II Navigator HDD Service

Torque Limiter Function

The torque limiter function utilizes signals from controller A5. When the front vise
switch S22 is in the CLAMP position or the 2-speed gearbox switch S8 is in the HIGH
position, directional valve DV7 and relief valve PV3 in torque limiter manifold A7 limit
pressure applied to the rotation motors when in forward (clockwise) rotation to 2000 psi
(138 bar).

The torque limiter function keeps the rod joints from being overtightened when adding
to the drill string.

NOTE: Refer to "Torque Limiter/Loop Flush Valve A7," page 9-11 for information
on torque limiter function, as well as the drill rotation hydrostatic closed-loop circuit.

Rear Vise CLAMP Mode

REAR VISE
CYLINDER CY8

L20
FROM
HYDRAULIC
DV17
ENABLE
Vises

S10

L25 DV32

DIVERTER/FLUID VALVE A9

FROM
CONTROLLER VISE VALVE A13
A5
Operation To operate rear vise Clamp mode:

• Seat switch S11 must be closed (operator in seat).

• Remote Lockout system must be in Run mode.
• Front vise CY7 must be clamped.
• Operator must press top of rear vise switch S21 on right joystick.

12-10
D20x22 Series II Navigator HDD Service Theory

When required operating conditions are met:

• Switch S21 sends signal to controller A5 via display DP-10.

• PFC pump PMP2 sends oil to diverter/drilling fluid valve A9.
• Hydraulic enable solenoid L20 in diverter/drilling fluid valve A9 is energized and
shifts DV17, allowing oil to reach vise valve assembly A13.
• Controller A5 sends a signal to solenoid L25 in vise valve A13 and shifts DV32,
sending oil to the base end of cylinder CY8.
• CY8 extends and clamps drill string.
The check valve in DV30 maintains the cylinder in the clamped position, even though
no oil is flowing to the cylinder.

NOTE: If the rear vise clamp function does not operate as expected, see
"Troubleshooting/Testing the Rear Vise," page 12-20.

Rear Vise UNCLAMP Mode

REAR VISE
CYLINDER CY8

Vises
L20
FROM
HYDRAULIC
ENABLE DV17
S10

L24

L25

DV32

DIVERTER/FLUID VALVE A9

FROM
CONTROLLER VISE VALVE A13
A5
Operation To operate rear vise Unclamp mode:

• Seat switch S11 must be closed (operator in seat).

• Remote Lockout system must be in Run mode.
• Front vise CY7 must be clamped.
• Operator must press bottom of rear vise switch S21 on right joystick.

12-11
 Theory D20x22 Series II Navigator HDD Service

When required operating conditions are met:

• Switch S22 sends signal to controller A5 via display DP-10.

• PFC pump PMP2 sends oil to diverter/drilling fluid valve A9.
• Hydraulic enable solenoid L20 in diverter/drilling fluid valve A9 is energized and
shifts DV17, allowing oil to reach vise valve assembly A13.
• Controller A5 sends a signal to solenoid L25 in vise valve A13 and returns DV32 to
the de-energized position, sending oil to the rod end of cylinder CY8.
• Controller A5 sends a signal to solenoid L24 in vise valve A13 and shifts DV30,
allowing oil to return from the base end of CY8.
• CY8 retracts.
The de-energized valve position in vise valve A13 maintains the cylinder in the
unclamped (open) position.

If problems occur during unclamping, see "Troubleshooting/Testing the Rear Vise,"

page 12-20.
Vises

12-12
D20x22 Series II Navigator HDD Service Theory

Rear Vise Rotation EXTEND Mode

ROTATION VISE
CYLINDER CY9

L20
FROM
HYDRAULIC DV17
ENABLE
S10

DV33
L26

FROM
CONTROLLER
DIVERTER/FLUID VALVE A9 A5

VISE VALVE A13

Operation To operate rear rotation vise EXTEND mode:

• Seat switch S11 must be closed (operator in seat).

Vises
• Remote Lockout system must be in Run mode.
• Front vise CY7 must be clamped.
• Rear vise CY8 must be clamped.
• Rod loader arms must be retracted under rod box.
• Signal must be sent from controller A5.

12-13
 Theory D20x22 Series II Navigator HDD Service

When required operating conditions are met:

• Switches S21 and S22 sends signal to controller A5 via display DP-10.
• PFC pump PMP2 sends oil to diverter/drilling fluid valve A9.
• Hydraulic enable solenoid L20 in diverter/drilling fluid valve A9 is energized and
shifts DV17, allowing oil to reach vise valve assembly A13.
• When the front and rear vise cylinders CY7 and CY8 have extended fully, the
pressure in the valve manifold increases to 2500 psi and relief valve PV6 shifts
allowing flow to DV33.
• Controller A5 sends a signal to solenoid L26 in vise valve A13 and shifts DV33,
sending oil to the base end of cylinder CY9.
• Cylinder CY9 extends.
The rear vise rotation cylinder CY9 is used during the joint-break sequence when
pulling drill rod back. After a rod is pulled back and has engaged front vise cylinder
CY7, front vise switch S21 causes oil to flow to the base end of rear vise cylinder CY8,
allowing it to clamp onto the male end of the rod which has just been pulled back.

Once the rear vise cylinder CY8 has clamped completely, oil flows to the base end of the
rotation cylinder CY9, rotating rear vise cylinder CY8, as well as the rod clamped in it.
This loosens the rod from the drill string and allows the operator to use the reverse
rotation function to completely unscrew the rod.
Vises

NOTE: If the rear vise clamp function does not operate as expected, see
"Troubleshooting/Testing the Rear Rotation Vise," page 12-21.

12-14
D20x22 Series II Navigator HDD Service Theory

Rear Vise Rotation RETRACT Mode

ROTATION VISE
CYLINDER CY9
L20

FROM DV17
HYDRAULIC
ENABLE
S10

DV33
L26

FROM
CONTROLLER
DIVERTER/FLUID VALVE A9 A5

VISE VALVE A13

Operation To operate rear rotation vise RETRACT mode:

• Seat switch S11 must be closed (operator in seat).

Vises
• Remote Lockout system must be in Run mode.
• Rear vise CY8 must be clamped, and then rear vise clamp switch S22 must be
pressed down to UNCLAMP.
• Rod loader arms must be extended into drill string.
• Signal must be sent from controller A5.
When required operating conditions are met:

• Switch S22 sends signal to controller A5 via display DP-10.

• PFC pump PMP2 sends oil to diverter/drilling fluid valve A9.
• Hydraulic enable solenoid L20 in diverter/drilling fluid valve A9 is energized and
shifts DV17, allowing oil to reach vise valve assembly A13.
• Controller A5 sends a signal to solenoid L26 in vise valve A13 and shifts DV33,
sending oil to the rod end of cylinder CY9.
• Cylinder CY9 retracts.
NOTE: Once the rear rotation vise cylinder has retracted, the controller sends the
signal to solenoid L25 and rear vise cylinder CY8 retracts.

NOTE: If the rear vise clamp function does not operate as expected, see
"Troubleshooting/Testing the Rear Rotation Vise," page 12-21.

12-15
 Troubleshooting D20x22 Series II Navigator HDD Service

TROUBLESHOOTING
Troubleshooting procedures are given for each operating mode of the different functions
of this chapter. Begin each procedure by performing a pretest inspection of the machine.
See "Pretest Inspection," page 12-16.

Often problems can be solved by doing a walk-around inspection of the machine

looking for obvious problems.

If nothing is found during the pretest inspection, continue by operating all other actuator
functions of the machine to help further isolate problems. See "Troubleshooting
Machine Performance," page 12-18.

Pretest Inspection
Visually check to inspect for obvious signs of failure before any exhaustive
troubleshooting or testing procedures are performed.

Mechanical

Inspect mechanical linkages, cables, and connectors from joystick controllers and
control valves for:
Vises

• damage, misalignment, or improper adjustment

Electrical

Inspect electrical circuits for clues to malfunction. Always check the following items
before turning on switches or running the machine.

• Look for bare wires that could cause grounds or shorts.

• Look for broken, missing, corroded, or loose connections on the power wires that
supply electrical circuit components.
• Check all ground connections on the machine and chassis for tight
connections. Cleaning harness connections or ground connections can often correct
what appears to be a malfunctioning component.
• Check for overheated components after the unit has been stopped for awhile. They
will often smell like burned insulation.

Continued on next page...

12-16
D20x22 Series II Navigator HDD Service Troubleshooting

Hydraulic

WARNING: Pressurized fluid can penetrate body tissue and result in serious injury or
death. Leaks can be invisible. Keep away from any suspected leak. Relieve pressure in the
hydraulic system before searching for leaks, disconnecting hoses, or performing any other
work on the system. If you must pressurize the system to find a suspected leak, use an
object such as a piece of wood or cardboard rather than your hands. When loosening a
fitting where some residual pressure may exist, slowly loosen the fitting until oil begins to
leak. Wait for leaking to stop before disconnecting the fitting. Fluid injected under the skin
must be removed immediately by a surgeon familiar with this type of injury.

Check hydraulic circuits for any failures such as:

• Broken, kinked, loose, or leaking hoses and fittings on supply, pressure, and return
to hydraulic components
• Check level of hydraulic fluid in hydraulic tank. Low fluid levels can cause erratic
behavior in hydraulic circuits. Correct level is between the two lines on dipstick. If
needed, add new fluid that has been filtered through a 5-micron filter.

Also review information in the General Information chapter under "Hydraulic

Troubleshooting," page 1-12. Correct any problems found during the inspection.
Operate machine to verify the fault is fixed.

Vises
Test Equipment Needed
To perform the troubleshooting procedures in this chapter, the following test equipment
will be needed:

• Multimeter for continuity tests, voltage measurements, resistance

measurements in the various electrical circuits
• Hydraulic testing tools

NOTE: The hydraulic component test procedures discussed in this chapter will refer
the technician to the Industrial Dealerships Technician’s Shop Manual (Vermeer P/N
105400V80). Test procedures and equipment needed for performing the various test on
hydraulic components will be listed in the manual.

12-17
 Troubleshooting D20x22 Series II Navigator HDD Service

Troubleshooting Machine Performance

Possible faults may occur in the vises function that are directly related to faults in other
functions. These other faults may not be readily apparent, because those particular
functions are not currently being operated.

Operate the machine functions and document performance of working actuators.

Make note of any functions not operating normally based on the theory given in each
chapter for that function. To help isolate a faulty component or function, compare the
notes you have taken to the normal operation given for each mode of a particular
function.

After checking the performance of all functions, if the problem is isolated to the original
function in question, return to the troubleshooting/testing for that mode. If multiple
functions are affected, proceed with troubleshooting based on the possible results listed
next.

Possible Results The possible results listed are meant to guide the service technician in a logical manner
to isolate a fault as quickly as possible.

1. If faults are noted when operating all machine actuators, it would indicate a function
or component that is common to all the actuators is most likely faulty. The following
common functions and components should be investigated:
Vises

• Engine. Refer to "Engine," page 3-6.

• Remote Lockout. Refer to Chapter 15.

2. If faults are noted in the vise functions, as well as the ground drive, rack lift,
stabilizer, stakedown and rod loader functions, and all other functions are OK, the
hydraulic components common to just these functions should be investigated,
including:
• PFC pump PMP2. See "PFC Pump PMP2," page 4-6.
• Diverter/fluid valve A9. See "Oil Supply Function," page 4-6.
3. If faults are noted in only the vise, stakedown and rod loader functions, and all other
functions are OK, the hydraulic components common to just the vises should be
investigated:
• PFC pump PMP2. See "PFC Pump PMP2," page 4-6.

12-18
D20x22 Series II Navigator HDD Service Troubleshooting

Troubleshooting/Testing the Front Vise

Before beginning any troubleshooting or testing procedures, perform the "Pretest
Inspection," page 12-16. If nothing obvious is found, continue.

1. In order to ensure the fault is isolated to just the front vise clamping mode, the
technician should operate all machine functions and observe the actuators as
discussed in "Troubleshooting Machine Performance," page 12-18.
2. If any functions other than the front vise clamp function are faulty, continue
troubleshooting based on the possible results given. If all other machine functions
are operating normally, continue.
NOTE: Refer to the Industrial Dealerships Technician’s Shop Manual (Vermeer P/N
105400V80) for helpful information on testing electrical circuits for shorts, opens, and
high resistance.

3. Note the time it takes to retract and extend the cylinder under warm oil conditions. It
should take approximately three seconds to fully extend and two seconds to fully
retract.
4. Test for acceptable voltage starting at coil L22 of DV31. If voltage is acceptable,
continue below.
5. Test resistance of solenoid coil L22.
Expected result: Resistance should measure 7.2 ohms @ 68°F (20°C). If OK,

Vises
continue below. If not, replace coil.

6. Test for acceptable voltage starting at coil L23 of DV29. If voltage is acceptable,
continue below.
7. Test resistance of solenoid coil L23.
Expected result: Resistance should measure 9.8 ohms @ 68°F (20°C). If OK,
continue below. If not, replace coil.

8. Continue testing for acceptable voltage in the rest of the circuit at pins/terminals of
components and wire harness connector inputs and outputs back to controller. If
voltage is not within specification (10.5 volts minimum), repair or replace faulty
component(s) or wire harness segment(s).
9. Test cylinder CY7 for internal leakage. Refer to the Vermeer Industrial Dealerships
Technician’s Shop Manual (Vermeer P/N 105400V80), for information on testing
and repairing hydraulic cylinders. Repair or replace if necessary. If cylinders test
OK, continue.
10. Remove and inspect cartridge valves DV29 and DV31 in vise valve assembly A13.
Refer to component repair information in this chapter. Repair or replace any faulty
components.

12-19
 Troubleshooting D20x22 Series II Navigator HDD Service

Troubleshooting/Testing the Rear Vise

Before beginning any troubleshooting or testing procedures, perform the "Pretest
Inspection," page 12-16. If nothing obvious is found, continue.

1. In order to ensure the fault is isolated to just the rear vise clamping mode, the
technician should operate all machine functions and observe the actuators as
discussed in "Troubleshooting Machine Performance," page 12-18.
2. If any function other than the rear vise function is faulty, continue troubleshooting
based on the possible results given. If all other machine functions are operating
normally, continue.
NOTE: Refer to the Industrial Dealerships Technician’s Shop Manual (Vermeer P/N
105400V80) for helpful information on testing electrical circuits for shorts, opens, and
high resistance.

3. Note the time it takes to retract and extend the cylinder under warm oil conditions. It
should take approximately three seconds to fully extend and two seconds to fully
retract.
4. Test for acceptable voltage at coil L25 of DV32. If voltage is acceptable, continue
below.
Expected result: 12 volts DC, ± 1.2V.
5. Test resistance of solenoid coil L25.
Vises

Expected result: Resistance should measure 7.2 ohms @ 68°F (20°C). If OK,
continue below. If not, replace coil.
6. Test for acceptable voltage at coil L24 of DV30. If voltage is acceptable, continue
below.
Expected result: 12 volts DC, ± 1.2V.
7. Test resistance of solenoid coil L24.
Expected result: Resistance should measure 9.8 ohms @ 68°F (20°C). If OK,
continue below. If not, replace coil.
8. Continue testing for acceptable voltage in the rest of the circuit at pins/terminals of
components and wire harness connector inputs and outputs back to controller. If
voltage is not within specification (10.5 volts minimum), repair or replace faulty
component(s) or wire harness segment(s).
9. Test cylinder CY8 for internal leakage. Refer to the Vermeer Industrial Dealerships
Technician’s Shop Manual (Vermeer P/N 105400V80), for information on testing
and repairing hydraulic cylinders. Repair or replace if necessary. If cylinders test
OK, continue.
10. Remove and inspect cartridge valves DV30 and DV32 in vise valve assembly A13.
Refer to component repair information in this chapter. Repair or replace if
necessary.

12-20
D20x22 Series II Navigator HDD Service Troubleshooting

Troubleshooting/Testing the Rear Rotation Vise

Before beginning any troubleshooting or testing procedures, perform the "Pretest
Inspection," page 12-16. If nothing obvious is found, continue.

1. In order to ensure the fault is isolated to just the rear vise rotation mode and/or the
auto greaser, the technician should operate all machine functions and observe the
actuators as discussed in "Troubleshooting Machine Performance," page 12-18.
2. If any function (other than the rear vise and auto greaser functions) is faulty,
continue troubleshooting based on the possible results given. If all other machine
functions are operating normally, continue.
NOTE: Refer to the Industrial Dealerships Technician’s Shop Manual (Vermeer P/N
105400V80) for helpful information on testing electrical circuits for shorts, opens, and
high resistance.

3. Note the time it takes to retract and extend the cylinder under warm oil conditions. It
should take approximately one second to fully extend and two seconds to fully
retract.
4. Test for acceptable voltage at coil L26 of DV33. If voltage is acceptable, continue
below.
Expected result: 12 volts DC, ± 1.2V.
5. Test resistance of solenoid coil L26.

Vises
Expected result: Resistance should measure 7.2 ohms @ 68°F (20°C). If OK,
continue below. If not, replace coil.
6. If only the auto greaser function is faulty, test for acceptable voltage at coil L1 of
DV36. If voltage is acceptable, continue below.
Expected result: 12 volts DC, ± 1.2V.
7. Test resistance of solenoid coil L1.
Expected result: Resistance should measure 9.8 ohms @ 68°F (20°C). If OK,
continue below. If not, replace coil.
8. Continue testing for acceptable voltage in the rest of the circuit at pins/terminals of
components and wire harness connector inputs and outputs back to controller. If
voltage is not within specification (10.5 volts minimum), repair or replace faulty
component(s) or wire harness segment(s).
9. If only the rear vise rotation mode is faulty, test cylinder CY9 for internal leakage.
Refer to the Vermeer Industrial Dealerships Technician’s Shop Manual (Vermeer
P/N 105400V80), for information on testing and repairing hydraulic cylinders.
Repair or replace if necessary. If cylinders test OK, continue.
Continued on next page...

12-21
 Troubleshooting D20x22 Series II Navigator HDD Service

10. If only the auto greaser function is faulty, test cylinder CY12 for internal leakage.
Refer to the Vermeer Industrial Dealerships Technician’s Shop Manual (Vermeer
P/N 105400V80), for information on testing and repairing hydraulic cylinders.
Repair or replace if necessary. If cylinders test OK, continue.
11. Remove and inspect cartridge valve DV33 in vise valve assembly A13. Refer to
component repair information in this chapter. Repair or replace if necessary.
12. If only the auto greaser function is faulty, remove and inspect cartridge valve DV36
in auto greaser valve A16. Refer to component repair information in this chapter.
Repair or replace if necessary.

Specifications
Listed below are the electrical and hydraulic specifications for the vise functions.

Electrical:

• Nominal circuit voltage - 12 volts DC

• Vise valve solenoid coils L22,L25 and L26 resistance - 7.2 ohms @ 68°F (20°C)
• Vise valve solenoid coils L23 and L24 resistance - 9.8 ohms @ 68°F (20°C)
Hydraulic:
Vises

• Vise cylinders CY7, CY8 and CY9 maximum pressure - 3000 psi
(207 bar)
• PFC Pump PMP2 normal output flow - variable to 24 gpm (90.8 L/min)
• PFC Pump PMP2 standby pressure compensator valve setting - 250 psi (17.2 bar)
• PFC Pump PMP2 high pressure compensator valve setting - 3300 psi (227.5 bar)
• Vise valve assembly A13 relief valve PV6 (for rotation sequence) pressure setting -
2500 psi (172 bar)

12-22
D20x22 Series II Navigator HDD Service Troubleshooting

Component Repair/Replace
If troubleshooting procedures determine a component is in need of repair or
replacement, refer to the appropriate procedures at the back of the chapter or other
chapters where instructed. After repairs have been made, refer to "Hydraulic Fluid
Sampling," page 4-26 and follow instructions.

WARNING: Pressurized fluid can penetrate body tissue and result in serious injury or
death. Leaks can be invisible. Keep away from any suspected leak. Relieve pressure in the
hydraulic system before searching for leaks, disconnecting hoses, or performing any other
work on the system. If you must pressurize the system to find a suspected leak, use an
object such as a piece of wood or cardboard rather than your hands. When loosening a
fitting where some residual pressure may exist, slowly loosen the fitting until oil begins to
leak. Wait for leaking to stop before disconnecting the fitting. Fluid injected under the skin
must be removed immediately by a surgeon familiar with this type of injury.

Vises

12-23
 Component Repair D20x22 Series II Navigator HDD Service

COMPONENT REPAIR
Vise Valve Assembly A13

2
Vises

Remove 1. Remove cover plate (1) over stakedown valve and vise valve.
2. Label, disconnect, and cap all hydraulic hoses to fittings.
3. Disconnect wire harnesses going to solenoids.
4. Remove fittings.
5. Remove screws (2), washers (3), and nuts (4) holding vise valve (5) to mounting
plate.
6. Lift vise valve (5) from mounting plate.

12-24
D20x22 Series II Navigator HDD Service Component Repair

Directional Valve DV29–DV33 and Relief Valve PV6

Disassembly 1. Remove nuts which secure coils to valve.
2. Remove coils from valve and replace if
necessary.
3. Remove cartridge valves from manifold
and check for damage or contamination.
If necessary, replace.
4. Remove relief valve from manifold and
check for damage or contamination. If
necessary, replace.
Use following torque specifications when
assembling valve.

• All solenoid retaining nuts – 5 ft-lb (6.8 Nm)

• DV29, DV30 – 20 ft-lb (27.1 Nm)
• DV31, DV32, DV33 – 25 ft-lb (33.9 Nm)
• PV6 – 25 ft-lb (33.9 Nm)

Vises

12-25
 Component Repair D20x22 Series II Navigator HDD Service

Vise Cylinders CY7, CY8 and CY9

10 11

10

2
Vises

3
1
2
11
8
4
5

7 6

Remove NOTE: Auto rod greaser is clamped to front vise cylinder CY7. To replace front vise
cylinder, first loosen two bolts clamping greaser assembly to cylinder CY7.

1. Extend rotation cylinder slightly to expose pin that holds vise assembly to cylinder
rod. Remove screw (1), washers (2), and nut (3) at rod end of cylinder. Remove rod
end of cylinder from vise assembly.
2. A pin secures base end of rotation cylinder to rack. Work a screwdriver under edge
of head of pin (5) and pry up. Use a pliers or vise grip to pull cotter pin (7) out.
3. Remove larger pin (5) and collar (6). Remove cylinder.
4. Retract rotation cylinder. Label, disconnect and cap hoses. Remove fittings (8).
Continued on next page...

12-26
D20x22 Series II Navigator HDD Service Component Repair

5. Remove four bolts (9) holding rear vise clamp cylinder (10) to vise assembly. Lift
cylinder from frame.
6. Clean any residue from threads of bolts and holes in frame.
7. Label, disconnect and cap hoses. Remove fittings (11).
8. Remove four bolts (9) holding front vise clamp cylinder (10) to vise assembly. Lift
cylinder from frame.
9. Clean any residue from threads of bolts and holes in frame.
10. Label, disconnect and cap hoses. Remove fittings (11).
For rear vise cylinder CY8, torque fittings to 12.5 ft-lb (17 Nm). For front vise, torque
fittings to 19 ft-lb (26 Nm).

If rebuilding cylinder, refer to parts books for rebuild/repair kit and cylinder repair
procedures found in the Technician’s Shop Manual.

Apply thread sealant grade 277 to threads of four mounting bolts. Install cylinder and
use a crisscross pattern to torque mounting bolts to 570 ft-lb (773 Nm).

Extend rotation cylinder to install on vise jaw.

If needed, reinstall auto rod greaser assembly and tighten clamps.

Vises

12-27
 Component Repair D20x22 Series II Navigator HDD Service

Vise Rotation Cylinder CY9

2
3
7
5

7
7
4
7
7
1

6
Disassembly 1. Remove snap ring (1).
Vises

2. Pull rod assembly out of cylinder body (2). Ensure ports are open and position to
direct oil into a suitable draining pan.
3. Remove nut (3) from rod assembly.
IMPORTANT: Do not clamp onto unpainted portion of rod. Scarring rod can cause
premature seal failure.

4. Slide gland (4) and piston (5) off rod (6).

5. Remove and replace seal kit components (7). Refer to the D20x22 Series II Parts
Manual for seal kit components and locations. Apply a light coat of petroleum jelly
to seals before installing.
6. Slide gland and piston onto rod and tighten nut.
7. Push rod assembly into cylinder body.
8. Slide gland (4) into cylinder body and secure with snap ring (1).
9. Install cylinder.

12-28
D20x22 Series II Navigator HDD Service Component Repair

Front and Rear Vise Clamp Cylinders CY7 and CY8

6 10 1 5
8 9

2 3 4 7
11 12 13

Disassembly and 1. Remove locknut (12) on head gland (10).

Vises
Assembly
2. Pull rod assembly (9) and locking insert (1) out of cylinder body (13). Ensure ports
are open and position to direct oil into a suitable draining pan.
3. Remove nut (3) from rod assembly.
IMPORTANT: Do not clamp onto unpainted portion of rod. Scarring rod can cause
premature seal failure.

4. Slide gland (10), rod wiper (2), and piston (11) off rod.
5. Remove and replace seal kit components (1–8). Refer to the D20x22 Series II Parts
Manual for seal kit components and locations. Apply a light coat of petroleum jelly
to seals before installing.
6. Slide gland and piston onto rod and tighten nut.
7. Push rod assembly into cylinder body.
8. Slide gland (10) into cylinder body and secure with lock nut (12).
9. Install cylinder.

12-29
This page intentionally left blank.
D20x22 Series II HDD Navigator Service Overview

Chapter 13: Rod Greaser

OVERVIEW
This chapter consists of information about circuits and components necessary for
operation of the optional auto rod greaser.

THEORY
Components
The functions covered in this section include the following components:

• Vise Function Components

• Greaser Valve Assembly A16, including:
• Directional Valve DV36
• Solenoid L1

Rod Greaser
• Greaser Cylinder CY12
• Greaser Switch S12

13-1
 Theory D20x22 Series II Navigator HDD Service

Component Locations

AUTO GREASER
CYLINDER CY12

REAR VISE ROTATION

CYLINDER CY9
Rod Greaser

LEFT JOYSTICK A1

VISE VALVE A13

AUTO GREASER VALVE A16

13-2
D20x22 Series II HDD Navigator Service Theory

Hose Connections
Refer to "Hose Connections," page 12-3 in the Vises chapter.

Schematics
For hydraulics schematic, refer to "Hydraulic Schematic," page 12-4. Electrical
schematic is below.

A1 LEFT HANDJOYSTICKHEAD

Rod Greaser

13-3
 Theory D20x22 Series II Navigator HDD Service

Auto Greaser Function – Greasing Mode

GREASER
CYLINDER CY12
FRONT VISE
GREASER CYLINDER CY7
VALVE A16
L20 DV36
FROM L1
DV17
HYDRAULIC
ENABLE
S10 FROM
GREASER S12

L22
DV31
FROM
CONTROLLER
A5
DIVERTER VALVE A9
VISE VALVE A13

Operation To operate auto rod greaser:

Rod Greaser

• There must be grease available in greaser cylinder CY12.

• Seat switch S11 must be closed (operator in seat).
• Remote Lockout system must be in RUN mode.
• Front vise cylinder CY7 must be extended.
• Greaser switch S12, on left joystick, must be pushed and held.
When required operating conditions are met:

• PFC pump PMP2 sends oil to diverter/drilling fluid valve A9.

• Hydraulic enable solenoid L20 in diverter/drilling fluid valve A9 is energized and
shifts DV17, allowing oil to reach vise valve assembly A13.
• When the front and rear vise cylinders CY7 and CY8 have extended fully, the
pressure in the valve manifold increases to 2500 psi and relief valve PV6 shifts
allowing flow to DV33.
• Controller A5 sends a signal to solenoid L22 in vise valve A13 and shifts DV31,
sending oil to the base end of cylinder CY7 and valve A16.
• Switch S12 sends a signal to solenoid L1 in greaser valve A16 and shifts DV36,
sending oil to the base end of cylinder CY12.
• Greaser cylinder CY12 will extend. Grease will be applied to the threads of drill
rod.
NOTE: If the auto greaser function does not operate as expected, see
"Troubleshooting/Testing the Auto Greaser Function," page 13-7.

13-4
D20x22 Series II HDD Navigator Service Troubleshooting

TROUBLESHOOTING
Troubleshooting procedures are given for each operating mode of the different functions
in this chapter. Begin each procedure by performing a pretest inspection of the machine.
See "Pretest Inspection," page 13-5.

Often problems can be solved by doing a walk-around inspection of the machine

looking for obvious problems.

If nothing is found during the pretest inspection, continue by operating all other actuator
functions of the machine to help further isolate problems. See "Troubleshooting
Machine Performance," page 12-18.

Pretest Inspection
Visually check to inspect for obvious signs of failure before any exhaustive
troubleshooting or testing procedures are performed.

Mechanical

Rod Greaser
Inspect mechanical linkages, cables, and connectors from joystick controllers and
control valves for:

• damage, misalignment, or improper adjustment

Electrical

Inspect electrical circuits for clues to malfunction. Always check the following items
before turning on switches or running the machine.

• Look for bare wires that could cause grounds or shorts.

• Look for broken, missing, corroded, or loose connections on the power wires that
supply electrical circuit components.
• Check ground connections on the machine and chassis for tight
connections. Cleaning harness connections or ground connections can often correct
what appears to be a malfunctioning component.
• Check for overheated components after the unit has been stopped for awhile.

Continued on next page...

13-5
 Troubleshooting D20x22 Series II Navigator HDD Service

Hydraulic

WARNING: Pressurized fluid can penetrate body tissue and result in serious injury or
death. Leaks can be invisible. Keep away from any suspected leak. Relieve pressure in the
hydraulic system before searching for leaks, disconnecting hoses, or performing any other
work on the system. If you must pressurize the system to find a suspected leak, use an
object such as a piece of wood or cardboard rather than your hands. When loosening a
fitting where some residual pressure may exist, slowly loosen the fitting until oil begins to
leak. Wait for leaking to stop before disconnecting the fitting. Fluid injected under the skin
must be removed immediately by a surgeon familiar with this type of injury.

Check hydraulic circuits for any failures.

• Look for broken, kinked, loose, or leaking hoses or fittings at hydraulic components.
• Check fluid level in hydraulic tank. Low fluid levels can cause erratic behavior in
hydraulic circuits. Correct level is between the two lines on dipstick. If needed, add
new fluid that has been filtered through a
5-micron filter.

Also review information in the General Information chapter under "Hydraulic

Rod Greaser

Troubleshooting," page 1-12. Correct any problems found during the inspection.
Operate machine to verify the fault is fixed.

13-6
D20x22 Series II HDD Navigator Service Troubleshooting

Troubleshooting/Testing the Auto Greaser Function

Before beginning any troubleshooting or testing procedures, perform the "Pretest
Inspection," page 13-5. If nothing obvious is found, continue.

1. In order to ensure the fault is isolated to just the auto greaser, the technician should
operate all machine functions and observe the actuators.
2. If any functions other than the auto greaser function are faulty, continue
troubleshooting based on the possible results given. If the vise functions are also
faulty, refer to "Troubleshooting Machine Performance," page 12-18. If all other
machine functions are operating normally, continue.
NOTE: Refer to the Vermeer Industrial Dealerships Technician’s Shop Manual
(Vermeer P/N 105400V80), for helpful information on testing electrical circuits for
shorts, opens, and high resistance.

3. Note the time it takes to retract and extend the cylinder under warm oil conditions. It
should take less than a second to fully extend or retract.
4. Test for acceptable voltage starting at solenoid coil L1 of valve DV36. If voltage is
acceptable, continue below.
5. Test resistance of coil L1.

Rod Greaser
Expected result: Resistance should measure 9.8 ohms @ 68°F (20°C). If OK,
continue below. If not, replace coil.

6. Remove and inspect the cartridge valve in greaser valve assembly A16. Repair or
replace any faulty components.

Test Equipment Needed

To perform the troubleshooting procedures in this chapter, the following test equipment
will be needed:

• Multimeter for continuity tests, voltage measurements, resistance

measurements in the various electrical circuits.
• Various hydraulic testing tools

NOTE: Hydraulic component test procedures discussed in this chapter will refer to the
Vermeer Industrial Dealerships Technician’s Shop Manual (Vermeer P/N
105400V80). Test procedures and equipment needed for performing the various test on
hydraulic components will be listed in the manual.

13-7
 Troubleshooting D20x22 Series II Navigator HDD Service

Specifications
Listed below are the electrical and hydraulic specifications for the rod greaser function.

Electrical:

• Nominal circuit voltage - 12 volts DC

• Greaser valve solenoid coil L1 resistance - 9.8 ohms @ 68°F (20°C)
Hydraulic:

• Vise valve A13 relief valve PV6 shift pressure setting - 2500 psi (172.3 bar)
• PFC Pump PMP2 normal output flow - variable to 24 gpm (90.8 L/min)
• PFC Pump PMP2 standby pressure compensator valve setting - 250 psi (17.2 bar)
• PFC Pump PMP2 high pressure compensator valve setting - 3300 psi (227.5 bar)

Component Repair/Replace
If troubleshooting procedures determine a component is in need of repair or
replacement, refer to the appropriate procedures at the back of the chapter or other
Rod Greaser

chapters where instructed. After repairs have been made, refer to and follow
instructions.

WARNING: Pressurized fluid can penetrate body tissue and result in serious injury or
death. Leaks can be invisible. Keep away from any suspected leak. Relieve pressure in the
hydraulic system before searching for leaks, disconnecting hoses, or performing any other
work on the system. If you must pressurize the system to find a suspected leak, use an
object such as a piece of wood or cardboard rather than your hands. When loosening a
fitting where some residual pressure may exist, slowly loosen the fitting until oil begins to
leak. Wait for leaking to stop before disconnecting the fitting. Fluid injected under the skin
must be removed immediately by a surgeon familiar with this type of injury.

13-8
D20x22 Series II HDD Navigator Service Component Repair

COMPONENT REPAIR
Auto Greaser Cylinder CY12

Rod Greaser
Remove NOTE: Auto rod greaser assembly is mounted to a plate that is clamped to front vise
cylinder.

1. Label and disconnect hoses from cylinder (1), and cap open ends of hoses.
2. Remove two bolts holding cylinder (1) to grease bucket top (2).
3. Remove cylinder (1).
4. Note orientation and remove fittings (3) from cylinder.
5. Install fittings in new cylinder. Torque fittings to 9.5 ft-lb (12.9 Nm).
6. Insert end of cylinder ram into sleeve inside grease bucket top.
7. Install bolts mounting cylinder to grease housing. Torque bolts to 35 ft-lb (47 Nm).
8. Connect hoses and torque to 9.5 ft-lb (12.9 Nm).

13-9
 Component Repair D20x22 Series II Navigator HDD Service

5 8

4 6 2
3
7

IMPORTANT: Protect rod assembly when extended to avoid damage to chrome

surfaces.

IMPORTANT: Use aluminum-jawed vise (1) to grip rod assembly without clevis.
Rod Greaser

Cylinder 1. Place cylinder on a clean surface.

Disassembly
2. Clamp cylinder body (1) into a vise. Do not apply excessive clamping force to
cylinder body.
3. Remove gland (2) with spanner wrench.
4. Pull rod assembly from cylinder tube.
5. Remove nut (3).
6. Refer to the D20x22 Series II Parts Manual for seal kit part number which includes
the following items.
• PSP Seal (4)
• O-Ring (5)
• Piston O-Ring (6)
• Backup Ring (7)
• Rod Seal (8)
• Dust Seal (9)

13-10
D20x22 Series II HDD Navigator Service Component Repair

Auto Greaser Valve A16

4
5

3 2

1. Disconnect electrical supply to solenoid (1).

Rod Greaser
2. Remove nuts (2), washers (3), and bolts (4).
3. Remove valve (5).
NOTE: Make note of O-ring and backup washer orientation.

4. Inspect valve and O-rings for damage and ensure no external contaminants are
present.
5. Inspect valve body cavity for burrs or other irregularities which could damage O-
rings during installation.
6. Replace O-rings and backup washers if needed.
7. Dip valve in clean filtered oil.
8. Screw valve in by hand until O-ring contacts valve body. Torque valve to 20 ft-lb
(27.1 Nm). Torque solenoid nut to 5 ft-lb (6.8 Nm).
9. Connect electrical harness to solenoids.

13-11
This page intentionally left blank.
D20x22 Series II Navigator HDD Service Overview

Chapter 14: Drilling Fluid

OVERVIEW
This chapter consists of the functions and components necessary to supply the drill
string with drilling fluid while boring and the wash wand with water for cleanup.

THEORY
Components
The functions covered in this section include the following components:

• Drilling Fluid Pump PMP3

• Drilling Fluid Pump Motor MH10
• Diverter/Drilling Fluid Valve Assembly A9, including:
• Directional Valve DV18
• Solenoid L17

Drilling Fluid
• Relief Valve PV4
• Check Valve CV2
• Fluid Shutoff Control Valve A19, including:
• Directional Valve DV15
• Solenoid L16
• Ball Valve A20
• Ball Valve Cylinder CY6
• Drilling Fluid Pressure Gauge Light E6
• Switches S7 and S14
• Drilling Fluid Motor PPU B3

14-1
 Theory D20x22 Series II Navigator HDD Service

Component Locations

FLUID SHUTOFF CYLINDER CY6

(BENEATH HYDRAULIC TANK)

FLUID SHUTOFF VALVE DV15

Drilling Fluid

FLUID PUMP PMP3

FLUID PUMP MOTOR MH10

LEFT JOYSTICK A1

Continued on next page...

14-2
D20x22 Series II Navigator HDD Service Theory

DIVERTER/FLUID VALVE A9

Drilling Fluid
FLUID PUMP PRESSURE GAUGE E6

SWITCH S7

14-3
 Theory D20x22 Series II Navigator HDD Service

Hose Connections
PFC PUMP DIVERTER/FLUID VALVE A9
PMP2

TORQUE LIMITER
VALVE A7 T PORT

FLUID
PUMP
FLUID SHUTOFF MOTOR
VALVE DV15 MH10

FLUID SHUTOFF
CYLINDER CY6 OIL
COOLER
HE1
Drilling Fluid

HYDRAULIC
TANK RES1

TRANSPORT VALVE A11

14-4
D20x22 Series II Navigator HDD Service Theory

Hydraulic Schematic

FLUID PUMP
PMP3

FLUID SHUTOFF FLUID

CYLINDER CY6
MOTOR MH10

DV18

FLUID SHUTOFF
VALVE DV15

DIVERTER/FLUID VALVE A9

Drilling Fluid
OIL COOLER HE1

RETURN MANIFOLD A17 PFC PUMP PMP2

SUCTION MANIFOLD A15

14-5
 Theory D20x22 Series II Navigator HDD Service

Electrical Schematic

E 7 D IS P L A Y D P 1 0 -A

E 7 D IS P L A Y D P 1 0 -B
A 1 L E F T H A N D J O Y S T IC K H E A D
Drilling Fluid

C 148 C O N TR O LLER

J1 - G R AY

J2- B LA C K

14-6
D20x22 Series II Navigator HDD Service Theory

Drilling Fluid Function – Fluid On Mode

DIVERTER/FLUID VALVE A9
FLUID
PUMP
PMP3
FLUID
SHUTOFF MOTOR
CYLINDER CY6 MH10

FROM
FLUID ON/ L17
OFF S14 DV18

FROM PFC PUMP PMP2

Operation To operate drilling fluid function:

Drilling Fluid
• Seat switch S11 must be closed (operator in seat).
• Remote Lockout system must be in RUN mode.
• Engine must be running.
• Front vise must be open.
• Fluid on/off button S14 must be toggled to ON position.
When required operating conditions are met:

• Switch S14 sends signal to controller A5 via display DP-10.

• PFC pump PMP2 sends oil to diverter/drilling fluid valve A9.
• Controller A5 verifies position of front vise and sends signal to drilling fluid on/off
solenoid L17 in diverter/drilling fluid valve A9. Solenoid is energized and shifts
DV18, allowing oil to reach motor MH10.
• Motor MH10 drives water pump PMP3, pushing drilling fluid to the ball valve and
then to the nozzle.
NOTE: If drilling fluid mode does not operate as expected, see "Troubleshooting/
Testing the Drilling Fluid Function," page 14-14.

14-7
 Theory D20x22 Series II Navigator HDD Service

Drilling Fluid Function – Shutoff Mode

DIVERTER/FLUID VALVE A9
FLUID
PUMP
PMP3
FLUID
SHUTOFF MOTOR
CYLINDER CY6 MH10

FROM L17
FLUID ON/
OFF S14
DV18
FROM SHUTOFF S7

FROM PFC PUMP PMP2

Operation To turn drill fluid OFF, perform one of the following:

Drilling Fluid

• Push bottom of fluid ON/OFF switch S14, or

• Push drilling fluid shutoff switch S7 to closed position.
When required operating conditions are met:

• If switch S14 was pressed, controller A5 sends signal to solenoid L17. DV18 shifts
and flow stops to motor MH10.
• If switch S7 was pressed, switch sends signal to controller A5. Controller A5 sends
signal to solenoid L16 of drilling fluid shutoff valve A19, causing DV15 to shift. Oil
flows to base end of shutoff cylinder CY6. Cylinder extends and closes ball valve
A20.
NOTE: When the front vise is closed, the controller will send a signal to the ball valve
solenoid which will cause the ball valve to close. The controller will also shut down the
drilling fluid pump.

NOTE: If drilling fluid OFF mode does not operate as expected, see
"Troubleshooting/Testing the Drilling Fluid Function," page 14-14.

14-8
D20x22 Series II Navigator HDD Service Troubleshooting

Wash Wand
Operation To operate wash wand:

• Remote Lockout system must be in RUN mode.

• Engine must be running.
• Front vise must be open.
• Fluid system on/off button S14 must be toggled to ON position.
• Seat switch S11 must be open (operator not in seat).
• Wash wand must be connected to machine.
NOTE: Wash wand mode will operate with the same hydraulic and electrical
connections as drilling fluid ON mode. If drilling fluid wash wand mode does not
operate as expected, see "Troubleshooting/Testing the Drilling Fluid Function," page
14-14.

TROUBLESHOOTING
Before performing any troubleshooting procedures, see "Pretest Inspection," page 14-
10.

Drilling Fluid
Often problems can be solved by simply doing a walk-around inspection of the machine
looking for the obvious.

If nothing obvious is found during the inspection, actuate other functions of the machine
to help further isolate faults. See "Testing Machine Performance," page 14-12.

14-9
 Troubleshooting D20x22 Series II Navigator HDD Service

Pretest Inspection
If faults occur, do the following visual checks to inspect for obvious signs of failures
before any exhaustive troubleshooting or testing is performed.

Mechanical

Inspect the mechanical valve control linkages for damage, misalignment, proper
adjustment.

Electrical

Inspect electrical circuits for clues to malfunction. Always check the following items
before turning on switches or running the unit.

• Look for bare wires that could cause grounds or shorts.

• Look for broken, missing, corroded, or loose connections on the power wires that
supply electrical circuit components.
• Check all ground connections on the machine and chassis for tight
connections. Cleaning harness connections or ground connections can often correct
what appears to be a malfunctioning component.
• Check for overheated components after the unit has been stopped for awhile. They
Drilling Fluid

will often smell like burned insulation.

Hydraulic

WARNING: Pressurized fluid can penetrate body tissue and result in serious injury or
death. Leaks can be invisible. Keep away from any suspected leak. Relieve pressure in the
hydraulic system before searching for leaks, disconnecting hoses, or performing any other
work on the system. If you must pressurize the system to find a suspected leak, use an
object such as a piece of wood or cardboard rather than your hands. When loosening a
fitting where some residual pressure may exist, slowly loosen the fitting until oil begins to
leak. Wait for leaking to stop before disconnecting the fitting. Fluid injected under the skin
must be removed immediately by a surgeon familiar with this type of injury.

Check hydraulic circuits for any failures.

• Look for broken, kinked, loose, or leaking hoses and fittings on supply, pressure,
and return to hydraulic components.
Continued on next page...

14-10
D20x22 Series II Navigator HDD Service Troubleshooting

• Check level of hydraulic fluid in hydraulic tank. Low fluid can cause hydraulic
actuators to behave erratically. Correct level is between the two lines on dipstick. If
needed, add new fluid that has been filtered through a 5-micron filter.
Also review information in the General Information chapter under "Hydraulic
Troubleshooting," page 1-12. Correct any problems found during the inspection.
Operate machine to verify any problem has been repaired.

Test Equipment Needed

To perform the troubleshooting procedures in this chapter, the following test equipment
will be needed:

• Multimeter for continuity tests, voltage measurements, resistance

measurements in the various electrical circuits
• Various hydraulic testing tools

NOTE: The hydraulic component test procedures discussed in this chapter will refer
the technician to the Vermeer Industrial Dealerships Technician’s Shop Manual
(Vermeer P/N 105400V80). Test procedures and equipment needed for performing the
various tests on hydraulic components will be listed in the manual.

Drilling Fluid

14-11
 Troubleshooting D20x22 Series II Navigator HDD Service

Testing Machine Performance

Possible faults may occur in the drilling fluid function that are directly related to faults
in other functions. These other faults may not be readily apparent, because those
particular functions are not currently being operated.

Operate the machine functions and document performance of working actuators.

Make note of any functions not operating normally based on the normal operation given
in each chapter for that function. To help isolate a faulty component or function,
compare the notes you have taken to the normal operation given for each mode of a
particular function.

After doing all the machine performance checks, if the fault is isolated to the original
function in question, return to the troubleshooting/testing for that mode. If multiple
functions are affected, proceed with troubleshooting based on the possible results listed
below.

Possible Results 1. If faults are noted when operating all the machine functions, it would indicate a
function or component that is common to all the actuators is malfunctioning. The
following shared functions and components should be investigated:
• Engine. See "Engine," page 3-6.
Drilling Fluid

• Shared hydraulic components. See Chapter 4.

• Remote Lockout. See Chapter 15.
2. If problems are noted in the vises, stakedown, rod loader, auto greaser, and drilling
fluid functions, and all other functions are working properly, the following functions
should be investigated:
• Diverter/fluid valve assembly A9. See "Oil Supply Function," page 4-6.
• PFC Pump PMP2. See "PFC Pump PMP2," page 4-6.
3. If problems are noted in drilling fluid functions, and all other functions of the
machine are working properly, the electrical and hydraulic components common to
just this function should be investigated.

14-12
D20x22 Series II Navigator HDD Service Troubleshooting

Testing Drilling Fluid Performance

1. Conduct machine inspection.
2. Sit in seat.
3. Start engine.
1
4. Ensure Remote Lockout is in RUN mode.
5. Ensure front vise is open.
6. Move fluid switch S14 (1) to ON position.
Observe flow meter on display. Refer to
"Specifications," page 14-24 for
maximum flow rates.

7. While observing fluid shutoff cylinder,

press fluid shutoff switch S7 (2). Fluid
shutoff cylinder will rapidly extend.
8. Close front vise. The fluid shutoff cylinder
should retract.
9. Time the results of cylinder extension and

Drilling Fluid
retraction. It should take approximately
2
one second.
10. Connect wash wand attachment.
11. With fluid switch S14 in ON position, leave seat. Observe wash wand flow.
12. With operator in seat again, press fluid switch S14 to OFF position.

14-13
 Troubleshooting D20x22 Series II Navigator HDD Service

Troubleshooting/Testing the Drilling Fluid Function

Before beginning any troubleshooting or testing procedures, perform the "Pretest
Inspection," page 14-10. If nothing obvious is found, continue.

1. In order to ensure the fault is isolated to just the drilling fluid functions, the
technician should operate all machine functions and observe the actuators as
discussed in "Testing Machine Performance," page 14-12.
2. If any functions other than the drilling fluid function are faulty, continue
troubleshooting based on the possible results given. If all other machine functions
are operating normally, continue.
3. Pressure can vary based on flow rates and nozzle sizes used in the tooling. A
maximum indication of psi (bar) on the drilling fluid pressure gauge could be an
indicator that flow has become restricted (drill head clogged). If maximum pressure
is indicated, continue with step 5.
If there is no or low flow, or flow does not increase when adjusting, it may indicate
a problem in the drilling fluid electrical or hydraulic circuit or the fluid pump itself.
If so, continue with step 6.

WARNING: Relieve drilling fluid pressure in the drill string before cleaning out
Drilling Fluid

nozzles with a tip cleaner. Drilling fluid under pressure can penetrate body tissue
and result in serious injury or death. Fluid injected under the skin must be removed
immediately by a surgeon familiar with this type of injury.

4. Clean drill head nozzle with a tip cleaner.

NOTE: Refer to the Vermeer Industrial Dealerships Technician’s Shop Manual
(Vermeer P/N 105400V80), for helpful information on testing electrical circuits for
shorts, opens, and high resistance.

Continued on next page...

14-14
D20x22 Series II Navigator HDD Service Troubleshooting

5. If an obstruction is suspected at the fluid shutoff cylinder, remove and inspect ball
valve. Refer to component repair section.
6. Test for acceptable voltage at solenoid
coil L16 (1) of fluid shutoff valve
manifold A19. If voltage is acceptable,
continue with step 8. If not, continue
with step 9.
7. Test resistance of solenoid coil L16. 1
Resistance should measure 9.8 ohms @
68°F (20°C). If OK, continue with step
8. If not, replace coil.
8. Test for acceptable voltage at solenoid
coil L17 of DV18 which is located in diverter/drilling fluid valve A9. If voltage is
acceptable, continue with step 9. If not, continue with step 10.
9. Test resistance of solenoid coil L17. Resistance should measure 8.8 ohms @ 68°F
(20°C). If OK, continue. If not, replace coil.
10. Continue testing for acceptable voltage in the rest of the circuit at pins/terminals of
components and wire harness connector INPUTS and OUTPUTS. If voltage is not
within specification (10.5 volts minimum), repair or replace faulty component(s) or
wire harness segment(s). If everything is OK, continue.

Drilling Fluid
11. Test hydraulic circuit starting with the pump motor MH10 for excessive internal
leakage. Refer to the Vermeer Industrial Dealerships Technician’s Shop Manual
(Vermeer P/N 105400V80), for information on testing hydraulic motors. If motor
tests OK, continue.
12. Remove and inspect cartridge valve in fluid shutoff valve assembly A19. Repair or
replace any faulty components. If valve assembly is OK, continue.
13. Remove and inspect the cartridge valve in diverter/drilling fluid valve assembly A9.
Repair or replace any faulty components. If valve assembly is OK, continue.
14. If the fluid shutoff valve is suspected, remove and test cylinder CY6. Refer to the
Vermeer Industrial Dealerships Technician’s Shop Manual (Vermeer P/N
105400V80), for information on testing cylinders.
15. Test pump PMP3 for excessive internal leakage. Refer to the Vermeer Industrial
Dealerships Technician’s Shop Manual (Vermeer P/N 105400V80), for
information on testing hydraulic pumps. If pump tests OK, continue.
16. Disassemble and inspect drilling fluid pump PMP3 for damage or contamination.
Refer to "Fluid Pump PMP3," page 14-32 for information. Repair or replace if
necessary.

14-15
 Troubleshooting D20x22 Series II Navigator HDD Service

Check Controllers First

The controller A5 has LEDs on the faceplate that assist in troubleshooting.

View the controller faceplates and LEDs, see "Key to LEDs," page 2-17. The LEDs
indicate the control is sending an output or an input. The fluid function-specific LEDs
will be illuminated when the controller is sending an output signal or receiving an input
signal.
Drilling Fluid

14-16
D20x22 Series II Navigator HDD Service Troubleshooting

Ball Valve Not Turning On/Off

1. With ignition switch S2 turned ON,
observe LED on controller A5 while 1
repeatedly pressing and releasing fluid on/
off switch S14 (1) on the left joystick.
Expected result: Fluid LED will turn on
and off. Pressing and releasing the button
once turns it on, pressing it again turns it
off.

If so, continue below.

If not, look at the fault display. 520310-5 indicates a problem with the solenoids L16
or L17 or the wiring leading to and from these solenoids. If there is no fault code,
troubleshoot the switch. See "Troubleshooting the Fluid On/Off Switch," page
14-24.

2. Disconnect solenoid L16. Measure voltage to the solenoid L16 when the LED on
controller A5 is glowing.
Expected result: 12 volts DC, ± 1.2 vDC. If so, continue below.

Drilling Fluid
If not, test continuity from solenoid to controller and from solenoid to ground. If
open, repair or replace faulty segment.

3. Measure resistance across solenoid terminals.

Expected result: 9.8 Ω, ± 1.0 Ω. If so, continue below. If not, replace solenoid.
Refer to "Fluid Shutoff Valve Assembly A19," page 14-26.

4. With the machine turned on, open and close the front vise. Watch cylinder CY6.
Expected result: The cylinder will smoothly retract when front vise is closed. If so,
the valve and controller appears to be working and the lines to and from the cylinder
are not clogged. If the cylinder does not retract at all, continue below.

5. Disconnect rod of the cylinder CY6 from the ball valve. Attempt to rotate the ball
valve by hand.
Expected result: The valve turns on and off. If so, continue below. If not, replace
ball valve.

Continued on next page...

14-17
 Troubleshooting D20x22 Series II Navigator HDD Service

6. With the ball valve still disconnected from the cylinder, start machine and watch
cylinder CY6 as you turn fluid switch S14 ON and OFF.
Expected result: The cylinder will smoothly extend when fluid is turned on, and
smoothly retract when fluid is turned off. If so, the valve appears to be working and
the lines to and from the cylinder are not clogged. Since the cylinder would not
overcome the resistance of the ball valve, assume the piston seals are allowing oil
past the piston. Replace cylinder seals, see general cylinder rebuild guidelines in the
Technician’s Shop Manual P/N 105400V80.

If the cylinder extends or retracts erratically, or extends but will not retract, remove
and repair cylinder CY6. See general cylinder rebuild guidelines in the
Technician’s Shop Manual P/N 105400V80.

If the cylinder does not extend at all, or does not retract at all, continue below.

7. Shut down machine, disconnect hoses to the cylinder CY6, and connect them
reversed. Restart machine and watch the cylinder. Also watch Fluid On indicator on
the console so you can tell when switch is turned on and off.
Expected result: The fluid is OFF at start-up, so if the cylinder was retracted, it will
extend at start-up. If so, the lines to and from the cylinder do not appear to be
clogged. Turn fluid switch ON. If cylinder does not retract, replace valve DV15.
Drilling Fluid

If the cylinder was retracted and did not extend, shut down and remove and inspect
all lines to and from the valve DV15 and the cylinder CY6 for obstructions. Replace
lines if needed.

If the cylinder was extended at start-up, turn the fluid switch ON, then OFF again a
few seconds later. If cylinder CY6 retracts then extends again, valve DV15 appears
to be working and lines to and from the cylinder do not appear to be obstructed. If it
does not retract when turned ON, shut down the machine, and remove and inspect
lines to and from the cylinder and valve for obstructions. If none are found, replace
the valve DV15.

14-18
D20x22 Series II Navigator HDD Service Troubleshooting

Fluid Pump Motor Does Not Turn at Regulated Speed

Check the obvious things first, such as:

• Ensure front vise is not clamped. Do this

by pressing switch S21 (1) on the right 1
joystick.
• Ensure Remote Lockout system is in
RUN mode.
• Observe ball valve cylinder CY6 as fluid
is turned on to ensure ball valve is being
opened. If not, troubleshoot that circuit.
See
"Ball Valve Not Turning On/Off," page
14-17.
• If fluid is mixed with additives to create drilling mud, there may be a clog in the
fluid line at the ball valve between the ball valve and the outlet at the gearbox. Also,
if antifreeze is not used during cold weather, fluid in the line can freeze. The
blockage may cause resistance in excess of the pressure relief setting of PV4 (1365
psi or 94 bar). Disconnect fluid line at the inlet side ball valve and try pumping fluid
again. If it flows, clean out the fluid line on the outlet side of the ball valve.

Drilling Fluid
After checking those things, continue below.

1. Start machine, run engine at 2400 rpm

and watch pressure gauge (1) as you turn
on the fluid using switch S14. Indicator 1
on display will glow when fluid is turned
ON.
Expected result: After start-up, the
indicated pressure will indicate standby
setting of the compensator on the pump
PMP3, about 250 psi (17 bar). When the
switch S14 is turned ON, the pressure will dip, then rise as the pump comes on
stroke.

If the pressure reaches 1365 psi, ± 50 psi (94 bar, ± 3.5 bar) and stays there, pump
flow is going over the relief valve PV4, probably due to resistance in the fluid
pump. Clean or rebuild fluid pump PMP3.

If the pressure rises to some value below 1365 psi (94 bar) and stays there, flow is
going over relief, but the relief is opening too soon. Replace relief valve PV4.

If the pressure remains at its original setting, the valve DV15 is not shifting or has
failed in the closed position. Continue with next step.

Continued on next page...

14-19
 Troubleshooting D20x22 Series II Navigator HDD Service

2. With the fluid turned ON, press and hold S14 to turn on FULL FLOW. Observe
pressure gauge and output from the fluid pump.
Expected result: Fluid pump PMP3 will turn at full speed and produce full flow. If
so, the PFC pump PMP2 is working normally. Continue at the next step.

If not, check fault display on the engine bay controller. If it shows

520310-5, troubleshoot solenoid L17 for the full flow circuit. See page "Full Flow
Switch Does Not Increase Speed of Fluid Pump," page 14-21.

If there is no fault code, check the pressure gauge. If it reads 1365 psi, ± 50 psi (94
bar, ± 3.5 bar), clean or rebuild fluid pump PMP3. If it indicates less than 1365 psi
(94 bar), the PFC pump PMP2 may be worn beyond requirements.

3. Shut down machine, then turn keyswitch S2 to ON. Observe the LED on the
controller A5 while repeatedly pressing and releasing the fluid on/off switch (1) on
the left joystick.
Expected result: LED will turn on and off. Pressing and releasing the button once
turns it ON, pressing it again turns it OFF.

If so, switch S14 is good, and the wiring to the controllers is good. Continue below.
Drilling Fluid

If not, troubleshoot switch S14. See "Troubleshooting the Fluid On/Off Switch,"
page 14-24.

4. Disconnect solenoid L17. Measure voltage to the solenoid L16 when the LED on
controller A5 is glowing.
Expected result: 12 volts DC, ± 1.2 vDC. If so, wiring from the controller to the
solenoid L17 and from L17 to ground is good. Continue below.

If not, test continuity from the controller to the solenoid, and from the solenoid to
ground. If open, repair or replace the faulty segment.

5. Measure resistance from across the solenoid terminals.

Expected result: 9.8 Ω, ± 1.0 Ω. If so, solenoid is apparently good. Continue below.
If not, replace solenoid L17.

6. Label or mark solenoid L17. Remove retaining nut on DV18 and slide solenoid L17
off the valve.

14-20
D20x22 Series II Navigator HDD Service Troubleshooting

Full Flow Switch Does Not Increase Speed of Fluid Pump

If regulated fluid flow also does not work, troubleshoot it first—see
"Fluid Pump Motor Does Not Turn at Regulated Speed," page 14-19. If regulated
fluid flow is working, continue below.

1. Press S14 once to turn on the regulated fluid flow. The fluid flow indicator on the
control console will glow when regulated flow is turned on. Watch the LED on
controller A5 while pressing and holding S14.
Expected result: The LED will glow. If so, continue below.

If not, troubleshoot the Fluid On/Off switch S14. See "Troubleshooting the Fluid
On/Off Switch," page 14-24.

2. Disconnect solenoid L16. Measure voltage to the solenoid L16 when the LED on
controller A5 is glowing.
Expected result: 12 volts DC, ± 1.2 vDC. If so, wiring from the controller to the
solenoid L12 and from L12 to ground is good. Continue below.

If not, test continuity from pin J1-6 of the controller to solenoid connector and from
solenoid connector to ground. If open, repair or replace the faulty segment.

Drilling Fluid
3. Measure resistance across the solenoid terminals.
Expected result: 9.8 Ω ± 1.0 Ω. If so, solenoid is apparently good. Continue below.
If not, replace the solenoid L16. See "Fluid Shutoff Valve Assembly A19," page
14-26.

4. Label or mark solenoid L16. Remove the retaining nut on DV31 and slide solenoid
L16 off the valve.
5. If not, perform a flow test for the fluid pump.

If the pump is worn beyond limits, replace pump (see "Drilling Fluid Pump PMP3
and Motor MH10," page 14-31).

If the pump appears to be in good condition, the fluid pump drive motor may need to
be replaced. Test motor MH10 that is driving the fluid pump. See test procedure on
the following page.

14-21
 Troubleshooting D20x22 Series II Navigator HDD Service

Fluid Pump Motor Will Not Reach Full Speed

Lack of speed indicates the motor is not receiving enough flow, or the internal leakage
inside the motor is great enough that a high percentage of flow is moving from the
pressure side to the return side of the motor without performing work.

One reason why flow to the motor may be insufficient is that pressure relief valve PV4
in diverter/fluid valve A9 is opening at a lower setting. Install pressure gauge at port P
on manifold A9. If pressure indicated on gauge indicates 1365 psi, ± 50 psi (94 bar, ±
3.5 bar) while pumping fluid at full flow (or regulated flow), examine the fluid pump
PMP3 to determine why it is producing so much resistance. If the indicated pressure on
PV4 is comfortably below 1365 psi (94 bar), continue with the flow test.

Flow Test of Motor 1. Attach a 15 gpm flow meter to the outlet of motor MH10. Ensure flow arrow on the
MH10 meter points away from the motor and towards the hose connected to the tank RES1.

from A12
MH9

flow meter
Drilling Fluid

RES1
motor
tank

NOTE: Some flow meters are equipped with flow control valves and pressure gauges
used to induce a load when testing pumps. If your flow meter has this valve, ensure it is
fully open.

2. Start machine, and run engine at 2400 rpm. Record engine RPM on the worksheet.
3. Press fluid flow switch S14 once to turn on the fluid flow. Press and hold it to turn
on full flow. Observe fluid flow on the display and note the flow indicated. Record it
on the worksheet next to “Fluid flow indicated on Display.”
4. While still pumping fluid at full flow, note the flow on the flow meter from MH10 to
tank. Record it on the worksheet next to “Hydraulic flow indicated on display.”
5. Shut down machine.
6. Complete the calculations described on the following worksheet. A simple pocket
calculator will be useful.

14-22
D20x22 Series II Navigator HDD Service Troubleshooting

Worksheet for Flow A. Fluid flow indicated on display_______________gpm

Test of Motor MH10
B. Hydraulic flow indicated on display____________gpm

C. Multiply the amount in item B by 231. This is the flow in cubic inches per minute.
Record it here. ______________in3/min

D. Take the value of item C and divide it by 6.2. This is the theoretical speed of the
output shaft of motor MH10. Record it here. __________rpm (theoretical)

E. Since this is a geroler motor, when new it is expected to have 80% volumetric
efficiency. Multiply item D by 0.80 and record it here. __________rpm (new)

F. A motor is considered worn out when its efficiency has deteriorated to 70% of its
theoretical value. Multiply item D by 0.70 and record it here. __________rpm (worn)

G. Since the fluid pump produces approximately 0.036 gallons of fluid flow for every
revolution, the fluid flow meter divides the RPM recorded by the pulse pickup B3 by
0.036 to compute the flow displayed. Multiply item A by 0.036 for the actual motor
output shaft speed. Record it here. ___________rpm (actual)

Interpreting the Compare the value of item G (actual RPM) with the values in item E and item F (new
Results and worn rpm). If the actual RPM falls between these two values, the motor wear

Drilling Fluid
appears to be within limits. Search for another cause for slow fluid pump speed.

If the actual speed (item G) is at or below the worn speed (item F), replace the motor
MH10. See "Drilling Fluid Motor MH10," page 14-39.

14-23
 Troubleshooting D20x22 Series II Navigator HDD Service

Troubleshooting the Fluid On/Off Switch

1. Watch LED J1-5 on the faceplate of controller A5 while repeatedly pressing the
fluid switch S14.
Expected result: Starting with the LED dark, pressing and releasing the switch once
will turn fluid ON (LED glowing), pressing and releasing it again will turn the fluid
OFF (LED dark). When the fluid is ON, pressing and holding switch S14 turns on
full flow until switch is released.

If so, switch S14 and wiring to and from the switch is working normally.

If not, continue below.

2. Disconnect left joystick at connector.

3. With the keyswitch S2 turned ON, test voltage at wire 112-OR from fuse F3 to
switch S14.
Expected result: 12 volts DC, ± 1.2 vDC. If so, replace joystick.

4. If not test continuity from fuse to switch and from switch to controller. Repair or
replace the faulty segment.
Drilling Fluid

Specifications
Listed below are the electrical and hydraulic specifications for the components in this
chapter.

Electrical:

• Nominal circuit voltage - 12 volts DC

• Ball valve control solenoid coil L16 - 9.8 ohms @ 68°F (20°C)
• Diverter/drill valve assembly A9 solenoid coil L17 resistance - 7.2 ohms @ 68°F
(20°C).
Hydraulic:

• Drilling fluid pump PMP3 rotation speed at full flow - 400 rpm.
• Drilling fluid motor MH10 displacement - 6.2 cid (102 cc)
• Drilling fluid motor MH10 maximum speed - 550 rpm
• Drilling fluid motor MH10 maximum torque (continuous) - 1936 ft-lb (219 Nm)
• Drilling fluid motor MH10 maximum pressure (continuous) - 2250 psi (155 bar)
Continued on next page...

14-24
D20x22 Series II Navigator HDD Service Troubleshooting

• Drilling fluid shutoff cylinder CY6 maximum pressure - 3300 psi (227.5 bar)
• PFC pump PMP2 normal output flow - variable to 24 gpm (90.8 L/min)
• PFC pump PMP2 standby pressure compensator valve setting - 250 psi (17.2 bar)
• PFC pump PMP2 high pressure compensator valve setting - 3300 psi (227.5 bar)
• Diverter/drill valve assembly A9 relief valve PV4 pressure setting - 1365 psi (94
bar).
• System pressure - 1600 psi (110 bar)

Component Repair/Replace
If troubleshooting procedures determine a component is in need of repair or
replacement, refer to the appropriate procedures at the back of the chapter or other
chapters where instructed. After repairs have been made, refer to "Hydraulic Fluid
Sampling," page 4-26 and follow instructions.

WARNING: Pressurized fluid can penetrate body tissue and result in serious injury or
death. Leaks can be invisible. Keep away from any suspected leak. Relieve pressure in the

Drilling Fluid
hydraulic system before searching for leaks, disconnecting hoses, or performing any other
work on the system. If you must pressurize the system to find a suspected leak, use an
object such as a piece of wood or cardboard rather than your hands. When loosening a
fitting where some residual pressure may exist, slowly loosen the fitting until oil begins to
leak. Wait for leaking to stop before disconnecting the fitting. Fluid injected under the skin
must be removed immediately by a surgeon familiar with this type of injury.

14-25
 Component Repair D20x22 Series II Navigator HDD Service

COMPONENT REPAIR
Fluid Shutoff Valve Assembly A19
Remove 1. Label, disconnect and cap all hoses and fittings.
1
2. Disconnect electrical wiring harnesses from coil.
3. Remove bolts, washers, and nuts holding valve to 2
mounting plate on hydraulic tank.

Disassembly

1
Drilling Fluid

2 3

1. Remove nut (1) solenoid coil (2) and cartridge valve (3).
2. Inspect O-rings and replace if necessary.
3. Inspect seals and valve components (1) for contamination or wear. Clean valve
body.
NOTE: Before installing components, apply a light coat of petroleum jelly to O-rings.

Install O-rings with cartridge valves (2). Torque cartridge valves to 20 ft-lb (27.1 Nm).
Torque nut on coils to 5 ft-lb (6.8 Nm).

When installing control valve, reverse removal procedures. Torque mounting bolts to 10
ft-lb (13 Nm).

14-26
D20x22 Series II Navigator HDD Service Component Repair

Drilling Fluid Shutoff Cylinder CY6 and Ball Valve A20

4
3
5
2
3

7
6

NOTE: Ball valve and cylinder are located on a mounting bracket beneath hydraulic
tank.

Drilling Fluid
Remove 1. Label, disconnect and cap hoses and fittings (1).
2. Remove bolt (2), washers (3), and nut (4) holding rod end of cylinder to lever arm
(5).
3. Remove nut (6) and washer (7) holding base end of cylinder to pin.
4. Remove nuts on studs holding ball valve to mounting flange.
Reverse steps to install. Torque mounting nut (6) to 90 ft-lb (120 Nm). Torque nuts on
ball valve studs to 30 in-lb (3.3 Nm).

14-27
 Component Repair D20x22 Series II Navigator HDD Service

Cylinder
Disassembly

4 5 2
3 1

7
6 8

1. Remove head snap ring (1).

2. Pull rod assembly (2) out of barrel assembly (3).
3. Remove lock nut (4) from rod.
IMPORTANT: Do not clamp onto unpainted portion of rod. Scarring rod can cause
premature seal failure.

4. Remove piston (5) from rod.

Drilling Fluid

5. Remove seals (6) from piston.

6. Slide gland (7) off rod and remove seals (8).
7. Refer to D20x22 Series II Parts Manual for seal kit components. Apply a light coat
of petroleum jelly to seals before installation.
Reverse steps for assembly.

14-28
D20x22 Series II Navigator HDD Service Component Repair

Ball Valve
Disassembly

16

14

13
15

7 8 12
6 11
5
4
1
2 10
4 9
1

14

Drilling Fluid
16
13

15
17

3
IMPORTANT: Drain the system and cycle the valve open and closed once to relieve
trapped pressure. Leave valve in the open position. During disassembly, do not scratch
internal bore surfaces.

1. Remove nuts (3) on one end of each stud (17).

Note the position of
handle before
disassembly. Also, ball
must be rotated to the
closed position to
remove it.
Continued on next page...
2. Loosen four body studs, but remove only three studs (17). Swing out body center
(9), using a stud as a pivot. Remove support rings (13) and ball (12), saving them for
assembly. Remove and discard O-rings (15) and seat sub-assemblies (14).
3. Remove stem nut (1) and stem spring (4) holding lever arm on center valve body
(9). Discard spring.
4. Remove grounding spring (2), nut (1), stem spring (4), and gland (5). Discard
springs, gland and stem bearings.
5. Remove packing support (6). Carefully pry top and bottom packings (7) and (8) out
of bore. Discard packing support and packings.

14-29
 Component Repair D20x22 Series II Navigator HDD Service

6. Remove stem (11) and stem bearing (10).

7. Inspect valve body and all parts for contamination and damage.

Ball Valve Assembly 1. Thoroughly clean body center (9), stem (11) and sealing surfaces on flanges (16).
Also, clean support rings (13).
IMPORTANT: If lubricant is used on the stem shank, stem bearings, and top and
bottom packings, it must be a silicone or Teflon-based lubricant. Do not use a petroleum
base lubricant. Also, do not apply lubricant to stem threads.

2. Slide new stem bearings (10) on stem and install stem. Insert ball (12) in body
center until stem tang is engaged, rotating stem to open position. Ball is now secure.
Keep the packings and 3. Push new bottom and top packings (8) and (7), followed by new packing support
packing support straight (6), into packing bore.
during installation.
4. Place new gland (5) and two new springs (4) (convex sides facing each other) on
stem.
5. Thread nut (1) on stem; hold stem with handle; and torque nut to 100 in-lb (11.3
Nm).
Drilling Fluid

During assembly, the 6. Install handle, new spring (4) (convex side facing handle) and nut (1). Torque nut to
handle must be 100 in-lb (11.3 Nm).
positioned as it was
before disassembly to IMPORTANT: Lubricate new O-rings (15) and new seat subassemblies (14), using a
indicate the proper silicone or Teflon-based lubricant. Do not use a petroleum base lubricant.
direction of valve flow.
7. Place support rings (13) (chamfered sides toward ball), seat subassemblies (metal
springs away from ball) and O-rings in body center (9).
8. Swing body center back into position. Install body
studs (17) and nuts. With valve in fully open position, 4 1
torque studs in five stages, using illustrated numerical,
crisscross sequence. Torque values for each stage are
as follows: 25 in-lb (2.8 Nm), 50 in-lb (5.7 Nm), 100
in-lb (11.3 Nm), 180 in-lb (20.3 Nm) and 180 in-lb
(20.3 Nm).

2 3

14-30
D20x22 Series II Navigator HDD Service Component Repair

Drilling Fluid Pump PMP3 and Motor MH10

Drilling Fluid
5
8
6 7
2

Remove 1. Clean motor and drilling fluid pump area.

2. Label, disconnect and cap all hoses.
3. Remove bolts, washers and nuts holding pump (1) and motor (2) to machine.
4. Hoist pump and motor off mounting plate.
5. Remove fittings (3–5).
6. Remove bolts (6), washers (7), and nuts (8) holding motor (2) to
pump (1).
To install pump and motor, reverse steps above. Torque mounting bolts to
90 ft-lb (120 Nm).

14-31
 Component Repair D20x22 Series II Navigator HDD Service

Fluid Pump PMP3

Replacing Suction 1. To access suction and discharge valves, valve
and Discharge cover clamps must be removed from each side of
Valves fluid chamber. Remove cap screw and valve
cover clamp from each side of fluid chamber.
2. Insert end of a standard screwdriver into valve
cover groove and pry each of four valve covers
away from fluid chamber and remove.
3. Remove discharge valve disc-spring assembly
and perforated valve cage from each of four pump
cylinders.
4. Use a finger to reach through opening at center of
seat and work seat loose from chamber. Note,
optional valve seat removal tool (FMC part
number 1250638) may be used to simplify this
procedure. Insert round end of tool into seat and
rock from side to side to loosen seat, then use
other end of tool to hook under valve seat and
remove.
Drilling Fluid

5. Use same procedure to remove suction valve cage

and valve seat, which are located directly under
discharge valve seat. Turning valve seat on edge
will help it go through discharge valve seating
area easier. Repeat for remaining three pump
cylinders.
6. Inspect all valve components and replace as
necessary. Note that even small damage or
erosion to sealing area of valve or O-ring can
adversely affect performance of pump.
7. With O-ring in place on each valve seat, place a
few drops of light oil around O-ring to aid in
installation. Place each valve seat SQUARELY in
counterbore in bottom of fluid chamber. Turn
valve seat on edge to help pass through narrow
areas of pump. Use round end of FMC
Technologies valve tool to aid in installation of
valve seats.

Continued on next page...

14-32
D20x22 Series II Navigator HDD Service Component Repair

8. Place valve cage on valve seat and insert disc/spring assembly inside of cage on
valve seat. Note that bottom of valve disk should be installed facing top of valve
seat.
9. Repeat previous two steps to install discharge valve seat and discharge valve cage.
10. Place valve covers (with O-rings on BOTTOM groove) in place over valve
assembly.
11. Replace valve cover clamp and cap screw and tighten to 35 ft-lb (47 Nm). Note:
Overtightening cap screw can damage valve components.

Drilling Fluid

14-33
 Component Repair D20x22 Series II Navigator HDD Service

Replacing Piston 1. Fluid chamber must be removed to provide access

Cup Seals to piston cups. To remove fluid chamber, first
remove four hex bolts holding it to power frame,
then lift it off top of ceramic cylinders.
2. Each piston cup is held in place with a cap screw
and piston retainer. Remove cap screw and piston
retainer from each of four cylinders.
3. Lift each ceramic cylinder off from top of power
frame. Friction will usually keep piston inside
cylinder as it is removed. Once cylinder and
pistons are removed for each of four cylinders,
take them to a bench and push them out of
cylinder.

4. Inspect all O-rings, gaskets, seals, and other

Drilling Fluid

components for signs of damage or wear. Any

damaged components should be replaced at this
time. Inspect cylinder liners for cracks or grooves
by running thumbnail around bore of cylinder and
replace if any wear or damage is detected. New
cups will wear quickly if operated in cylinders
with rough or grooved bores.
NOTE: To provide maximum operational time
between service, it is recommended that all four
piston cups, not just one that shows signs of leakage,
be replaced whenever piston service is required.

5. Plastic umbrella shields keep any fluid that leaks

past piston cups from entering power frame and
contaminating oil reservoir. Insure that umbrella
fluid shield is not damaged. If umbrella requires
replacement, best way to remove it from pump is
to cut it free with a sharp knife.

Continued on next page...

14-34
D20x22 Series II Navigator HDD Service Component Repair

6. To install new umbrella shields, fold plastic as shown and insert through opening
and over ends of plunger rod. For easier installation of umbrella, immerse in hot
water for 2-3 minutes to soften. Press tops of umbrellas to place pilot washers over
ends of plunger rods with groove in up position.
7. To rebuild, first place O-rings and packing holders in position on ends of plunger
rod.
8. Place gasket and ceramic cylinder in counterbore of power frame.
9. Apply light oil or glycerin around the OD of piston cups, then place them in open
(top) end of cylinders. Use thumb to press cups down firmly into holder of each
cylinder.
10. Insert cup retainers into cylinders with ribbed side facing piston cup.
11. Secure piston assembly using cap screws. Torque to 10 ft-lb (13 Nm).
12. Insert top gasket in fluid chamber counterbore using heavy oil or grease to hold in
place.
13. Return fluid chamber to position over cylinders and insure that all seals are in place.
Use a slight twisting motion on the fluid end to insure all cylinders are fully seated
in fluid end counterbores.
14. Replace fluid end cap screws. Torque cap screws in 3 stages to 55 ft-lb (74.5 Nm).

Drilling Fluid

14-35
 Component Repair D20x22 Series II Navigator HDD Service

Replacing Power 1. Remove bottom drain pipe plug and drain all oil
End Bearings from power frame.
2. Disconnect suction and discharge piping, power
source, and remove pump from mounting base.
3. Although it is not required, it is easier to remove
crankshaft if fluid end and pistons have been
removed. To remove fluid end, follow steps 1–3
of section titled "Replacing Piston Cup Seals,"
page 14-34.
4. Remove 12 hex head cap screws, washers, and
mounting base from rear of pump. After
mounting base is removed, rear cover gasket can
be removed.
5. Remove cap screws from connecting rod
assemblies and take out back half of four
connecting rods. Note orientation of machine
markings on connecting rod and cap. Connecting
rod halves are not interchangeable and must be
reassembled in their original orientation and in
same cylinder.
Drilling Fluid

6. Remove oil slinger from crankshaft.

7. Push connecting rods and crosshead assemblies as far forward into power frame as
possible to provide clearance for crankshaft.
Continued on next page...

14-36
D20x22 Series II Navigator HDD Service Component Repair

8. Use snap ring pliers to remove four crankshaft

retainer snap rings from each side of pump.
9. Using a hammer and wood block (or rubber
mallet on end of crankshaft), drive each
crankshaft until one bearing on each shaft clears
power frame. Drive from gear side of shafts.
10. Remove exposed bearings from the crankshaft
using a press. Be sure to provide suitable support
for the back side of the bearings during this step.
Note: Never pound directly on the bearings or
they may be damaged. Crankshafts with single
bearing on each end may now be removed
through bottom of power frame.
11. Carefully clean and inspect all parts. Replace
worn or damaged components as necessary.
12. Place a single bearing on the gear side of each
crankshaft and install in pump. Once the
crankshaft has been placed in the proper position
in the power frame the remaining bearings can be
installed on the opposite end of the shaft.

Drilling Fluid
13. Insure that timing marks on gears are aligned as
shown for proper piston motion. Arrow (or dot)
on one gear must be centered between two arrows
(or dots) on other gear. Note area highlighted by
circle in photo to right.
14. Place oil seals over the ends of the crankshaft
with the lip of the seals facing the inside of the
power frame.
15. Seat snap rings in the grooves in the bearing
housing against the oil seals and tap the
crankshaft to allow a SLIGHT endplay in the
crankshaft.
16. Reassemble connecting rods and shell bearings
around the crankshaft. The connecting rod and
cap are a matched set. Be sure to properly match
the connecting rods and caps back into their
original position, orientation, and cylinder.
Torque connecting rod bolts to 7 ft-lb (9.4 Nm).
Continued on next page...

14-37
 Component Repair D20x22 Series II Navigator HDD Service

17. Complete reassembly by reversing steps 1–8. Torque mounting base cap screws to
15 ft-lb (20.3 Nm). Be sure to replace the drain plug in the mounting base.
18. Refill power frame with oil and turn the shaft over several revolutions by hand.
When piston cups are not installed the pump shaft should rotate freely.

Servicing Wrist Pin 1. Remove fluid chamber, cylinders, and piston cups
Bearings using steps 1–3 from the Replacing Piston Cup
Seals section, and the crankshaft as described in
steps 1–10 of "Replacing Power End
Bearings," page 14-36.
2. Once the crankshaft has been removed the
connecting rod and crosshead assembly can be
pulled from the back of the power frame opening.
3. The wrist pin is a slip fit through the connecting
rod and crosshead. Check for signs of wear on the
pin and connecting rod bushing. Replace pin if
noticeable wear is found. The complete
connecting rod assembly must be replaced if the
Drilling Fluid

bushing is worn, as the wrist pin bushing is not

field replaceable.
4. Reverse the sequence from steps 1–3 when
reassembling the crosshead rod and cap. Insure
that these parts are reassembled in their exact former orientation and position.

14-38
D20x22 Series II Navigator HDD Service Component Repair

Drilling Fluid Motor MH10

1
4 3
5
6
7
8
2

10

17
15

16
13
15
13
14

Drilling Fluid
13

12
11

Disassembly
Continued on next page...
1. Follow steps to remove motor in "Drilling Fluid Pump PMP3 and Motor MH10,"
page 14-31.
2. Disconnect, label, and plug hydraulic hoses.
3. Remove motor mounting bolts, motor, and key (1).
4. Clamp motor in vise so output shaft (2) is vertical, and end cap (16) is on top. Clamp
on the mounting flange using just enough clamping force to hold the motor securely.
Protect mounting flange with soft vise jaws.

14-39
 Component Repair D20x22 Series II Navigator HDD Service

17

16
13
15
13
14
13
11

5. Remove seven cap screws (17) from end cap and disassemble motor parts, as shown
above. Do not disassemble geroler (15).
6. Unclamp motor and remove output shaft
(2), thrust needle bearing (3), and thrust
bearing race (4).
Drilling Fluid

7. Clamp motor in a vise so mounting

flange is on top. Clamp across port area.
Do not clamp on motor housing. Use just
2
enough clamping force to hold motor
securely. 3
4
8. Remove four cap screws (10) that hold
11
mounting flange (8) to motor housing
(11).
NOTE: Thread sealant is applied to these screws when assembled at factory. Do not
exceed 500 in-lb (56 Nm) of removal torque.

NOTE: If thread sealant is holding screws too tightly, heat motor housing, with a
propane torch, while turning screw. Apply heat to where screw threads into motor
housing. Apply just enough heat to remove screw, do not overheat motor housing or
mounting flange.

Continued on next page...

14-40
D20x22 Series II Navigator HDD Service Component Repair

9. Remove mounting flange (8) from motor

housing (11). Exclusion seal (9), pressure
seal (6), and backup ring (5) will come 8
off with mounting flange. 9

5 11
6
7

10. Carefully remove exclusion seal (9),

6 7
pressure seal (6), and backup ring (5)
from mounting flange (8). A seal removal
tool may be fabricated by bending and
rounding end of a small blade
screwdriver.
IMPORTANT: Do not damage mounting
flange where shaft passes through it.
9 8

Drilling Fluid

14-41
 Component Repair D20x22 Series II Navigator HDD Service

Assembly 1. Check all mating surfaces. Replace any parts with scratches or burrs that could
cause leakage. Wash all metal parts in clean solvent. Blow them dry with
pressurized air. Do not wipe parts dry with paper towels or cloth as lint will cause
damage to hydraulic system. Check key way and chamfered area of output shaft;
remove any nicks, burrs or sharp edges that could damage shaft seals during
assembly.
NOTE: Always replace seals when assembling hydraulic motors. Refer to the D20x22
Series II Parts Manual for seal kit components.

IMPORTANT: During assembly lubricate new seals with petroleum jelly. Lubricate
machined surfaces and bearings with clean hydraulic fluid.

2. Remove all old thread sealant from the mounting flange cap screws and threaded
holes. Threads must be clean and dry for new thread sealant to hold properly.
3. Lubricate and install output shaft, needle thrust bearing, and bearing race into
housing.
IMPORTANT: Do not permit oil to get into four threaded holes.

4. Lubricate exclusion seal and press it

into its seat in mounting flange. Refer to
figure at right for correct seal 1
Drilling Fluid

3
orientation.
2
5. Lubricate and install backup ring and
pressure seal. Use seal driver (1) and
seal tube (2) available from Eaton to
press pressure seal (3) into place.
IMPORTANT: Be sure exclusion seal and
pressure seal are undamaged and properly
seated.

6. Apply thread sealant grade 277 or

similar product to threads of four holes
in motor housing where mounting
flange will be attached. Apply thread
sealant so that it coats threads. Remove
excess.
7. Install a protective sleeve or bullet over
output shaft. Lubricate inner edges of
exclusion and pressure seals. Lubricate
and install 1-15/16"
(49 mm) diameter O-ring seal on mounting flange. Then slide mounting flange
down over shaft.
Continued on next page...

14-42
D20x22 Series II Navigator HDD Service Component Repair

8. Remove protective sleeve and install four cap screws. Tighten cap screws in a
crisscross pattern to 250 in-lb (28 Nm). Be sure output shaft does not fall out of
housing.
IMPORTANT: Thread sealant must cure completely before motor is put into service.
Curing time is six hours. Use of sealant primer reduces curing time to 15 minutes.
Follow manufacturer’s product instructions.

9. Clamp motor in vise so output shaft is vertical and down. Clamp on mounting
flange.
10. Pour clean hydraulic fluid into motor to provide start up lubrication.
11. Lubricate and install one of three largest diameter seals (1) in groove in motor
housing (2).
12. Install drive (3).
NOTE: If splined ends of drive are different lengths, install longer end into output
shaft.

NOTE: Installation at this point involves motor timing. Timing determines output
shaft rotation direction.

13. Align shaft timing dot (4) with any bolt

Drilling Fluid
8
hole. Bolt hole will be used for timing 9
reference.
14. Install spacer plate, and note position of
threaded hole (5) in housing aligned with 7
timing dot on shaft.
IMPORTANT: Ensure slots in spacer plate
provide passage for hydraulic fluid, as well as 6
the cap screws. If spacer plate is flipped,
motor will not operate.

15. Lightly stretch, lubricate and install

second large diameter seal (6) in geroler 4
seal groove.
5
16. Install geroler (7).
17. For standard (CW rotation) timing, align
any star point (8) with threaded hole (5)
noted for location of timing dot.
18. For reverse (CCW rotation) timing, align
any star valley (9) with threaded hole (5)
noted for location of timing dot.
Continued on next page...

14-43
 Component Repair D20x22 Series II Navigator HDD Service

19. Rotate geroler to align screw holes and install drive spacer.
20. Lubricate and install last seal in end cap seal groove.
21. Install end cap and seven cap screws.
22. Tighten cap screws in a cross pattern, to 235–250 in-lb (27–28 Nm).
23. Install speed sensor. Turn speed
sensor in to bottom (making
sure jam nut is backed off
sufficiently), back off 1/4 turn
(CCW). If reference notch is not
positioned as shown, continue
turning (CCW) to align
reference notch 90 off of
centerline of motor or
perpendicular to motor shaft.
24. Hold speed sensor in this position and tighten jam nut to 75–125 in-lb
(8.5–14 Nm)
Drilling Fluid

14-44
D20x22 Series II Navigator HDD Service Overview

Chapter 15: Remote Lockout

OVERVIEW
Remote Lockout is a communication and control tool that allows a worker anywhere
along the bore path or at the exit site to directly lock out drill rod rotation, thrust, and
fluid flow. Lights, sound, and vibration indicate various modes so the machine operator
and remote user know that the lockout system is operating properly and whether drilling
functions are locked out.

Hydraulic Lockout or Engine Shutdown Option

The Remote Lockout system is equipped with an option to operate as either a hydraulic
lockout (default) or an engine shutdown system. Plugs and connectors are located under
the operator station’s left arm rest.

Hydraulic Lockout Backup Engine Shutdown

To ensure drill remains locked out during a confirmed hydraulic lockout, rotation water
pump, and thrust hydraulic pressures are monitored. If any of the hydraulic pressures
increase, or it drilling fluid system is turned on, engine will shut down. The engine

Remote Lockout
cannot be restarted in Drill mode (with operator seated) until the run button on the
remote transmitter is pushed.

NOTE: When in Transport mode (operator not in seat), the machine will not respond
to Remote Lockout system commands until machine is returned to Drill mode (operator
in seat).

Remote Lockout should not be considered as an emergency stop. It is very unlikely that
disabling thrust and rotation could be done quickly enough to prevent death or serious
injury.

Remote Lockout will not shut down the power units on stand-alone drilling fluid
systems or air compressors. These externally powered units must be manually shut off.

Remote Lockout should be used to lock out the machine before working on or near the
drill string. Examples include:

• Before approaching the drill head.

• Before attempting any tooling change or attaching a product to be pulled in.
• Before attempting to apply any wrench or other tool to drill string.
• Before manually adding or removing drill rod from drill string.
• Before entering an exit pit.

15-1
 Theory D20x22 Series II Navigator HDD Service

THEORY
Functions
The following functions are included in this chapter:

• Hydraulic Lockout
• Engine Shutdown Lockout
• Hydraulic Lockout with Backup Engine Shutdown

Components
The functions covered in this section include the following components.

• Remote Lockout Base Module A4

• Remote Unit Battery Charger J1
• Antenna E1
• Remote Unit E8
Remote Lockout

• Remote Lockout Horn B2

• Remote Lockout Mode Jumper J4
• Hydraulic Lockout Plug P74
• Engine Shutdown Lockout Plug P75

15-2
D20x22 Series II Navigator HDD Service Theory

Component Locations

JUMPER J4
HYDRAULIC PLUG P74
ENGINE SHUTDOWN PLUG P75

Remote Lockout
REMOTE
TRANSMITTER E8

BATTERY CHARGER J1

REMOTE LOCKOUT BASE A4

ANTENNA E1

DISPLAY E10

15-3
 Theory D20x22 Series II Navigator HDD Service

Electrical Schematic

E 7 D IS P L A Y D P 1 0 -A

C 148 C O N TR O LLER

J1 - G RAY
Remote Lockout

A 4 R E M O T E L O C K -O U T

15-4
D20x22 Series II Navigator HDD Service Theory

Hydraulic Lockout Function

NOTE: See "Electrical Schematic," page 15-4 to view voltage and hydraulic paths
with machine in hydraulic lockout mode.

Operation To operate drilling functions in hydraulic lockout mode:

• Operator must be seated at drill controls.

• Remote Lockout system must be in Run mode.
The following theory of operation explains how the electrical and hydraulic functions
react when the hydraulic remote lockout is activated under normal conditions:

• At start-up, voltage is present at the base module A4 through ignition switch S2.
• Once the operator is seated, seat switch S11 will close, sending a signal to Remote
Lockout module A4 through CAN (Controller Area Network).
When remote lockout transmitter E8 sends a lockout command, the remote unit will
signal base module A4.

• Base module A4 communicates through CAN to de-energize thrust and rotation

EDCs and drilling fluid function. Hydraulic enable solenoid L20 will also be de-

Remote Lockout
energized.
NOTE: If the hydraulic LOCKOUT function does not operate as expected, see
"Troubleshooting/Testing the Remote Lockout Function," page 15-16.

Confirmation Pressure transducers B5 and B8 have 0.5–4.5 volts output, which it uses to verify
hydraulic shutdown. If the output voltage of the transducer is outside these limits, or the
transducer is disconnected, the base module will not confirm hydraulic lockout. A
lockout is confirmed if the voltage of both pressure transducers is between 0.25–1.0 V.
Voltage outputs between 1.0–4.5 V is considered high pressure and a lockout will not be
confirmed. If high pressure is encountered when in a confirmed lockout, power is
removed from fuel coil L32, causing engine shutdown.

Confirmation at the transmitter is caused by the pressure transducers. The transmitter

can not confirm the lockout until the pressure is low.

Continued on next page...

15-5
 Theory D20x22 Series II Navigator HDD Service

Hydraulic Lockout Pressure transducers B5 and B8 are installed in rotation and thrust pump PMP1 to
with Backup Engine monitor rotation and thrust hydraulic pressures to ensure that the drill remains locked
Shutdown Function out during a confirmed hydraulic lockout. The lockout is confirmed when the voltage
falls in the 0.25–1.0 V range.

Pressure transducer B5 is installed near rotation and thrust pump PMP1 to monitor
thrust hydraulic pressure to ensure that the drill remains locked out during a confirmed
hydraulic lockout. The lockout is confirmed when the voltage from the pressure
transducers fall within the 0.25–1.0 V range.

The engine cannot be restarted until the run button is pushed or the operator is out of the
seat. See "Power On," page 15-11.
Remote Lockout

15-6
D20x22 Series II Navigator HDD Service Theory

Engine Shutdown Lockout Function

Option Procedure The Remote Lockout function is equipped with an option to operate as an engine
shutdown.

To activate the engine shutdown option, gray

jumper plug (1) must be moved from
hydraulic connector (power applied to circuit 1
782B-TN) to engine shutdown connector
(ground connected to circuit 782C-TN).

To change system back to hydraulic lockout,

reverse above procedure.

Operation To operate drilling functions in engine shutdown lockout mode:

• Operator must be seated at drill controls.

• Remote Lockout system must be in Run mode.
The following theory of operation explains how the electrical and hydraulic functions
react when the engine shutdown lockout is activated under normal conditions:

Remote Lockout
• At start-up, voltage is present at base module A4 through ignition switch S2.
• Once the operator is seated, seat switch S11 will close, sending a signal to base
module A4 via CAN.
When remote lockout sends a lockout command, the remote unit E8 will signal base
module A4.

• Remote Lockout module A4 sends a command to engine bay controller via CAN to
remove voltage to de-energize engine fuel coil L32.
NOTE: If the engine shutdown lockout function does not operate as expected, see
"Troubleshooting/Testing the Remote Lockout Function," page 15-16.

Confirmation Engine shutdown lockout confirmation is defined as a CAN message sent to the base
module A4 to indicate the engine has been shutdown. Confirmation is caused by the oil
pressure switch. When the oil pressure switch on the engine changes state, the lockout is
confirmed.

15-7
 Troubleshooting D20x22 Series II Navigator HDD Service

TROUBLESHOOTING
General System Information
Remote Lockout is equipped with an option to operate as either a hydraulic lockout
(default) or an engine shutdown system. For theory of operation of hydraulic lockout,
refer to "Hydraulic Lockout Function," page 15-5. For theory of operation on engine
shutdown lockout, refer to "Engine Shutdown Lockout Function," page 15-7.

The remote unit user can select either Run or Lockout mode. System status is indicated
by indicator lights on the display and horn B2.

NOTE: When the machine is started and there is no radio signal between the remote
unit and base module, a steady warning will be sounded by horn B2 and will be
indicated by a flashing yellow light at the control panel when in Drill mode (operator in
the seat). The horn can be silenced by pressing the alarm horn cancel button. The yellow
light will continue to flash.

If the machine is in Run mode, red indicator light will be on. If the machine is in
Lockout mode, red lockout indicator light will be on.
Remote Lockout

15-8
D20x22 Series II Navigator HDD Service Troubleshooting

Base Module Indicators

NOTE: The light patterns shown below are in 0.1 second units.

Light A indicates power supply.

• Power OFF

• Power ON (green)

Light B indicates status of radio connection.

• Base module is in “Registering” mode (red).

Remote Lockout
• Base module is initializing internal radio (green). Radio needs to be replaced.

• No communications with remote unit (green). Normal state.

• Remote unit is in range (green). Normal state.

Light C, on this machine, allows user to verify software (green)

(LK2 CAN - P/N 296272506 & 296272510). Normal state.

• CAN NOT OK if lights are (red).

Continued on next page...

15-9
 Troubleshooting D20x22 Series II Navigator HDD Service

Light D indicates lockout state.

• Run (green)

• Engine Lockout requested (green)

• Engine locked (red)

• Hydraulic Lockout requested (green)

• Hydraulic locked (red)

Remote Lockout

15-10
D20x22 Series II Navigator HDD Service Troubleshooting

Power On
Remote Unit On Turn on remote unit by either pressing the
1 2
black Power ON/OFF Button (1) and
holding for 2 seconds or pressing the red
lockout button (2) and holding for 2
seconds.

Base Module Run Turn ignition key to ON.

The ignition key must be ON before the Remote Lockout system is turned on. If not, a
loss of radio signal will be indicated at the remote unit. A loss of signal indicates that the
remote unit and base module are not communicating with each other. Reasons for a loss
of signal are:

• The remote unit is too far away from the machine. Range is up to 0.6 mile (1 km).
• The remote signal is blocked by an obstruction between the remote unit and

Remote Lockout
machine.
• The remote battery is fully discharged.
• The remote unit is turned on when machine is off.
• The system is not operating correctly.
• The antenna connection is poor or broken.
NOTE: Range of signal can be significantly affected by obstructions, such as
buildings, thick vegetation or equipment, located between the remote unit and machine.

If there is no communication with the remote unit,

the yellow signal light (1) begins to flash. If the
machine was in Run mode prior to shutdown, the 3
green RUN light (2) turns on. Engine can be
started, and machine can be operated. If there is
2
no communication with remote for 10 seconds
1
after turning power on, the base module sounds a
continuous alarm until alarm cancel button (3) is
pressed and held for a second.

Continued on next page...

15-11
 Troubleshooting D20x22 Series II Navigator HDD Service

If the Remote Lockout system is in hydraulic mode,

and the base module was locked out prior to shutdown,
then the red lockout light (1) turns on. In this state, the
engine can be started, but thrust and rotation will be
disabled. 1

If the Remote Lockout system is in engine shutdown

mode, and the base module was locked out prior to
shutdown, then the red lockout light (1) turns on. If the
machine is in Drill mode (operator in seat), the engine
can not be started until the machine is unlocked. If the
machine is in Transport mode (operator not in seat), the
engine can be started and the transport functions will
work. If the operator then sits down, the engine will be
shut down immediately.

Lockout Mode
Remote Lockout

When pressed, the red Lockout button transmits a lockout command for drill string
rotation, thrust and pullback, and fluid flow to be stopped. See "Hydraulic Lockout
Function," page 15-5. When the machine has confirmed successful lockout, the red
light comes on solid, followed by a cycle of three 1/2-second beeps then a pause. This
cycle occurs three times.

IMPORTANT: The Remote Lockout system can take up to 5 seconds to process the
lockout. During this time the green lights will flash. The lockout is not complete until
the three beeps cycle occurs three times and the red light is on.

Power Off
Press black Power ON/OFF button and hold for 2 seconds to shut off remote power.
Turn ignition switch S2 to OFF to shut off base module power.

15-12
D20x22 Series II Navigator HDD Service Troubleshooting

Remote Registration
In the event that the base module A4 or remote unit E8 are replaced, registration of the
two units must take place.

NOTE: Perform these steps within one minute of turning on the machine.

1. Turn ignition switch to ON. The yellow

signal light will flash steady. Wait more
than five seconds.
2. Remove 2-pin jumper (2) used to select
Engine Shutdown or Hydraulic
Shutdown mode. Wait for 3 seconds and
put jumper back into position. 2

3. View lights on base module. Light B (1)

will change from a flashing green

to a double flashing red.

Remote Lockout
The Remote Lockout signal light on
operator console display will be double
blinking.
Base module is now in registration mode.

4. Turn remote unit ON.

Continued on next page...

15-13
 Troubleshooting D20x22 Series II Navigator HDD Service

5. Press and hold red and black buttons on 1

remote unit until yellow light (1) double
flashes.
Wait for registration results. It normally takes
less than 30 seconds to complete registration.

After successful registration, Light B on base

module is solid green.

Remote unit is now registered to the base

module and all previous registration information is erased.

Remote unit should now respond to commands.

NOTE: Re-registering will not solve communication issues. If the base & remote are
communicating, re-registering will not affect performance. Registering only needs to be
performed when replacing the base module or remote unit.
Remote Lockout

15-14
D20x22 Series II Navigator HDD Service Troubleshooting

Battery Condition
Low Battery NOTE: Low battery indication is only
displayed on the remote unit. 1

When there is approximately 10% of battery

life left, blue light (1) on remote unit will
flash. All functions will operate normally.

Discharged Battery If battery discharges and a loss of signal occurs in RUN mode, the system will allow
drilling to continue uninterrupted. If battery discharges in LOCKOUT mode, a new
battery must be installed and RUN mode selected before drilling can continue.

Recharge Battery The docking station will charge the battery while installed in battery charging
compartment with power cord plugged into power receptacle, even when the machine
has been shut down.

It is recommended to keep a second battery (user-supplied) in battery charging

Remote Lockout
compartment in the event of transmitter battery failure.

NOTE: The Remote Lockout battery will not charge if the machine battery disconnect
switch S1 is switched to disconnect.

An amber light located on underside of charging compartment will flash when battery is
fully charged. Green light in same location will come on to indicate power to charger.

15-15
 Troubleshooting D20x22 Series II Navigator HDD Service

Troubleshooting/Testing the Remote Lockout Function

The following test can be performed to verify the Remote Lockout components are
functioning properly. For additional troubleshooting information, refer to
"Troubleshooting at the Controller," page 2-16 and "Electrical Schematic," page
15-4.

Remote Unit To test run switch, lights, horn, and vibrator:

1. Turn remote unit off with black power button.

2. Press and hold the green unlock button for 2 seconds:

• All lights should turn on in sequence and flash.

• Horn should sound with two different tones.

• Vibrator should function.

To test remote unit module:

Remote Lockout

1. Turn machine (receiver) OFF.

2. Turn remote ON by pressing and holding the black button.
3. The yellow signal light should flash in the pattern indicated below (initializing

remote),
then turn to this pattern (radio initialized).

4. If the radio enters the initialized mode, RF module is OK. If the radio does not leave
the initializing mode, RF module needs to be returned for repair.
To test red lockout button:

1. Turn remote unit OFF with black button.

2. Press and hold red lock button.
Continued on next page...

15-16
D20x22 Series II Navigator HDD Service Troubleshooting

3. The yellow signal light should flash in the pattern indicated below (initializing
remote),

then, for less than a second, turn to this pattern (radio initialized).

4. The yellow light should turn OFF.

5. The green light should begin to flash.

6. After 5 seconds the horn should sound. The red button works.

Base Module See if power is getting to the unit. If so, light A

will light solid.

To test remote unit module:

1. Turn machine ON.

2. Watch light B, it should flash green in the pattern indicated below (initializing

Remote Lockout
remote),

then turn to this pattern (remote in range).

3. If the Base enters the initializing mode, RF module is OK. If the radio does not
leave the initializing mode, Base needs to be returned for repair.

Verify Software To verify the unit’s software:

1. Check part number of the hardware that is supposed to be on the machine.

2. Compare part number to the numbers below and verify that light C is flashing
properly for the software.
Color Light C Flash Pattern Part Number of Unit
Green LK2–CAN
296272506 (U.S.),
296272510 (Int’l)

Continued on next page...

15-17
 Troubleshooting D20x22 Series II Navigator HDD Service

Verify CAN 1. Turn machine on.

Operation
2. Watch LIGHT C, should flash GREEN in the pattern indicated below:

3. If LIGHT C flashed RED in same pattern the module is not communicating with the
CAN (Controller Area Network) bus.

Problems might be:

The wires on Pins 7 and 8 are not seated properly on the connector.
The CAN wire harness is damaged.
Other modules on the CAN bus are disconnected.
The module is damaged.
Check that the resistance value on the CAN bus is 120Ω for one resistor, 60Ω for
two resistors. All controllers must be disconnected for this test.
Hydraulic or Engine To determine shutdown mode:
Shutdown Lockout
Mode 1. Turn machine and remote ON.
Remote Lockout

2. Press lockout button on remote.

3. The following patterns of base module light D indicate Hydraulic Lockout.

Flashing Green Request Hydraulic Lockout

Solid Red Hydraulic Lockout Confirmed

4. These patterns indicate Engine Shutdown Lockout.

Flashing Green Request Engine Shutdown

Flashing Red Engine Shutdown Lockout Confirmed

Continued on next page...

15-18
D20x22 Series II Navigator HDD Service Troubleshooting

Battery Check battery condition:

• Full battery charge will be 7.2–7.9 volts between the + and

- terminals.
• Low battery charge (battery is in need of charge). Battery is
below 6.9 volts between the T and - terminals.
The remote blue low battery light will illuminate.
• To check if thermal protection is functional, check for 7.5–6.0K ohm between the T
and - terminals.

Battery Charger NOTE: The battery charger has one light (1)
that flashes orange and green.

The charger lights indicate as follows:

NOTE: The indications listed below apply to 1

all versions, unless otherwise stated.

• Power test to unit: Green light is ON (input

voltage is between 9–36 volts DC).

Remote Lockout
• Battery is not detected: Green light is ON.
• Battery is charging: Orange light is on SOLID.
• Battery is charged and trickle charging: Orange light flashes fast at 4 times a
second.

Charge is complete after 6 hours in the charger for a completely discharged battery.
Continued on next page...

15-19
 Troubleshooting D20x22 Series II Navigator HDD Service

• Battery is detected but not charging:

Rev. A. If Orange light flashes slowly at 1 flash every 2 seconds, battery is hot or T
terminal is damaged.

Rev. B/C. If Orange light flashes slowly at 1 flash every second, battery is hot or T
terminal is damaged.

If so:
1. Check resistance on battery T terminal.
2. Check voltage on charger’s T terminal.

Terminal Test With battery out of holder, test voltage:

• between - tab and the +. Voltage should be around 13.4 volts.

• between - tab and the T. Voltage should be around 2.1 volts.
The H tab is not connected.
Remote Lockout

15-20
D20x22 Series II Navigator HDD Service Overview

Chapter 16: Strike Alert

OVERVIEW
The Strike Alert function alerts personnel near the machine of an electrical hazard. It
sounds an alarm if current is passing through the drill rod, or if there is a difference in
voltage between the machine and the voltage stake.

If the drilling tool or rod strikes a source of electrical power, the rod, the machine and
the ground around the machine will become electrically charged. If anyone touches both
the ground and the machine at the same time, they may be injured or killed by electrical
shock. A worker walking near the machine or drill string may also be shocked from the
voltage difference on the surface of the ground.

THEORY
Circuits

Strike Alert
The following circuits are included in this chapter:

• Voltage Strike
• Current Strike
• Voltage Test
• Current Test

Components
The circuits covered in this section include the following components:

• Strike Alert Module A3

• Strike Alert Coil L6
• Strike Alert Stake E3
• Strike Alert Horn B1

16-1
 Theory D20x22 Series II Navigator HDD Service

Component Locations

STRIKE ALERT MODULE A3

VOLTAGE STAKE E3
INDICATOR LIGHT DS15
Strike Alert

HORN CANCEL SWITCH S9

HORN AD1

TEST SWITCH S8

SENSING COIL B2

16-2
D20x22 Series II Navigator HDD Service Theory

Strike Alert System Test

The D16x20 Series II/D20x22 Series II Operator’s Manual directs the operator to
conduct a test of the Strike Alert system each time the machine is started. The Strike
Alert system test consists of a simultaneous current and voltage test.

The system test is performed with the voltage stake E3 inserted in the ground. When test
switch is closed, AC current from terminal 4 of A3 passes through the sensing ring B2.
This induces a current in the sensing coil of the sensing ring. A wire connects the coil to
the module, delivering the induced current to module A3. Simultaneously, strike alert
module A3 allows voltage to be passed through the voltage stake. The module then
senses the voltage difference between that point and machine ground. The module then
verifies proper operation.

Module A3 responds by briefly sounding the alarm horn.

NOTE: It is important that the ground sense stake be inserted in the ground and the
machine make electrical contact with the ground during the test. It might be required to
insert ground stakes or drill in one rod to ensure good electrical connection between the
machine and the ground. Wetting the ground at the machine and voltage stake might
help to ensure the connection.

NOTE: The alarm must sound when the Test Button is pressed. A successful test is

Strike Alert
indicated when the green light remains steady ON after the test button is released. If
there is a flashing green light after releasing the test button, the Strike Alert system is not
functioning correctly, see "Troubleshooting/Testing," page 16-6.

16-3
 Theory D20x22 Series II Navigator HDD Service

Electrical Schematic

E 7 D IS P L A Y D P 1 0 -A

C 148 C O NTRO LLER

J1 - G R AY

A 3 S T R IK E A L E R T
Strike Alert

16-4
D20x22 Series II Navigator HDD Service Theory

Voltage Strike Circuit

Operation The module’s voltage strike circuit senses if the machine is electrically charged by:

• Detecting a difference in the voltage of the machine, compared to the voltage at the
ground sense stake E3 through terminal 6.
• If the voltage difference exceeds 25 volts (AC or DC) or within the frequency range
of 15–85 Hertz, the module sounds the alarm.
NOTE: If a problem is suspected with the strike alert circuitry, see "Troubleshooting/
Testing," page 16-6.

Current Strike Circuit

Operation The module’s current strike circuit senses current flow through the drill rod by:

• Detecting the induced current in the sensing coil L6 through terminals 3 and 4. Coil
L6 is mounted so it encircles the drill rod.
• If the module detects approximately 0.10 amps of current within the frequency
range of 15–85 Hertz in the coil, the module sounds the alarm.
NOTE: If a problem is suspected with the strike alert circuitry, see "Troubleshooting/

Strike Alert
Testing," page 16-6.

16-5
 Troubleshooting/Testing D20x22 Series II Navigator HDD Service

TROUBLESHOOTING/TESTING
IMPORTANT: This system is designed to warn an operator that the machine is in
contact with energized electric power. If a job site is being visited because the Strike
Alert “keeps going off,” assume that the ground and/or machine is electrified. The crew
should contact utility companies to have local power turned off and repaired before they
resume drilling. Do not assume this has been done. Before approaching a machine
connected to a drill string in the ground, verify with the crew that all the statements
below are true:

• The local utility has turned off the power.

• Utility personnel have been or are on the scene.
• Utility personnel have checked with their instruments and verified that the area is
not electrified.
• Since then, the crew has not drilled out or pulled back any farther, possibly
contacting another underground power source.

Determining What to When troubleshooting Strike Alert circuits:

Troubleshoot
• perform the daily test for the Strike Alert module
• check the integrity of the wiring harness
Strike Alert

• check the alarm cancel button on the control panel

• check the lights on module A3 and the green light on the control panel
NOTE: If the horn sounds and no strike has occurred, check Light “D” on the module.
Troubleshoot wiring and components based on what the light indicates. Refer to "Strike
Alert Module Lights," page 16-8.

Daily Test The test causes Strike Alert module A3 to sound the horn B1 until the test button is
released.

If the test works, it proves that:

• The horn B1 is connected and working.

• Ground stake E3 is connected to module A3.
• The module is responding correctly to the voltage at terminal 3.
• Sensing ring L6 is complete (not shorted) and connected to module A3.
• Module A3 is sending current through terminal 9 and responding correctly when it
receives current through the coaxial cable.
If the test fails, focus on the items above.

Continued on next page...

16-6
D20x22 Series II Navigator HDD Service Troubleshooting/Testing

VCTool Software The Strike Alert module operates in stand-alone mode, but is connected to the CAN bus
to send information to the machine controller. A connection between a PC running
VCTool software and the machine will allow monitoring of current and voltage outputs
from the Strike Alert module.

If the machine is experiencing false positives, check the base line voltage and current.
Compare the difference between the voltages when a drill rod is in the vise/strike alert
assembly (through the coil) and no drill rod is in the vise/strike alert assembly. This may
give an indication of a failed coil. Compare the difference between voltages while drill
rod is at various locations underground. This may give an indication of ambient
electricity in the soil. Contact the factory for more information.

Control Panel Light

The green light on the control panel will indicate the following:

• Off when a test is in progress or the light is burned out

• Flashing when the ground stake is not in the ground

Strike Alert
• Double flashing when the current sensor has failed

• Triple flashing when there is a ground stake wiring problem

• Solid On when a test is passed or system is ready

16-7
 Troubleshooting/Testing D20x22 Series II Navigator HDD Service

Strike Alert Module Lights

Light A indicates power supply state.

• Power off

• Power on (green)

Light B indicates system state.

• Self-test passed

• Ground stake not in ground (red)

Strike Alert

• Current sensor failed (red)

• Ground stake wiring failed (red)

Light C indicates CAN bus state.

• CAN bus is present (green) (normal operation)

• no CAN bus is present (red) (failed operation)

Continued on next page...

16-8
D20x22 Series II Navigator HDD Service Troubleshooting/Testing

Light D indicates alarm state.

• No alarm (green)

• Voltage alarm (red)

• Current alarm (red)

Strike Alert

16-9
 Component Repair D20x22 Series II Navigator HDD Service

COMPONENT REPAIR
Voltage Stake E3

3 2

6
7
9
4
7
5

1
Strike Alert

7 8

1. Remove screws (5) and washers (7) on clamp (9) and wire rings (6) holding cable
(4) to underside of voltage stake.
2. Remove bolts (3) on handle (2).
3. Remove bolt (8) and washer (7) to remove voltage stake assembly from machine.
To assemble the voltage stake, reverse the steps above.

16-10
D20x22 Series II Navigator HDD Service Component Repair

Strike Alert Coil Assembly L6

4 3

6
9 7

Strike Alert
1. Remove wiper (2) from mounting bracket (1).
2. Remove bolts (3) holding coil (4) in mounting bracket.
3. Unscrew bolts (5) holding mounting bracket to vise assembly.
4. Remove roller bolt (9). Remove guide plate (6), guide roller tube (7), and bushing
(8) from center of strike alert.
5. Disconnect strike alert harness from coil (4).
Reverse steps for installation.

16-11
This page intentionally left blank.
D20x22 Series II Navigator HDD Service Overview

Chapter 17: VCTool Software

OVERVIEW
Vermeer’s CAN Tool (VCTool) is a Controller Area Network (CAN) diagnostic tool
software designed to monitor messages using the SAE J1939 CAN specification.
VCTool allows a technician to monitor and log these J1939 CAN messages in real time.
It can be used with any Vermeer controller-based machine.

INSTALLATION
Procedures and requirements for installation of VCTool software are available in a
presentation on the Compass Trenchless service software downloads internet site. The
installation file is also available at that location.

The configuration file (JSYM) is available for download on the Compass service
Trenchless drills downloads internet site. By default, .jsym files are installed in the

VCTool Software
VCTool\systems directory. Ensure the file appropriate to the D20x22 Series II HDD has
been downloaded to the computer before connecting to the machine.

17-1
 Connection D20x22 Series II Navigator HDD Service

CONNECTION
The cables, sold as one part (P/N
296276088), are necessary to connect
Vermeer machines equipped with a Vermeer
controller to a laptop computer’s USB port. 2 1

Attach connector (1) to USB port of

computer. Attach connector (2) to connector
(3). Attach connector (4) to diagnostic port, if
present, or 3-pin CAN relay. 4

The diagnostic port, if present, or CAN relay

(5) is located behind the operator station
control panel. Remove resistor from end of
relay before connecting cable.
VCTool Software

Other helpful items are a CAN splice harness

(P/N 296287412) that is useful for splicing
into a CAN line with CG150 and a 50-foot
extension harness (P/N 296287410).
5

USING THE VCTOOL

Opening Definition Files
The first step in monitoring data on the J1939 network is to locate and open the
definition (.jsym) file that contains the definitions for your specific equipment.

To open a .jsym file, select File>Open from

the drop-down menu or click on the button
(1) on the toolbar.

17-2
D20x22 Series II Navigator HDD Service Using the VCTool

Main Screen
The main screen displays each message that it receives from the CAN bus. Each row
represents a different message.

Columns

1 2 3 4 5 6

Msg (Message) (1) indicates the name of the sending or receiving controller.

VCTool Software
Field (2) is the name of the individual parameter for which data is listed. Also, the
controller pin assignment for that parameter is shown, if appropriate.

Value (3) is the value of the parameter described in the Field. It can be numerical or text
depending on the data type.

DTC (Diagnostic Trouble Code) (4) consists of three parts: Suspect Parameter Number
(SPN), Failure Mode Identifier (FMI), and Occurrence Count (OC). This column
decodes the J1939 DTC and identifies the field that has the problem and displays the
FMI.

Node (5) is an identification number of the controller that originated the CAN message.

AVG/Last/# (6) consists of three parts: AVG (Average Time), Last (Last Time), and #
(Number). AVG is the time, in milliseconds, that the message row is updated. Last is the
time, in milliseconds, between the message row updates. # is the number of messages
received since the last reset.

17-3
 Using the VCTool D20x22 Series II Navigator HDD Service

Buttons Load Workspace (version 1.2 and earlier) loads a configuration (.cfg) file that contains
information about the layout of the main screen. The configuration file is linked to a
definition file (.jsym) with an identical name that is specific to the machine. If no
configuration (.cfg) file is loaded, a default layout will be used. This command is also
found in the drop-down menu (File>Load Workspace).

Open Definition file (1) opens a system

1 2 3 4 5 6
definition (.jsym) file into the existing
configuration. The definition file (.jsym) is
specific to the machine and contains the
definitions for the CAN messages that might
appear on a given CAN bus. If no definition
(.jsym) file is present, VCTool can not be
used. This command is also found in the 7 8 9
drop-down menu (File>Open Definition).

Begin Message Recording (2) begins the logging of the data that is transmitted on the
CAN bus. The button may be selected once a log has been opened. Refer to "Logging,"
page 17-7. This command is also found in the drop-down menu (Log>Begin Message
Recording).

End Message Recording (3) stops the logging of the currently open log file. This
VCTool Software

command is also found in the drop-down menu (Log>End Message Recording).

Toggle All/Selected Rows (4) will cause the main screen to show only the selected rows
when pressed once. When pressed once more, it will cause the main screen to show all
rows. This command is also found in the drop-down menu (Arrange>Show All Rows or
Arrange>Show Selected Rows).

Move Row Up (5) and Move Row Down (6) will re-arrange the rows. Click on the
desired row and press one of the move buttons to cause a row to leap over the adjacent
row. This command is also found in the drop-down menu (Arrange> Move Row Up or
Arrange>Move Row Down).

Reset Count and Average Interval (7) resets the counters for average time between
messages, last time between messages, and number of messages received. This clears
the AVG/Last/# column. This command is not found in the drop-down menu.

Toggle Bus Connection (8) appears in version 1.3 and later. This stops the connection to
the CAN bus when pressed once. When pressed once more, the connection is re-
established. This command is not found in the drop-down menu.

Continued on next page...

17-4
D20x22 Series II Navigator HDD Service Using the VCTool

Show Controller Configuration (9) appears in version 1.3 and later. It is grayed-out
when not connected to a CAN bus. This opens the controller configuration dialog box.
This dialog box is for use by factory personnel. This command is also found in the drop-
down menu (Options>Show Controller Configuration).

Formatting Rows may be moved and shown/hidden to group parameters for ease of comparison.
Column widths may be adjusted for ease of viewing and complete view of the
information in the column.

The Arrange drop-down menu has four options: Move Row Up, Move Row Up, Show
All Rows, and Show Selected Rows. These options are described with their counterpart
buttons in "Buttons," page 17-4.

Rows are selected or de-selected for showing/hiding by clicking on the checkmark at the
far left of the main screen. Rows are selected for movement by clicking on the row
outside the checkmark column.

The font and type size of the main screen may be adjusted on the Set Font dialog box.
Select Options>Set Font from the drop-down menu.

VCTool Software
The rate, in milliseconds, at which the main screen is
updated may be set on the Screen Update Rate dialog
box. VCTool is initially set to read the CAN bus every
20 ms (1). Select Options>Set Update Rate from the
1
drop-down menu.

NOTE: This rate may not be reached, depending on

Windows minimum process switching rate. Therefore,
the exact rate at which parameters are read is dependant on the computer’s operating
system and cannot be guaranteed to occur at the specified update rate. The Last section
of the AVG/Last/# column will display this timing discrepancy by showing rates that are
multiples of the minimum process switching rate, instead of the desired rate.

17-5
 Using the VCTool D20x22 Series II Navigator HDD Service

Creating Graphs
To create a graph which allows watching multiple fields in real-time, perform the
following steps.

1. Connect to CAN bus.

2. Right mouse click on a row, and select Add
To Graph. Select as many rows as desired.
3. Select Show from the Graph drop-down 2 1
menu.
4. Select a time interval (1). The vertical lines
in the graph occur at the time interval.
Selecting a larger interval will allow you to
watch a larger time slice in the graph window, but will cause any spikes to appear
sharper or not appear at all.
5. Press Pause button (2) to stop the graph. The button will now say Run. Press Run to
resume graphing.
VCTool Software

17-6
D20x22 Series II Navigator HDD Service Using the VCTool

Logging
Logging saves CAN data messages to be viewed outside of VCTool. The process helps
identify problems that occur too quickly to see or that involve multiple inputs.

Create a log file before logging data.

1. Connect to CAN bus.

2. Choose a format for log file (1). Log files
may be saved as text files (tab delimited)
or in CANalyzer format (Vector
Informatik CANalyzer format).
CANalyzer format is useful for logging
large amounts of data to be sent back to
factory. Text file format can be exported
to Excel program for analysis. From Log 2 1
drop-down menu, check or remove
checkmark from CANalyzer Format as
required.
3. If creating a text file, choose which rows to log. Place checkmarks (2) in all rows to
be logged. Select Log>Save All Rows or Log>Save Selected Rows to log only rows

VCTool Software
with checkmarks.
4. If version 1.2 or earlier, from Log drop-down menu, select Create Log File.
5. Press the Begin Message Recording
button (3) or select Log>Begin Message
Recording.
To stop logging, press the End Message
4
Recording button (4) or select Log>End
Message Recording. Once stopped, a dialog 3
box will appear to save the log file.

To delete an open file, select Erase Log File

from Log drop-down menu.

17-7
This page intentionally left blank.
D20x22 Series II Navigator HDD Service Index

A Drilling Fluid Valve, 4-30

Auto Greaser, 13-1, 13-4 Drive Chuck, 9-58
Auto Greaser Cylinder, 13-9 DTC, 17-3
Auto Greaser Valve, 13-11 E
B EDC, 9-49
Ball Valve, 14-17, 14-27 Engine, 2-11, 3-6
Base Module, 15-9, 15-17 Engine Shutdown, 15-1
Base Module Run, 15-11 Engine Shutdown Lockout, 15-2, 15-7
Battery, 15-15, 15-19 E-stop
Battery Condition, 15-15 See Emergency Stop Switch, 3-20
Excessive Heat, 4-20
C Excessive Leakage, 4-20
CAN, 17-1 Excessive Noise, 4-14
CAN Bus, 2-22 Excessive Vibration, 4-14
Charge Check Valve, 9-53
Charge Pump, 9-8, 9-55
F
Closed Loop Pump, 4-8, 9-47 Fault Codes, 2-21
Component Locations Fluid Pump, 14-31
Drilling Fluid, 14-2 FMI, 17-3
Ground Drive, 8-2 Front Vise, 12-8
Hydraulic Fluid Distribution, 4-3 Full Flow Switch, 14-21
Rack Angle, 7-2 G
Remote Lockout, 15-3
Gear Pump, 9-8
Rod greaser, 13-2
Gearbox, 8-19, 9-61
Rod Loader, 11-2
Graph, 17-6
Rotation, 9-2
Ground Disconnect Switch, 3-21
Stabilizer, 6-2
Ground Drive, 8-1
Stakedown, 5-2
Ground Drive Motor, 8-19
Strike Alert, 16-2
Thrust/Pullback, 10-2 H
Vises, 12-2 High Pressure Relief Valve, 9-53
Control Panel Light, 16-7 Hose Connections
Controller, 2-14, 17-1 Drilling Fluid, 14-4
Current, 16-3 Ground Drive, 8-6
Current Strike, 16-5 Hydraulic Fluid Return, 4-5
Cylinder Hydraulic Fluid Supply, 4-4
Auto Greaser, 13-9 Rack Angle, 7-3
Fluid Shutoff, 14-27 Rod greaser, 13-3
Rack Angle, 7-13 Rod Loader, 11-3
Rod Loader, 11-22 Rotation, 9-5
Stabilizer, 6-16 Stabilizer, 6-4
Stakedown, 5-30 Stakedown, 5-3
Vise, 12-26 Thrust/Pullback, 10-6
D Vises, 12-3
Hydraulic Fluid Sampling, 4-26
Daily test, 16-3, 16-6
Hydraulic Lockout, 15-1, 15-2, 15-5
Discharged Battery, 15-15
Hydraulic lockout, 15-5
Display, 2-19
Hydraulic Lockout Backup Engine Shutdown, 15-1
Diverter Valve, 4-30
Hydraulic Lockout with Backup Engine Shutdown Func-
Drill Out Mode, 12-8
tion, 15-6
Drilling Fluid Motor, 14-19, 14-31, 14-39
Hydraulic or Engine Shutdown Lockout Mode, 15-18
Drilling Fluid Off, 14-8
Drilling Fluid Pump, 14-21, 14-31 I
Drilling Fluid Pump Motor, 14-22 Implement pump
Drilling Fluid Shutoff Cylinder, 14-27 See PFC Pump, 4-6
Drilling Fluid Shutoff Valve, 14-26
Index D20x22 Series II Navigator HDD Service

J A4, 15-5, 15-7

Joystick, 2-23, 2-24 A5, 2-14
Jsym, 17-2 A7, 5-25, 9-56
Jumper for Shutdown, 15-7 A8, 10-24
A9, 4-30
K B5, 15-5, 15-6
Kubota Warranty, 1-2 B8, 15-6
CB1, 3-19
L CB2, 3-19
Lights on Remote Lockout, 15-9 CY1, 7-13
Limit Switch, 10-38, 11-27 CY10, 11-22
Loader Arm Extend Switch, 11-14 CY11, 11-22
Loader Arm Retract Switch, 11-14 CY2, 6-16
Lockout, 15-12 CY3, 6-16
Lockout Mode, 15-12 CY4, 5-30
Log file, 17-7 CY5, 5-30
Loop Flush Valve, 9-56 CY6, 13-9, 14-27
Low Battery, 15-15 CY7, 12-26
M CY8, 12-26
CY9, 12-26
Message, 17-3
E7, 2-19
Motor
ENG1, 3-6
Drilling Fluid, 14-31, 14-39
HE1, 4-12, 4-37
Ground Drive, 8-19
L20, 15-5
Rod Loader, 11-24
L32, 15-7
Rotation, 9-66
MH1, 9-66
Stakedown, 5-27
MH10, 14-31, 14-39
Thrust, 10-26
MH2, 10-26
Mud
MH3, 10-26
See Drilling Fluid, 14-1
MH4, 10-26
O MH5, 8-19
OC, 17-3 MH6, 8-19
Oil Cooler, 4-37 MH7, 5-27
Oil Cooling, 4-12 MH8, 5-27
Oil Supply, 4-6 MH9, 11-24
Outrigger PMP1, 4-8, 9-47
See Stabilizer, 6-1 PMP2, 4-17, 4-32
PMP3, 9-55, 14-31
P S1, 3-21
PFC Pump, 4-6, 4-32 S2, 3-21, 15-5
Plug for Shutdown, 15-7 S20, 15-5
Power ON, 15-11 S39, 3-20
Remote Lockout, 15-1
R Remote Registration, 15-13
Rack Angle Cylinder, 7-13 Remote Unit, 15-11, 15-16
Radiator, 4-37 Rod Box, 11-25
Rear Vise, 12-10, 12-11, 12-13, 12-15 Rod Greaser, 13-1
Recharge Battery, 15-15 Rod lift switch, 11-14
Reference Designator Rod Loader Cylinder, 11-22
A1, 2-23 Rod Loader Motor, 11-24
A11, 6-14 Rod Loader Switch, 11-27
A13, 12-24 Rod Loader Valve, 11-19
A14, 11-19 Rotation gearbox, 9-61
A16, 13-11 Rotation Motor, 9-66
A19, 14-26 Rotation Pump, 4-8, 9-47
A2, 2-24 Rotation Vise, 12-13, 12-15
A20, 14-27 Run, 15-11
D20x22 Series II Navigator HDD Service Index

S Torque Limiter Valve, 9-56

Schematic Towing, 9-22
Drilling Fluid, 14-5 Track
Ground Drive, 8-3 See Ground Drive, 8-1
Hydraulic Fluid Distribution, 4-5 Track Tension
Rack Angle, 7-4 Adjustment, 8-23
Remote Lockout, 15-4 Tightener, 8-21
Rod greaser, 13-3 Transducer, 15-6
Rod Loader, 11-4 Transport Valve, 6-14
Rotation, 9-3 Troubleshooting
Stabilizer, 6-3 Auto Greaser, 13-7
Strike alert, 16-4 Circuit Breakers, 3-16
Thrust/Pullback, 10-4 Drilling Fluid, 14-9, 14-12, 14-14
Vises, 12-4 Drilling Fluid On/Off Switch, 14-24
Shutdown, 15-7 Engine, 3-12
Slowdown Switch, 10-38 Ground Drive, 8-13, 8-15
Software, 15-17, 15-18, 17-1 Hydraulic Fluid Distribution, 4-14
Specifications Oil Cooler, 4-20
Diverter Valve, 4-13 PFC Pump, 4-17
Drilling Fluid, 14-24 Pullback, 10-13
Engine, 3-18 Rack Angle, 7-9
Ground drive, 8-17 Remote Lockout, 15-8, 15-16
Machine, 2-10 Rod Loader, 11-13
Power, 3-18 Rod Loader Lift, 11-17
Pumps, 4-13 Rod Loader Select, 11-15
Rack Angle, 7-12 Rotation, 9-24
Rod greaser, 13-8 Stabilizer, 6-10
Rod Loader, 11-18 Stakedown, 5-19
Rotation, 9-44 Strike Alert, 16-6
Stabilizer, 6-12 Thrust, 10-13
Stakedown, 5-24 Vises, 12-18
Thrust/Pullback, 10-23 U
Vises, 12-22
USB, 17-2
SPN, 17-3
Stabilizer Cylinder, 6-16 V
Stakedown Cylinders, 5-30 Valve
Stakedown Motors, 5-27 Auto Greaser, 13-11
Stakedown Valve, 5-25 Ball, 14-27
Stop Switch, 3-20, 10-38 Fluid Shutoff, 14-26
Stopping the Machine, 2-1 Rod Loader, 11-19
Strike Alert, 16-1 Thrust, 10-24
Strike Alert Coil Assembly, 16-11 Torque Limiter, 9-56
Strike Alert Module Lights, 16-8 Transport, 6-14
Strike Alert test, 16-3, 16-6 Vise, 12-7, 12-24
Sub-Saver, 9-59 VCTool, 17-1
T Verify CAN Operation, 15-18
Verify software, 15-17, 15-18
Testing
Vermeer Warranty, 1-2
Drilling Fluid Motor, 14-22
Vise Clamp Mode, 12-8
Drilling Fluid Shutoff, 14-13
Vise Cylinder, 12-26
Ground Drive, 8-14
Vise Valve, 12-7, 12-24
Rod Loader, 11-14
Voltage Stake, 16-10
Stakedown, 5-20
Voltage strike, 16-5
Thrust Motor, 10-26
Thrust Pump, 9-47 W
Thrust Valve, 10-24 Warranty, 1-2
Torque Limiter Function, 12-10
Index D20x22 Series II Navigator HDD Service

Wash Wand, 14-9 See Drilling Fluid, 14-1

Water Worksheet for Flow Test of Drilling Fluid Motor, 14-23
 D20x22 Series II Navigator HDD Service

Diagrams and Schematics

Legend for Functional Diagrams
Functional diagrams display inputs and outputs • G—generator, alternator, battery charger, oscillator • (nc)—indicates switch that is “normally closed”
involved in system operation. • GA—diagnostic port, gauge port, or oil • (no)—indicates switch that is “normally open”
sampling port • (nnp)—indicates valve that is “normally non-
Different line weights and types are used to display
electric, hydraulic, mechanical and airborne inputs and • H—hose passing”
outputs. Dash-dot lines indicate that devices within are • HE—heat exchanger, radiator, oil cooler, • (np)—indicates valve that is “normally
included in a larger assembly. intercooler passing”
• J—jack, or female connector, receptacle
The diagrams read (generally) from left to right, with
inputs starting on the left and outputs traveling to the • K—relay, often shown divided into coil and
right. contacts within an outline
• L—inductor, such as solenoid or coil
Reference designator codes are used to identify the
types of the devices, the number after the letter code • M—electric motor
identifies the specific device. • MH—hydraulic motor
• P—plug, or male connector
• A—assembly of multiple devices or amplifier,
controller, or module • PMP—pump
• ACC—accumulator • PV—pressure control valve, such as a relief valve,
reducing valve, counterbalance valve, sequence
• B—transducer, sensor, pulse pickup, horn, buzzer
valve, or unloading valve
or speaker
• Q—isolator, power switchgear
• BT—battery
• R—resistor, rheostat, potentiometer
• C–capacitor
• RES—reservoir or tank
• CB—circuit breaker, the maximum
capacity is listed near the circuit breaker. • S—switch, limit switch
• CV—check valve • SR—strainer
• CY—cylinder • SV—shuttle valve
• D—delay devices, storage devices, registers, • T—transformer
recorders • TB—terminal board
• DV—directional control valve • U–modulator, converter, inverter
• DS—lamp or indicating device, such as a low oil • W—wire, cable, harness
pressure light
• X–test jack
• E—heating, signaling, lighting, display devices
• Z–electrical filtering elements, equalizer, limiter
• ENG—engine
• F—fuse or arrester
• FV—flow control valve such as needle valve,
orifice, or flow divider
• FL—filter

Addendum-1
D20x22 Series II Navigator HDD Service Hydraulic Schematic (Page 1 of 2)

HYDRAULIC SCHEMATIC (PAGE 1 OF 2)

A17
HE1
A8
MH4
MH3
MH2

FL2
PMP4
FL1
DV4
DV2

DV3

PMP1
DV5

B5
MH1

DV1

PV3

DV6
B8
A7

DV7
CV1

PV2
E10

Addendum-2
 Hydraulic Schematic (Page 2 of 2)

MH5

DV19
HYDRAULIC SCHEMATIC (PAGE 2 OF 2)

MH6
DV20
MH7 MH8

CY1 DV21
CY4 CY5
PMP3 MH10
CY2 DV22

CY6 CY3
DV23
DV25 DV26
DV15

DV27 DV28 A12

A11

DV16 CY12
E12
CY7 CY8 CY9
DV17

DV36
DV18 PV4
DV29
DV30
DV24
DV33

DV31 DV32
A9
A13 PV6

CY10 CY11
MH9

PMP2

A15 DV34 DV35

A14
D20x22 Series II Navigator HDD Service

Addendum-3
D20x22 Series II Navigator HDD Service Electrical Schematic (Page 1 of 3)

ELECTRICAL SCHEMATIC (PAGE 1 OF 3)

E7 DISPLAY DP10-B
E7 DISPLAY DP10-A

A2 RIGHT HAND JOYSTICK HEAD

A1 LEFT HAND JOYSTICK HEAD
Addendum-4
Electrical Schematic (Page 2 of 3) D20x22 Series II Navigator HDD Service

ELECTRICAL SCHEMATIC (PAGE 2 OF 3)

S2

A4 REMOTE LOCK-OUT
A3 STRIKE ALERT

Addendum-5
D20x22 Series II Navigator HDD Service Electrical Schematic (Page 3 of 3)

ELECTRICAL SCHEMATIC (PAGE 3 OF 3)

C148 CONTROLLER

J4- BROWN
J2- BLACK

J3 - GREEN
J1 - GRAY

Addendum-6
Electrical Schematic – Optional Tether D20x22 Series II Navigator HDD Service

ELECTRICAL SCHEMATIC – OPTIONAL TETHER

A21 TETHER CONTROLLER

Addendum-7
D20x22 Series II Navigator HDD Service Wire Harness Assembly - Control Panel

WIRE HARNESS ASSEMBLY - CONTROL PANEL

Addendum-8
Wire Harness Assembly - Rack D20x22 Series II Navigator HDD Service

WIRE HARNESS ASSEMBLY - RACK

Addendum-9
D20x22 Series II Navigator HDD Service Wire Harness Assembly - Engine Bay

WIRE HARNESS ASSEMBLY - ENGINE BAY

Addendum-10
D20x22 Series II Navigator HDD Service

Revision History
Revision Date Page(s) Description
S1_00 1/08 All 1st edition manual released.
S2_00 10/08 2-11, 3-6, 3-18, 4-6, 4-9, 4-13, 4-19, 5-4, 2nd edition manual released
5-7, 5-9, 5-11, 5-12, 5-14, 5-16, 6-3, 6-6, Updated drilling fluid valve solenoid
6-7, 7-4, 7-6, 7-7, 8-3, 8-7, 8-9, 9-4, symbols, adjusted pressure relief setting,
11-5, 11-7, 11-9, 11-10, 12-3, 12-4, corrected hydraulic schematic, updated
12-8, 12-9, 12-10, 12-11, 12-13, 12-15, electrical schematic, and updated
13-4, 14-5, 14-6, 14-7, 14-8, 14-19, 14-20, autogreaser.
14-22, 14-25, 15-4, 16-4
 WARNING CALIFORNIA
Proposition 65 Warning
The engine exhaust from this product
Diesel engine exhaust and some of its
contains chemicals known to the State
constituents are known to the State
of California to cause cancer, birth
of California to cause cancer, birth
defects, or other reproductive harm.
defects, and other reproductive harm.

When operated in California, any off-road diesel vehicle may

be subject to the California Air Resources Board In-Use Off-
Road Diesel Vehicle Regulation. It therefore could be subject
to retrofit or accelerated turnover requirements to reduce
emissions of air pollutants. For more information, please
visit the California Air Resources Board website at
http://www.arb.ca.gov/msprog/ordiesel/ordiesel.htm.

Copyright 2008. All rights reserved.

Vermeer Corporation
1210 Vermeer Road East, P.O. Box 200
Pella, Iowa 50219-0200

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