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D20x22 NAVIGATOR®
Horizontal Directional Drill

Service
Manual

D20x22_S1_00
Serial No. 101 -
Order No. 105400Z20
This manual contains service requirements and This document may contain portions of technical
procedures needed by an experienced service person materials of various suppliers. Such component
to complete necessary service and repairs on the suppliers shall not be responsible for the direct results
machine. Study and understand these requirements of their technical materials being presented out of
and procedures thoroughly before servicing or context.
repairing the machine. There are also many
components which are not user-serviceable. Do not Designations used by component suppliers to
attempt any service which you do not fully understand, distinguish their products which appear in this manual
nor any service that you cannot do adequately and are the property of the respective trademark owner(s).
safely with the tools and equipment available to you. Vermeer Manufacturing Company is aware of the
Failure to do so could result in personal injury or following component suppliers trademarks.
equipment damage. If you encounter a problem that
you do not understand or cannot solve, contact your LOCTITE and VIBRA-SEAL are trademarks of Loctite
Vermeer service representative. Corporation.

The instructions, illustrations and specifications in this FLUKE is a trademark of Fluke Corporation.
manual are based on the latest information available at
the time of publication. Your machine may have product TEFLON is a trademark of E.I. DuPont de Nemours
improvements and options not yet contained in this and Company.
manual.
SUNDSTRAND is a trademark of Sauer-Sundstrand
Vermeer Manufacturing Company reserves the right to Corp.
make changes at any time without notice or obligation.

Additional copies of this manual are available. When

ordering, use the part number on the front cover.

VERMEER and VERMEER Logo are registered

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 Manufacturing Company.

Copyright © 2007
All rights reserved.
Vermeer Manufacturing Company
1210 Vermeer Road East, P.O. Box 200
Pella, Iowa 50219-0200, USA
D20x22 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
Caterpillar 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 ....................................................................................................................................1-8
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 ........................................................................................................................................1-10
Electrical Troubleshooting ..................................................................................................................................... 1-11
Common Electrical Problems ..........................................................................................................................1-11
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 ..............................................................................................................................1-17
Connecting Pressure Gauges ..........................................................................................................................1-17
Thermometer or Pyrometer .................................................................................................................................... 1-17
Digital Multimeter .................................................................................................................................................... 1-18
Measuring Voltage ............................................................................................................................................1-18
Measuring Resistance ......................................................................................................................................1-18
Table of Contents D20x22 Navigator HDD Service

Testing for Continuity .......................................................................................................................................1-19

Measuring Current ............................................................................................................................................1-19
Repair Guidelines ........................................................................................................................................ 1-20
Shop Requirements................................................................................................................................................. 1-20
Special Tools & Test Equipment......................................................................................................................1-20
Personnel and Lifting Requirements..................................................................................................................... 1-20
Replacement Parts .................................................................................................................................................. 1-20
Part Numbers/Hose Lengths/Fitting Orientation............................................................................................1-20
Parts Ordering ...................................................................................................................................................1-20
Torque Values.......................................................................................................................................................... 1-21

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............................................................................................................................................... 2-3
Engine ..................................................................................................................................................................2-3
Hydraulic Fluid ....................................................................................................................................................2-3
Operation Overview .................................................................................................................................................. 2-3
Legend for Reference Designators.......................................................................................................................... 2-3
Chapter 3 - Power................................................................................................................................................2-3
Chapter 4 - Hydraulic Fluid Distribution ...........................................................................................................2-4
Chapter 5 - Ground Drive....................................................................................................................................2-4
Chapter 6 - Thrust/Pullback................................................................................................................................2-4
Chapter 7 - Rotation ............................................................................................................................................2-5
Chapter 8 - Stakedown .......................................................................................................................................2-5
Chapter 9 - Stabilizer/Rack Angle ......................................................................................................................2-5
Chapter 10 - Vises ...............................................................................................................................................2-6
Chapter 11 - Rod Loader.....................................................................................................................................2-6
Chapter 12 - Drilling Fluid...................................................................................................................................2-7
Chapter 13 - Auto Greaser..................................................................................................................................2-7
Chapter 14 - Remote Lockout ............................................................................................................................2-8
Specifications ................................................................................................................................................ 2-9
Machine Reference and Orientation ........................................................................................................................ 2-9
General Machine Specifications .............................................................................................................................. 2-9
Hydraulic Specifications........................................................................................................................................... 2-9
Electrical Specifications ......................................................................................................................................... 2-10
Engine Specifications ............................................................................................................................................. 2-10
Fuel and Lubricants .................................................................................................................................... 2-11
Machine Interlocks ...................................................................................................................................... 2-12
Engine Start Interlocks ........................................................................................................................................... 2-12
Engine Protection Interlock.................................................................................................................................... 2-12
Operator Presence Interlock .................................................................................................................................. 2-12
Interlock ................................................................................................................................................................... 2-13
D20x22 Navigator HDD Service Table of Contents

Controllers A1 and A2................................................................................................................................. 2-13

Controller Faceplates.............................................................................................................................................. 2-14
Key to LEDs ............................................................................................................................................................. 2-15
Engine Bay Controller A1 .................................................................................................................................2-15
Console Controller A2 ......................................................................................................................................2-16
Key to Fault Codes .................................................................................................................................................. 2-17
Engine Bay Controller A1 .................................................................................................................................2-17
Console Controller A2 ......................................................................................................................................2-17
Controller LED Output Grouped According to Function ..................................................................................... 2-18
Power Distribution LEDs ..................................................................................................................................2-18
Engine LEDs ......................................................................................................................................................2-19
Thrust/Pullback or Left Track LEDs ................................................................................................................2-20
Rotation or Right Track LEDs ..........................................................................................................................2-21
Controller LEDs Associated with PFC Pump Functions ...............................................................................2-22
Hydraulic Valves.......................................................................................................................................... 2-25
Solenoids ................................................................................................................................................................. 2-25
Valves ....................................................................................................................................................................... 2-26

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

Overview......................................................................................................................................................... 3-1
Functions/Circuits/Components .................................................................................................................. 3-1
Functions/Circuits ..................................................................................................................................................... 3-1
Components .............................................................................................................................................................. 3-2
Component Locations............................................................................................................................................... 3-3
Troubleshooting ........................................................................................................................................................ 3-6
Pretest Inspection ..................................................................................................................................................... 3-6
Test Equipment Needed............................................................................................................................................ 3-6
Specifications ............................................................................................................................................................ 3-7
Electrical System ................................................................................................................................................3-7
Battery ..................................................................................................................................................................3-7
Circuit Breaker ....................................................................................................................................................3-7
Fuse Ratings........................................................................................................................................................3-7
Engine ..................................................................................................................................................................3-7
Component Repair/Replace...................................................................................................................................... 3-7
Engine............................................................................................................................................................. 3-8
Engine Service........................................................................................................................................................... 3-8
Engine Maintenance.................................................................................................................................................. 3-8
Engine Start Circuit ................................................................................................................................................... 3-9
Required Operating Conditions .........................................................................................................................3-9
Operation .............................................................................................................................................................3-9
Key Switch S4 at OFF ............................................................................................................................................. 3-10
Key Switch S4 at RUN or ACC................................................................................................................................ 3-10
Battery Charging Circuit ............................................................................................................................. 3-11
Testing the Circuits ..................................................................................................................................... 3-12
Measure Battery Voltage......................................................................................................................................... 3-12
Check for Power at Controllers and Remote Lockout Charger .......................................................................... 3-13
Table of Contents D20x22 Navigator HDD Service

One Power LED Dark ........................................................................................................................................3-14

Battery Charging Circuit ......................................................................................................................................... 3-15
Testing Components................................................................................................................................... 3-16
Test Fuses................................................................................................................................................................ 3-16
Testing Breaker CB1 and Main Power Relay K2................................................................................................... 3-17
Reason CB1 Tripped .........................................................................................................................................3-18
Testing S2 and S3 ................................................................................................................................................... 3-19
Testing Switch S4.................................................................................................................................................... 3-20
Component Repair ...................................................................................................................................... 3-21
Fuse Panel ............................................................................................................................................................... 3-21
Remove ..............................................................................................................................................................3-21
Install ..................................................................................................................................................................3-22
Breaker CB1 ............................................................................................................................................................. 3-22
Relay K2 ................................................................................................................................................................... 3-23
Emergency Stop Switches S2 or S3 ...................................................................................................................... 3-24
Replace ..............................................................................................................................................................3-24
Ignition Switch S4 ................................................................................................................................................... 3-24
Battery Disconnect Switch S1................................................................................................................................ 3-25
Replace ..............................................................................................................................................................3-25

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

Overview......................................................................................................................................................... 4-1
Specifications ............................................................................................................................................................ 4-1
Functions/Components ............................................................................................................................................ 4-1
Component Locations............................................................................................................................................... 4-3
Hydraulic Hose Connections - Fluid Supply and Return....................................................................................... 4-4
Troubleshooting ............................................................................................................................................ 4-5
Reference Diagrams.................................................................................................................................................. 4-5
Test Equipment Needed............................................................................................................................................ 4-5
Pretest Inspection ..................................................................................................................................................... 4-6
Excessive Noise/Vibration........................................................................................................................................ 4-7
Oil Supply..................................................................................................................................................... 4-10
PMP1 & PMP2 Hydrostatic Loop............................................................................................................................ 4-11
Outgoing Fluid...................................................................................................................................................4-11
Returning Fluid - Drill Mode .............................................................................................................................4-11
Returning Fluid - Transport Mode ...................................................................................................................4-11
Charge Pump ........................................................................................................................................................... 4-12
Operation ...........................................................................................................................................................4-12
Charge Pump Inlet Restriction Measurement.................................................................................................4-13
Charge Pressure Measurement .......................................................................................................................4-14
PFC Pump PMP3 ..................................................................................................................................................... 4-16
Supply ................................................................................................................................................................4-16
Return.................................................................................................................................................................4-16
Oil Filtering................................................................................................................................................... 4-17
With Functions Operating or At Rest .................................................................................................................... 4-17
Normal Operation ..............................................................................................................................................4-17
D20x22 Navigator HDD Service Table of Contents

Oil Cooling ................................................................................................................................................... 4-18

Oil Cooler HE1 ......................................................................................................................................................... 4-18
Normal Operation ..............................................................................................................................................4-18
Tracking Cooler Flow Valve Assembly A18 .......................................................................................................... 4-19
Hydraulic Fluid Sampling ........................................................................................................................... 4-19
Fluid Sample Collection Points........................................................................................................................4-21
Adjusting Relief PV4 ............................................................................................................................................... 4-22
Bypass Valve Adjustment....................................................................................................................................... 4-23
Charge Pump Replacement.................................................................................................................................... 4-23
PFC Pump PMP3 High and Low Pressure Compensator Adjustment................................................................ 4-24
Component Repair ...................................................................................................................................... 4-27
PMP1/PMP2 Charge Checks and High Pressure Relief Valves........................................................................... 4-28
Adjusting Charge Pressure Relief Valve PV4 ....................................................................................................... 4-29
PMP1/PMP2 Tandem Pump Replacement............................................................................................................. 4-30
Returning System to Service ...........................................................................................................................4-33
Servicing Hydrostatic Circuits ............................................................................................................................... 4-34
Filter Components................................................................................................................................................... 4-36
PMP3 Replacement ................................................................................................................................................. 4-37
EDCs for PMP1 and PMP2 ...................................................................................................................................... 4-39
Adjusting Pump Swashplate NEUTRAL Position...........................................................................................4-40
Nulling the EDC .................................................................................................................................................4-41
Testing Transducers B4 and B5............................................................................................................................. 4-42
Replacing Transducers B4 and B5 ........................................................................................................................ 4-43
Pump PMP3 Replacement ...................................................................................................................................... 4-44

Ground Drive .................................................................................................................................... 5-1

Overview......................................................................................................................................................... 5-1
Functions/Components ............................................................................................................................................ 5-1
Functions .............................................................................................................................................................5-1
Components ........................................................................................................................................................5-1
Component Locations............................................................................................................................................... 5-2
Hose Connections ..................................................................................................................................................... 5-4
Transport Mode ...................................................................................................................................................5-5
Charge Pressure Circuit ............................................................................................................................... 5-5
Drill/Transport Valve Assembly A7.......................................................................................................................... 5-7
Operation - Right Track ......................................................................................................................................5-7
Operation - Left Track .........................................................................................................................................5-7
Brake Release Circuit.................................................................................................................................... 5-8
Troubleshooting ........................................................................................................................................................ 5-8
Pretest Inspection ..................................................................................................................................................... 5-9
Machine Performance ............................................................................................................................................. 5-11
Possible Results ...............................................................................................................................................5-11
Test Equipment Needed.......................................................................................................................................... 5-12
Specifications .......................................................................................................................................................... 5-12
Component Repair/Replace.................................................................................................................................... 5-12
Ground Drive Circuit ................................................................................................................................... 5-13
Table of Contents D20x22 Navigator HDD Service

Troubleshooting/Testing ..................................................................................................................................5-15
Pilot Valve Assembly A8......................................................................................................................................... 5-16
Operation ...........................................................................................................................................................5-16
Troubleshooting/Testing ..................................................................................................................................5-17
Testing Pilot Valve Assembly A8 for Cross Port Leakage ............................................................................5-18
Track Drive Motors MH5 & MH6 ............................................................................................................................. 5-19
Operation ...........................................................................................................................................................5-19
Measuring Case Drain Flow .............................................................................................................................5-20
Analysis of Case Flow Test for MH5 and MH6................................................................................................5-21
Right Track Function................................................................................................................................... 5-21
Track Forward Mode ............................................................................................................................................... 5-21
Required Operating Conditions .......................................................................................................................5-21
Operation ...........................................................................................................................................................5-22
Troubleshooting/Testing ..................................................................................................................................5-22
Failure of Both Tracks ......................................................................................................................................5-24
Failure of Single Track......................................................................................................................................5-25
Tracks Operating in Single Direction ..............................................................................................................5-25
Track Reverse Mode ............................................................................................................................................... 5-25
Required Operating Conditions .......................................................................................................................5-25
Operation ...........................................................................................................................................................5-26
Left Track Function ..................................................................................................................................... 5-26
Track Forward Mode ............................................................................................................................................... 5-26
Required Operating Conditions .......................................................................................................................5-26
Operation ...........................................................................................................................................................5-26
Track Reverse Mode ............................................................................................................................................... 5-26
Required Operating Conditions .......................................................................................................................5-26
Operation ...........................................................................................................................................................5-26
Track Drive Circuit Cooling ........................................................................................................................ 5-27
Track Brakes Release ................................................................................................................................. 5-27
Required Operating Conditions .......................................................................................................................5-27
Operation ...........................................................................................................................................................5-28
Component Repair ...................................................................................................................................... 5-29
Seat Switch S11 ....................................................................................................................................................... 5-29
Charge Pump ........................................................................................................................................................... 5-29
PMP1/PMP2 Tandem Pump Adjustments ............................................................................................................. 5-29
EDCs for PMP1 and PMP2 ...................................................................................................................................... 5-29
Transducers B4 & B5 for PMP1/PMP2................................................................................................................... 5-29
PMP1/PMP2 Tandem Pump Replacement............................................................................................................. 5-29
Track Drive Motors MH5 & MH6 ............................................................................................................................. 5-30
Pilot Valve Assembly A8......................................................................................................................................... 5-32
Solenoid Coils L19, L20, and L21 ....................................................................................................................5-32
Drill Transport Valve Assembly A7........................................................................................................................ 5-33
Valves DV1, DV2, DV3, DV4, and DV5 .............................................................................................................5-33
Directional Valve DV1 .......................................................................................................................................5-34
Directional Valves DV2 & DV3..........................................................................................................................5-34
Directional Valves DV4 & DV5..........................................................................................................................5-35
Transport Joysticks ................................................................................................................................................ 5-35
D20x22 Navigator HDD Service Table of Contents

Thrust/Pullback ................................................................................................................................ 6-1

Overview......................................................................................................................................................... 6-1
Functions/Components ............................................................................................................................................ 6-1
Functions .............................................................................................................................................................6-1
Components ........................................................................................................................................................6-1
Component Locations............................................................................................................................................... 6-2
Hose Connections ..................................................................................................................................................... 6-5
Troubleshooting ........................................................................................................................................................ 6-6
Pretest Inspection ..................................................................................................................................................... 6-7
Machine Performance ............................................................................................................................................... 6-9
Possible Results .................................................................................................................................................6-9
Test Equipment Needed.......................................................................................................................................... 6-10
Specifications .......................................................................................................................................................... 6-10
Component Repair/Replace.................................................................................................................................... 6-10
Thrust/Pullback Circuit ............................................................................................................................... 6-11
Pump PMP2.............................................................................................................................................................. 6-12
Operation ...........................................................................................................................................................6-12
Charge Pump .....................................................................................................................................................6-12
Pilot Valve Assembly A8......................................................................................................................................... 6-13
Operation ...........................................................................................................................................................6-13
Troubleshooting ................................................................................................................................................6-14
Drill/Transport Valve Assembly A7........................................................................................................................ 6-15
Operation ...........................................................................................................................................................6-15
Troubleshooting/Testing ..................................................................................................................................6-16
Thrust/Pullback Valve Assembly A6...................................................................................................................... 6-17
Operation ...........................................................................................................................................................6-17
Troubleshooting/Testing ..................................................................................................................................6-17
Thrust/Pullback Function ........................................................................................................................... 6-18
LOW Speed .............................................................................................................................................................. 6-18
HIGH Speed.............................................................................................................................................................. 6-19
Thrust Mode ............................................................................................................................................................. 6-20
Required Operating Conditions .......................................................................................................................6-20
Operation ...........................................................................................................................................................6-20
Troubleshooting/Testing ..................................................................................................................................6-21
Pullback Mode ......................................................................................................................................................... 6-22
Required Operating Conditions .......................................................................................................................6-22
Normal Operation ..............................................................................................................................................6-22
Troubleshooting/Testing ..................................................................................................................................6-23
Component Repair ...................................................................................................................................... 6-24
Charge Pump ........................................................................................................................................................... 6-24
PMP1/PMP2 Tandem Pump Adjustments ............................................................................................................. 6-24
EDCs for PMP1 and PMP2 ...................................................................................................................................... 6-24
Transducers B4 & B5 for PMP1/PMP2................................................................................................................... 6-24
PMP1/PMP2 Tandem Pump Replacement............................................................................................................. 6-24
Pilot Valve Assembly A8......................................................................................................................................... 6-24
Drill Transport Valve Assembly A7........................................................................................................................ 6-25
High Speed Carriage Valve Assembly A6 ............................................................................................................. 6-26
Solenoid Coils L3, L4, and L5 ..........................................................................................................................6-26
Table of Contents D20x22 Navigator HDD Service

Motors MH2, MH3, and MH4 ....................................................................................................................... 6-27

Remove ..............................................................................................................................................................6-27
Install ..................................................................................................................................................................6-28
Drill Joysticks A19 & A20 ....................................................................................................................................... 6-29

Drill Rotation .................................................................................................................................... 7-1

Overview......................................................................................................................................................... 7-1
Functions/Components ............................................................................................................................................ 7-1
Functions .............................................................................................................................................................7-1
Components ........................................................................................................................................................7-1
Component Locations............................................................................................................................................... 7-2
Hose Connections ..................................................................................................................................................... 7-3
Schematic .................................................................................................................................................................. 7-4
Troubleshooting ........................................................................................................................................................ 7-5
Pretest Inspection ..................................................................................................................................................... 7-5
Machine Performance ............................................................................................................................................... 7-6
Possible Results .................................................................................................................................................7-7
Test Equipment Needed............................................................................................................................................ 7-7
Specifications ............................................................................................................................................................ 7-8
Electrical: .............................................................................................................................................................7-8
Hydraulic:.............................................................................................................................................................7-8
Component Repair/Replace...................................................................................................................................... 7-8
Hydrostatic Loop - PMP1 & PMP2............................................................................................................................ 7-8
Drill/Transport Valve Assembly A7.......................................................................................................................... 7-9
Operation - Drilling Mode ...................................................................................................................................7-9
Troubleshooting/Testing ..................................................................................................................................7-10
Pilot Valve Assembly A8......................................................................................................................................... 7-11
Operation - High Speed Rotation.....................................................................................................................7-11
Troubleshooting/Testing ..................................................................................................................................7-12
Torque Limiter Valve Assembly A9 ....................................................................................................................... 7-13
Operation ...........................................................................................................................................................7-13
Troubleshooting/Testing ..................................................................................................................................7-14
Rotation Motor MH1 ................................................................................................................................................ 7-15
Speed Shift Circuit ............................................................................................................................................7-15
Rotation Motor Flush Circuit............................................................................................................................7-15
Drill Rotation Function................................................................................................................................ 7-16
Drilling/Backreaming High Mode ........................................................................................................................... 7-16
Required Operating Conditions .......................................................................................................................7-16
Operation ...........................................................................................................................................................7-17
Troubleshooting/Testing ..................................................................................................................................7-18
Drilling/Backreaming Low Mode ........................................................................................................................... 7-22
Required Operating Conditions .......................................................................................................................7-22
Operation ...........................................................................................................................................................7-23
Troubleshooting/Testing ..................................................................................................................................7-23
Rotation Loop Cooling Circuit ................................................................................................................... 7-24
D20x22 Navigator HDD Service Table of Contents

Component Repair ...................................................................................................................................... 7-24

PUMP PMP1 ............................................................................................................................................................. 7-24
Pilot Control Valve Assembly A8 ........................................................................................................................... 7-24
Drill Transport Valve Assembly A7........................................................................................................................ 7-25
Torque Limiter Valve Assembly A9 ....................................................................................................................... 7-25
Manifold Removal .............................................................................................................................................7-25
Shuttle Valve SV1 ..............................................................................................................................................7-26
Relief Valve PV1 ................................................................................................................................................7-26
Rotation Motor MH1 ................................................................................................................................................ 7-27
Removal .............................................................................................................................................................7-27
Breakdown .........................................................................................................................................................7-27
Rotation Gearbox .................................................................................................................................................... 7-28
Removal .............................................................................................................................................................7-28

Stakedown ........................................................................................................................................ 8-1

Overview......................................................................................................................................................... 8-1
Functions/Components ............................................................................................................................................ 8-1
Functions .............................................................................................................................................................8-1
Components ........................................................................................................................................................8-2
Specifications ............................................................................................................................................................ 8-2
Component Locations............................................................................................................................................... 8-3
Hose Connections ..................................................................................................................................................... 8-4
Troubleshooting ........................................................................................................................................................ 8-5
Pretest Inspection ..................................................................................................................................................... 8-5
Machine Performance ............................................................................................................................................... 8-7
Possible Results .................................................................................................................................................8-7
Test Equipment Needed............................................................................................................................................ 8-8
Component Repair/Replace...................................................................................................................................... 8-8
Stakedown Hydraulic Circuit........................................................................................................................ 8-9
Pump PMP3.............................................................................................................................................................. 8-10
High Pressure Mode .........................................................................................................................................8-10
Troubleshooting/Testing ..................................................................................................................................8-10
Compensator ........................................................................................................................................................... 8-11
Pressure Compensator Spool..........................................................................................................................8-11
Load Sense ........................................................................................................................................................8-12
Troubleshooting/Testing ..................................................................................................................................8-13
Stakedown Valve Assembly A10............................................................................................................................ 8-14
Operation ...........................................................................................................................................................8-14
Troubleshooting/Testing ..................................................................................................................................8-15
Stake Out Mode ....................................................................................................................................................... 8-15
Required Operating Conditions .......................................................................................................................8-15
Operation ...........................................................................................................................................................8-16
Troubleshooting/Testing ..................................................................................................................................8-17
Stake In Mode .......................................................................................................................................................... 8-18
Required Operating Conditions .......................................................................................................................8-18
Normal Operation ..............................................................................................................................................8-18
Troubleshooting/Testing ..................................................................................................................................8-19
PMP3......................................................................................................................................................................... 8-19
Table of Contents D20x22 Navigator HDD Service

Adjusting Load Sense Spool and Compensator Settings.............................................................................8-19

Component Repair ...................................................................................................................................... 8-22
Replacing PMP3 ...................................................................................................................................................... 8-22
Stakedown Control Valve A10................................................................................................................................ 8-24
Valves DV11, DV12, DV13, and DV14 ..............................................................................................................8-24
Counterbalance Valves CV26 and CV27................................................................................................................ 8-25
Stakedown Motors MH7 and MH8 .......................................................................................................................... 8-26
Stakedown Cylinders CY1 and CY2....................................................................................................................... 8-27

Stabilizer/Rack Angle ...................................................................................................................... 9-1

Overview......................................................................................................................................................... 9-1
Functions/Components ............................................................................................................................................ 9-1
Functions .............................................................................................................................................................9-1
Components ........................................................................................................................................................9-1
Component Locations............................................................................................................................................... 9-2
Hose Connections ..................................................................................................................................................... 9-3
Troubleshooting ........................................................................................................................................................ 9-3
Pretest Inspection ..................................................................................................................................................... 9-4
Machine Performance ............................................................................................................................................... 9-6
Possible Results .................................................................................................................................................9-6
Test Equipment Needed............................................................................................................................................ 9-7
Specifications ............................................................................................................................................................ 9-7
Component Repair/Replace...................................................................................................................................... 9-7
Stabilizer/Rack Angle Circuit........................................................................................................................ 9-8
Pump PMP3................................................................................................................................................................ 9-9
Compensator ............................................................................................................................................................. 9-9
Rack Angle/Stabilizer Valve Assembly A11 ............................................................................................................ 9-9
Operation .............................................................................................................................................................9-9
Troubleshooting ..................................................................................................................................................9-9
Stabilizer Function ...................................................................................................................................... 9-10
Stabilizer LOWER Mode.......................................................................................................................................... 9-10
Required Operating Conditions. ......................................................................................................................9-10
Operation ...........................................................................................................................................................9-10
Troubleshooting/Testing ..................................................................................................................................9-11
Stabilizer RAISE Mode ............................................................................................................................................ 9-12
Required Operating Conditions .......................................................................................................................9-12
Operation ...........................................................................................................................................................9-12
Rack Angle Function................................................................................................................................... 9-13
Rack LOWER Mode ................................................................................................................................................. 9-13
Required Operating Conditions .......................................................................................................................9-13
Operation ...........................................................................................................................................................9-14
Troubleshooting/Testing ..................................................................................................................................9-14
Rack RAISE Mode ................................................................................................................................................... 9-15
Required Operating Conditions .......................................................................................................................9-15
Operation ...........................................................................................................................................................9-15
D20x22 Navigator HDD Service Table of Contents

Component Repair ...................................................................................................................................... 9-16

Rack Angle/Stabilizer Valve Assembly A11 .......................................................................................................... 9-16
Valves DV15, DV16 and PV11...........................................................................................................................9-16
Rack Angle Cylinder CY14...................................................................................................................................... 9-18
Stabilizer Cylinder CY13 ......................................................................................................................................... 9-19

Vises ............................................................................................................................................... 10-1

Overview....................................................................................................................................................... 10-1
Functions/Components .......................................................................................................................................... 10-1
Functions ...........................................................................................................................................................10-1
Components ......................................................................................................................................................10-2
Component Locations............................................................................................................................................. 10-3
Hose Connections ................................................................................................................................................... 10-5
Troubleshooting ...................................................................................................................................................... 10-6
Pretest Inspection ................................................................................................................................................... 10-6
Machine Performance ............................................................................................................................................. 10-8
Possible Results ...............................................................................................................................................10-8
Test Equipment Needed.......................................................................................................................................... 10-9
Specifications .......................................................................................................................................................... 10-9
Component Repair/Replace.................................................................................................................................... 10-9
Hydraulic Schematic ................................................................................................................................. 10-10
Electrical Schematic.................................................................................................................................. 10-11
Pump PMP3................................................................................................................................................ 10-12
Compensator ............................................................................................................................................. 10-12
Vise Valve Assembly A13 ......................................................................................................................... 10-12
Operation .........................................................................................................................................................10-12
DRILL OUT Mode ....................................................................................................................................... 10-13
Front Vise CLAMP Operation .............................................................................................................................. 10-13
Troubleshooting/Testing ...................................................................................................................................... 10-15
Front Vise UNCLAMP ............................................................................................................................................ 10-16
Required Operating Conditions .....................................................................................................................10-16
Operation .........................................................................................................................................................10-17
Troubleshooting/Testing ................................................................................................................................10-18
Torque Limiter Function ....................................................................................................................................... 10-19
PULLBACK Mode ...................................................................................................................................... 10-19
Front Vise Clamp ................................................................................................................................................... 10-19
Front Vise Unclamp............................................................................................................................................... 10-19
Rear Vise CLAMP .................................................................................................................................................. 10-20
Required Operating Conditions .....................................................................................................................10-20
Normal Operation ............................................................................................................................................10-21
Troubleshooting/Testing ................................................................................................................................10-22
Rear Vise Unclamp ................................................................................................................................................ 10-23
Required Operating Conditions .....................................................................................................................10-23
Operation .........................................................................................................................................................10-24
Troubleshooting/Testing ................................................................................................................................10-24
Rear Vise Rotate (Extend)..................................................................................................................................... 10-25
Table of Contents D20x22 Navigator HDD Service

Required Operating Conditions .....................................................................................................................10-25

Operation .........................................................................................................................................................10-26
Rear Vise Rotate (Retract) .................................................................................................................................... 10-27
Required Operating Conditions .....................................................................................................................10-27
Operation .........................................................................................................................................................10-27
Component Repair .................................................................................................................................... 10-28
Pump PMP3............................................................................................................................................................ 10-28
Vise Valve Assembly A13 ..................................................................................................................................... 10-28
Solenoids L1, L2, L6, L8 .................................................................................................................................10-28
Valves DV26, DV25, DV17, DV18, DV19 .........................................................................................................10-28
Check Valve CV19 ...........................................................................................................................................10-29
Vise Clamp Cylinders CY3 and CY4 .................................................................................................................... 10-30
Vise Rotation Cylinder CY5 .................................................................................................................................. 10-31

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

Overview....................................................................................................................................................... 11-1
Functions/Components .......................................................................................................................................... 11-1
Functions ...........................................................................................................................................................11-1
Components ......................................................................................................................................................11-1
Component Locations............................................................................................................................................. 11-2
Hose Connections ................................................................................................................................................... 11-4
Troubleshooting ...................................................................................................................................................... 11-5
Pretest Inspection ................................................................................................................................................... 11-5
Machine Performance ............................................................................................................................................. 11-6
Possible Results ...............................................................................................................................................11-7
Test Equipment Needed.......................................................................................................................................... 11-7
Specifications .......................................................................................................................................................... 11-8
Component Repair/Replace.................................................................................................................................... 11-8
Rod Loader Circuit ...................................................................................................................................... 11-9
Pump PMP3............................................................................................................................................................ 11-10
Compensator ......................................................................................................................................................... 11-10
Rod Loader Valve Assembly A14......................................................................................................................... 11-10
Operation .........................................................................................................................................................11-10
Drill Out Mode ............................................................................................................................................ 11-11
Extend Rod Loader Arm ....................................................................................................................................... 11-11
Operation .........................................................................................................................................................11-12
Troubleshooting/Testing ................................................................................................................................11-13
Retract Rod Loader Arm ....................................................................................................................................... 11-14
Operation .........................................................................................................................................................11-15
Troubleshooting/Testing ................................................................................................................................11-15
Pullback Mode ........................................................................................................................................... 11-16
Extend Rod Loader Arm ....................................................................................................................................... 11-16
Operation .........................................................................................................................................................11-17
Troubleshooting/Testing ................................................................................................................................11-17
Retract Rod Loader Arm ....................................................................................................................................... 11-18
Operation .........................................................................................................................................................11-19
Troubleshooting/Testing ................................................................................................................................11-19
D20x22 Navigator HDD Service Table of Contents

Component Repair .................................................................................................................................... 11-19

Pump PMP3............................................................................................................................................................ 11-19
Rod Loader Valve Assembly A14......................................................................................................................... 11-20
Solenoids L11, L13, L15, L16 .........................................................................................................................11-20
Valves DV20, PV14, PV15, DV21, DV22 .........................................................................................................11-20
Rod Lift Cylinders CY10 and CY11 ...................................................................................................................... 11-21
Rod Loader Shift Cylinders CY8 and CY9........................................................................................................... 11-22
Rod Loader Selector Cylinders CY6 and CY7..................................................................................................... 11-22

Drilling Fluid ................................................................................................................................... 12-1

Overview....................................................................................................................................................... 12-1
Functions/Components .......................................................................................................................................... 12-1
Functions ...........................................................................................................................................................12-1
Components ......................................................................................................................................................12-1
Specifications .......................................................................................................................................................... 12-2
Component Locations............................................................................................................................................. 12-3
Hose Connections ................................................................................................................................................... 12-5
Electrical Schematic ............................................................................................................................................... 12-6
Troubleshooting ...................................................................................................................................................... 12-7
Pretest Inspection ................................................................................................................................................... 12-7
Machine Performance ............................................................................................................................................. 12-9
Possible Results ...............................................................................................................................................12-9
Test Equipment Needed........................................................................................................................................ 12-10
Component Repair/Replace.................................................................................................................................. 12-10
Drilling Fluid Hydraulic Circuit................................................................................................................. 12-11
Pump PMP3............................................................................................................................................................ 12-12
Compensator ......................................................................................................................................................... 12-12
Drill Fluid Valve Assembly A12 ............................................................................................................................ 12-12
Operation .........................................................................................................................................................12-12
Troubleshooting/Testing ................................................................................................................................12-13
Water Pump PMP4................................................................................................................................................. 12-14
Operation .........................................................................................................................................................12-14
Water Pump Motor MH9 ........................................................................................................................................ 12-15
Operation .........................................................................................................................................................12-15
Drill Fluid OFF............................................................................................................................................ 12-16
Operation .........................................................................................................................................................12-16
Troubleshooting/Testing ................................................................................................................................12-16
Drill Fluid ON.............................................................................................................................................. 12-17
Variable Flow Mode ............................................................................................................................................... 12-17
Required Operating Conditions .....................................................................................................................12-18
Operation .........................................................................................................................................................12-18
Troubleshooting/Testing ................................................................................................................................12-19
Full Flow Mode ...................................................................................................................................................... 12-21
Table of Contents D20x22 Navigator HDD Service

Operation .........................................................................................................................................................12-22
Troubleshooting .................................................................................................................................................... 12-23
Check Controllers First......................................................................................................................................... 12-23
Ball Valve Not Turning On/Off .............................................................................................................................. 12-24
Water Pump Motor Does Not Turn at Regulated Speed .................................................................................... 12-27
Full Flow Switch Does Not Increase Speed of Water Pump.............................................................................. 12-31
Water Pump Motor Will Not Reach Full Speed ................................................................................................... 12-32
Flow Test of Motor MH9..................................................................................................................................12-33
Worksheet for Flow Test of Motor MH9............................................................................................................... 12-34
Interpreting the Results ..................................................................................................................................12-34
Water Flow Meter Not Working ............................................................................................................................ 12-35
Water Flow Meter Not Illuminated..................................................................................................................12-35
Troubleshooting the Water On/Off Switch .......................................................................................................... 12-36
Component Repair .................................................................................................................................... 12-36
Pump PMP3............................................................................................................................................................ 12-36
Drill Fluid Motor MH9 ............................................................................................................................................ 12-37
Valve Assembly A12 ............................................................................................................................................. 12-38
Disassembly ....................................................................................................................................................12-38
Assembly .........................................................................................................................................................12-38
Fluid Shutoff Valve Assembly A24 ...................................................................................................................... 12-39
Removal ...........................................................................................................................................................12-39
Disassembly ....................................................................................................................................................12-39
Fluid Shutoff Cylinder CY12 ................................................................................................................................. 12-40
Remove ............................................................................................................................................................12-40
Cylinder Disassembly .....................................................................................................................................12-41
Ball Valve ............................................................................................................................................................... 12-42
Ball Valve Assembly .......................................................................................................................................12-43

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

Overview....................................................................................................................................................... 13-1
Components ............................................................................................................................................................ 13-1
Component Locations............................................................................................................................................. 13-2
Hose Connections ................................................................................................................................................... 13-3
Greasing Mode ........................................................................................................................................................ 13-4
Required Operating Conditions .......................................................................................................................13-5
Normal Operation ..............................................................................................................................................13-5
Troubleshooting/Testing ..................................................................................................................................13-6
Component Repair ...................................................................................................................................... 13-7
Rod Thread Greaser Cylinder CY8......................................................................................................................... 13-7
Grease Cylinder ....................................................................................................................................................... 13-8
Cylinder Disassembly ............................................................................................................................................ 13-8
Auto Greaser Valve DV27 ....................................................................................................................................... 13-9
D20x22 Navigator HDD Service Table of Contents

Remote Lockout............................................................................................................................ 14-1

Overview....................................................................................................................................................... 14-1
Hydraulic Lockout or Engine Shutdown Option................................................................................................... 14-1
Hydraulic Lockout Backup Engine Shutdown...................................................................................................... 14-1
Theory........................................................................................................................................................... 14-2
Functions ................................................................................................................................................................. 14-2
Components ............................................................................................................................................................ 14-2
Component Locations............................................................................................................................................. 14-3
Hydraulic Schematic ............................................................................................................................................... 14-4
Electrical Schematic ............................................................................................................................................... 14-5
Hydraulic Lockout Function ................................................................................................................................... 14-6
Operation ...........................................................................................................................................................14-6
Hydraulic Lockout with Backup Engine Shutdown Function .......................................................................14-7
Engine Shutdown Lockout Function ..................................................................................................................... 14-8
Option Procedure ..............................................................................................................................................14-8
Operation ...........................................................................................................................................................14-8
Troubleshooting .......................................................................................................................................... 14-9
General System Information................................................................................................................................... 14-9
Base Module Indicators ........................................................................................................................................ 14-10
Power On................................................................................................................................................................ 14-12
Remote Unit On ...............................................................................................................................................14-12
Base Module Run ............................................................................................................................................14-12
Lockout Mode ........................................................................................................................................................ 14-13
Power Off ............................................................................................................................................................... 14-13
Remote Registration ............................................................................................................................................. 14-14
Battery Condition .................................................................................................................................................. 14-16
Low Battery......................................................................................................................................................14-16
Discharged Battery .........................................................................................................................................14-16
Recharge Battery ............................................................................................................................................14-16
Troubleshooting/Testing the Remote Lockout Function................................................................................... 14-17
Remote Unit .....................................................................................................................................................14-17
Base Module ....................................................................................................................................................14-18
Verify Software ................................................................................................................................................14-18
Verify CAN Operation .....................................................................................................................................14-19
Hydraulic or Engine Shutdown Lockout Mode.............................................................................................14-19
Battery ..............................................................................................................................................................14-20
Battery Charger ...............................................................................................................................................14-20
Terminal Test ...................................................................................................................................................14-21
Flow Chart for Determining Machine Problem (Without Remote) .................................................................... 14-22
Flow Chart for Determining Machine Problem (With Remote) .......................................................................... 14-23
Component Repair .................................................................................................................................... 14-24
Shuttle Valve .......................................................................................................................................................... 14-24
Disassembly ....................................................................................................................................................14-25
Table of Contents D20x22 Navigator HDD Service

Strike Alert...................................................................................................................................... 15-1

Overview....................................................................................................................................................... 15-1
Theory........................................................................................................................................................... 15-1
Circuits ..................................................................................................................................................................... 15-1
Components ............................................................................................................................................................ 15-1
Component Locations............................................................................................................................................. 15-2
Strike Alert System Test ......................................................................................................................................... 15-3
Electrical Schematic ............................................................................................................................................... 15-4
Voltage Strike Circuit .............................................................................................................................................. 15-5
Operation ...........................................................................................................................................................15-5
Current Strike Circuit .............................................................................................................................................. 15-5
Operation ...........................................................................................................................................................15-5
Troubleshooting/Testing ............................................................................................................................ 15-6
Determining What to Troubleshoot .................................................................................................................15-6
Daily Test Fails ..................................................................................................................................................15-6
Control Panel Light ................................................................................................................................................. 15-7
Strike Alert Module Lights ...................................................................................................................................... 15-8
Component Repair ...................................................................................................................................... 15-9
Voltage Stake E1 ..................................................................................................................................................... 15-9
Strike Alert Coil Assembly B2 .............................................................................................................................. 15-10
D20x22 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 Manufacturing Company 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.

General Information
Operating instructions are found in the D20x22 Operator’s Manual.
Lubrication and maintenance procedures are found in the D20x22
Maintenance Manual. Refer to Reference Publications for ordering
information.

Reference Publications
Vermeer The following Vermeer Manufacturing Publications are necessary for
Publications reference:

• D20x22 Navigator Directional Drill Operator’s Manual, order number

105400X98.
• D20x22 Navigator Directional Drill Maintenance Manual, order number
105400Y00.
• D20x22 Navigator Directional Drill Parts Manual, order number
105400ZGM.
• 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 Navigator HDD Service

Contact the Vermeer Parts Center to order these publications.

Vendor Publications The following vendor publications are optional reference materials:

• Caterpillar 3054C Engine Manual

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

WARRANTY CONSIDERATIONS
Vermeer Warranty
Vermeer 1 year Limited Warranty is printed inside the front cover of the
D20x22 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

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

Understand that only an authorized Caterpillar 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 Caterpillar authorized facility, consult the Yellow Pages of
the phone directory or contact Caterpillar’s Engine Warranty Service Dept.

1-2
D20x22 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 Manufacturing Company.

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 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 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 Navigator HDD Service

WARNING: 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 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.

1-7
 Troubleshooting Guidelines D20x22 Navigator HDD Service

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

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
General Information

Error the appropriate 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 2-12 to see the list of
interlocks used on this machine.

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.
Continued on next page...

1-8
D20x22 Navigator HDD Service Troubleshooting Guidelines

• 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?
—Is the problem intermittent or continuous?
—If intermittent, does is 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.

General Information

1-9
 Troubleshooting Guidelines D20x22 Navigator HDD Service

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

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.
General Information

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.

1-10
D20x22 Navigator HDD Service Troubleshooting Guidelines

Electrical Troubleshooting
Common Electrical Listed below are some common problems to consider when troubleshooting
Problems the 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...

1-11
 Troubleshooting Guidelines D20x22 Navigator HDD Service

• 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.

Hydraulic Troubleshooting
Leakage Path The hydraulic troubleshooting procedures are based on leakage path
Analysis analysis. Using 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.
General Information

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

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

General Information
the pump or motor should be replaced.

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 Navigator HDD Service

Directional Control Directional control valves have radial clearances between the valve bore and
Valves spool of between 5 to 15 micrometers. 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
General Information

flow).
• Actuators operate erratically.
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 consists 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 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 hydraulic system before searching for leaks,

General Information
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 engine is shut down.
Pressure

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 Troubleshooting Guidelines D20x22 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
Meters indicates 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.

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D20x22 Navigator HDD Service Troubleshooting Guidelines

Connecting a Needle valves are used to impose artificial loads on pumps so the
Needle Valve performance of the 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.

Connecting Pressure gauges are selected according to the expected maximum pressure
Pressure Gauges to be 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.

General Information
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 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.

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 Troubleshooting Guidelines D20x22 Navigator HDD Service

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 the circuit or device.

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

Measuring Resistance, measured in Ohms (Ω) is defined as the opposition to current

Resistance flow. Set the 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 the circuit or device.

2. Connect the positive (red) lead in the multimeter’s voltage or VΩ port.
Place the red probe on the wire or contact delivering power to the device.
3. Connect the negative (black) lead in the common or COM port. Place the
black probe on the wire or contact leading to ground for the device (the
multimeter is in parallel with the 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.

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D20x22 Navigator HDD Service Troubleshooting Guidelines

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

1. Turn off power to the device or circuit.

2. Disconnect the section of harness in question.
3. Place one probe on one end of the wire or terminal of the device. Place
the other probe on the other end of the same wire or opposite terminal of
the 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.

General Information
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 the circuit or device.

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

1-19
 Repair Guidelines D20x22 Navigator HDD Service

REPAIR GUIDELINES
Shop Requirements
Special Tools & Test To perform some tasks, special tools— available through Vermeer—may be
Equipment required. 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.
General Information

20General Information

Replacement Parts
Part Numbers/Hose Refer to the most current D20x22 Parts Manual, order number 105400ZGM
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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D20x22 Navigator HDD Service Repair Guidelines

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 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 engine off 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 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
transmitter 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.

2-1
 Starting Procedure D20x22 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 drill levers are in NEUTRAL.
4. On a cold engine, press glow plug button in the engine compartment to
turn on preheat system. Return to operator seat.
5. 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.
Machine Information

Allow starter motor to cool 2 minutes between attempts.

6. 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 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.

7. Turn remote transmitter on.

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

2-2
D20x22 Navigator HDD Service Starting Procedure

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.

Hydraulic Fluid Refer to "Fuel and Lubricants," page 2-11 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.

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.

Machine Information
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, vise, 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.

Chapter 3 - Power • Engine ENG1

• Rotation/Right Track Pump PMP1
• Thrust/Pullback/Left Track Pump PMP2
• Implement Drive Pump PMP3
• Battery BT1
• Fuse F1–F7
• Circuit Breaker CB2

2-3
 Starting Procedure D20x22 Navigator HDD Service

Chapter 4 - • Pump PMP1

Hydraulic Fluid • Pump PMP2
Distribution
• Implement pump PMP3
• Hydraulic Tank RES1 Including:
• Return Filter FL1 & FL2
• Oil Level Indicator GA6
• Charge Pump Filter FL3
• Oil Cooler HE1

Chapter 5 - Ground • Pump PMP1

Drive • Pump PMP2
• Drill/Transport Valve Assembly A7
• Directional Valves DV1–DV5
• Pilot Valve Assembly A8
• Coil L14 and DV8
Machine Information

• Coil L20 and DV9

• Coil L19 and DV10
• Right Track Drive Motor MH5
• Left Track Drive Motor MH6

Chapter 6 - Thrust/ • Pump PMP2

Pullback • Drill/Transport Valve Assembly A7
• Directional Valves DV1–DV5
• Pilot Valve Assembly A8
• Coil L14 and DV8
• Coil L20 and DV9
• Coil L19 and DV10
• Thrust/Pullback Valve Assembly A6
• Coil L3 and DV5
• Coil L4 and DV6
• Coil L5 and DV7
• Thrust/Pullback Motors
• MH2–MH4
• Thrust/Pullback Pressure Gauge GA4

2-4
D20x22 Navigator HDD Service Starting Procedure

Chapter 7 - Rotation • Pump PMP1

• Drill Transport Valve Assembly A1
• Directional Valves DV1–DV5
• Pilot Valve Assembly A8
• Coil L14 and DV8
• Coil L20 and DV9
• Coil L19 and DV10
• Torque Limiter Valve Assembly A9
• Coil L7 and SV1
• PV1
• Rotation Motor MH1

Chapter 8 - • Implement Pump PMP3

Stakedown • Stakedown Valve Assembly A10
• Directional Valves DV11–DV14

Machine Information
• Counterbalance Valves CV26–27
• Stakedown Motors MH7–MH8
• Stakedown Cylinders CY1–CY2

Chapter 9 - • Implement Pump PMP3

Stabilizer/Rack • Rack Angle/Stabilizer Valve Assembly A11
Angle
• Directional Valves DV16–DV17
• Pressure Relief Valve PV11
• Stabilizer Cylinder CY13
• Rack Angle Cylinder CY14

2-5
 Starting Procedure D20x22 Navigator HDD Service

Chapter 10 - Vises • Implement Pump PMP3

• Vise Valve Assembly A13
• Coil L1 and SV5
• Coil L6 and DV17
• Coil L8 and DV18
• Coil L2 and DV19
• Pressure Relief Valve PV13
• Front Vise Cylinder CY3
• Rear Vise Cylinder CY4
• Rear Vise Rotation Cylinder CY5
• Console Controller A2
• Drill Out/Pullback Switch S16
• Right Joystick Assembly A22
• Vise Engage Switch S13
• Rod Loader Arm Extend/Rear Vise Engage Switch S17
• Rear Vise Disengage/Rod Loader Arm Retract Switch S14
Machine Information

• Vise Disengage Switch S18

Chapter 11 - Rod • PFC Pump PMP3

Loader • Rod Loader Valve Assembly A14
• Coils L11 and L13 of Directional Valve DV20
• Coil L15 of DV21
• Coil L16 of DV22
• Pressure Relief Valves PV14–PV15
• Comb Cylinders CY6–CY7
• Rod Shift Cylinder CY8–CY9
• Rod Lift Cylinders CY10–CY11
• Right Joystick Assembly A22
• Vise Engage Switch S13
• Rod Loader Arm Extend/Rear Vise Engage Switch S17
• Rear Vise Disengage/Rod Loader Arm Retract Switch S14
• Vise Disengage Switch S18

2-6
D20x22 Navigator HDD Service Starting Procedure

Chapter 12 - Drilling • Water Pump Drive Motor MH9

Fluid • PFC Pump PMP3
• Valve Assembly A12 Including
• Full Flow Valve DV31
• Full Flow Solenoid L12
• Pressure Relief PV12
• Water On/Off Valve DV32
• Water On/Off Solenoid L18
• Flow Control Valve FV1
• Ball Valve Control Valve DV23
• Ball Valve Control Solenoid L17
• Ball Valve Cylinder CY12
• Water Flow Meter DS7
• Water ON Light DS8
• Water Control Switch S10
• Water Motor Speed Pickup B3

Machine Information
Chapter 13 - Auto • PFC Pump PMP3
Greaser • Hydraulic Fluid Distribution Components
• Valve Manifold Assembly A21 Including:
• Grease Cylinder Control Valve DV27
• Grease Cylinder Control Solenoid L9
• Joystick Control Including:
• Auto Greaser Switch S15
• Greaser Cylinder CY15

2-7
 Starting Procedure D20x22 Navigator HDD Service

Chapter 14 - Remote • Remote Transmitter A23

Lockout • Remote Lockout Base A4
• CAN Controlled
• Battery Charger A22
• Antenna E1
• Indicator Lights DS9–DS11
• Horn AD2
• Alarm Cancel Switch S19
Machine Information

2-8
D20x22 Navigator HDD Service Specifications

SPECIFICATIONS
Machine Reference and Orientation

Rear

Front

Machine Information
Right

Left, right, front, and rear of the machine is determined by the direction of
travel when the machine is propelled to the work site.

General Machine Specifications

Machine Dimensions Empty Rod Box
Approximate Weight 9200 lb (4173 kg) 11,200 lb (5080 kg)
Overall Length 17 ft 2″ (520 cm)
Overall Width 48″ (122 cm)
Overall Height (at top of air cleaner) 78″ (198 cm)

Hydraulic Specifications
Rotation Pump Flow 31 gpm (117 L/min) @ 2600 rpm
System Pressure 3335 psi (230 bar) relief
Charge Pressure 313 psi (21.5 bar)
Ground Drive 3335 psi (230 bar) relief
Thrust/Pullback 3045 psi (210 bar)

Continued on next page...

2-9
 Specifications D20x22 Navigator HDD Service

Electrical Specifications
Battery One 12-Volt BCI Group Size 31
Cold Cranking Amps 950 CCA
Circuit Breaker 1 105-Amp
Circuit Breaker 2 50-Amp

Fuse Ratings
F1 - 15-Amp
F2 - 5-Amp
F3 - 10-Amp
F4 - 10-Amp
F5 - 10-Amp
F6 - 5-Amp
F7 - 10-Amp

Engine Specifications
Model Caterpillar 3054C
Machine Information

86 hp (64 kW) at 2400 rpm (intermittent)

Maximum power
77 hp (57 kW) at 2200 rpm (continuous)
Fuel type/capacity Diesel, 35 gal (133 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 (4 L)
Alternator 42-amp

2-10
D20x22 Navigator HDD Service Fuel and Lubricants

FUEL AND LUBRICANTS

Lubricant Capacity Specifications / Notes
Refer to engine An Engine Operation Manual is supplied with each machine.
Engine Oil
specifications Refer to the manual for engine service requirements.
Hydraulic system: ISO 46: -13° – 86°F (-25° – 30°C)
Hydraulic Fluid ISO 68: -4° – 104°F (-20° – 40°C)
40 gal (151 L)
Vermeer HyPower 46 or ISO 100: 14° – 122°F (-10° – 50°C)
Vermeer HyPower 68 or
Tank: 27 gal (102 L) Use caution not to get dirt or other contaminants into the
Vermeer HyPower 100
system(s). Filter all fluid through a 5-micron filter before
adding.
IMPORTANT: Use of any oils other than those recommended
without written factory approval will jeopardize warranty.
All-Purpose Gear Lube Maintain Check Plug Oils must conform to API GL5 or MIL-L-2105D specifications.
Level -20° – 100°F (-30° – 40°C): 80W-90
-20° to 100°F (-30° – 40°C): 80W-90
20° to 120°F (-10° – 50°C): 85W-140
General Lubricating Oil As required SAE10W30
Vermeer Xtra Gold 10W39
Grease As required Lithium complex, extreme pressure NLGI Grade 2
Vermeer Ultra LC Grease To minimize condensation in bearings, grease machine after
it is shut down for the day.

Machine Information
Fittings and grease applicator nozzle must be clean before
applying grease. Replace all missing fittings.
Drilling Fluid Pump Crankcase 4.5 qt (4.3 L) SAE- 40
Vermeer Xtra Gold 40 (Classification MM or better)
Plusco Thread Compound (#235983-001)
Drill Rod Thread Compound As required
API Bulletin 7A1. This requires the compound to contain a
copper base to withstand high pressures and remain in the
threads.

2-11
 Machine Interlocks D20x22 Navigator HDD Service

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 switches S2 located at the transport operator station

and S3 at the drill operator station 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
lockout transmitter must be available to start the engine if shut down in
engine lockout mode, or to turn the rotation, thrust\pullback, or the
drilling fluid functions if shut down in the 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 234°F (112°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 in the seat, transport controls will not function. If the
operator is not seated, drill rotation and thrust functions will not
operate.

2-12
D20x22 Navigator HDD Service Controllers A1 and A2

Interlock
• Strike Alert Function. The Strike Alert function will not operate if the
machine’s electrical system is producing insufficient voltage. Hydraulic
function will be disabled if the voltage output falls below 10.2 volts DC.
See Chapter 15 for detailed information on the Strike Alert system.

• Remote Lockout Function. Remote Lockout disables the drilling controls

(rotation, thrust/pullback and drilling fluid pump) when in LOCKOUT. 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
cannot be started until the Remote Lockout receives a RUN signal from
the remote transmitter.

See Chapter 14 for detailed information on the Remote Lockout function.

Machine Information
CONTROLLERS A1 AND A2
There are two controllers on the machine. They are connected by a CAN bus,
so functionally, they act as a single controller.

The controllers A1 and A2 each have LEDs on the faceplate that assist in
troubleshooting.

These LEDs are visible through a Plexiglas cover. Engine bay controller A1
is located on the engine cover facing the operator console. Console controller
A2 is located below the operator console.

Continued on next page...

2-13
 Controllers A1 and A2 D20x22 Navigator HDD Service

Controller Faceplates
Labeled on the controller is the software
revision (1), hardware revision (2), part
number (3), and serial number (4) of the
controller.

3 4
1
2

The face of each controller shows a

number of LEDs, and each LED is
labeled. There is a fault window that
A1
displays a letter code.

LEDs in the upper part glow for

outputs the controller is sending to
some device (a solenoid or EDC).

LEDs in the lower part glow for inputs

Machine Information

the controller is receiving from various

switches and sensors.

Fault codes refer only to outputs from

the controller. It senses the voltage
being used by the actuator (solenoid or A2
light). If voltage is greater or lesser
than normal for this actuator, it
displays a fault code, such as “A.” The
code means either the solenoid, or the
wiring to the solenoid has short to ground, short to power, or is broken.

When troubleshooting any problem with the machine, consult these LEDs.

If the LED for an input is glowing, a electrical signal is being received by the
controller. If not, begin by checking for voltage at the switch.

If an input LED is glowing, look for the appropriate output LED. If it 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.

2-14
D20x22 Navigator HDD Service Controllers A1 and A2

Key to LEDs
Engine Bay Outputs
Controller A1
• Rd. Ld. Extend - Solenoid L13
• D/T Mode - Solenoid L14
• T/P Mode - L15 and L16
• Water & B.V. - Solenoids L18 and
L17
• Fuel - Solenoid L10
• Starter - coil of relay K1
• Rd. Ld. Retract - Solenoid L11
• Full Flow - Solenoid L12
• Thr. EDC+ - EDC on PMP2
• Thr. EDC- - EDC on PMP2
• Rot. EDC+ - EDC on PMP1
• Rot. EDC- - EDC on PMP1

Machine Information
• Rot. Speed - Solenoid L19
• Brake (release) - Solenoids L20 and L21

Inputs—Switches: (S)

• Power - Key switch S4

• F. Slow - Front slow proximity switch S20
• F. Stop - Front stop switch S21
• R. Slow - Rear slow proximity switch S22
• R. Stop - Rear stop switch S23
• Eng. Oil Pre. - Engine oil pressure switch S24
• Anti-Crash - Proximity switches front S29 and rear S30
• Rd. Ld. Stop - Rod loader stop switch S28
• DB2 - Manual rod loader switch S25 held to the up/out position
• W. Temp. Hi - Coolant temperature switch S26
• DB3 - Manual rod loader switch S27 held to the down/in position
• PB2 - Manual rod loader switch S27 held to the out/up position
• PB3 - Manual rod loader switch S25 held to the in/down position

2-15
 Controllers A1 and A2 D20x22 Navigator HDD Service

Console Controller Outputs—Solenoids (L) and

A2 Indicator Lights (DS)

• Water - DS9
• RL Stop - DS9
• RL Test - DS10
• RL Run - DS11
• Vise - Solenoid L1
• UV. Rotate - Solenoid L2
• Oil Press. - DS14
• RL Ack. - to lockout receiver module A4
• LV. Clamp - Solenoid L6
• UV. Clamp - Solenoid L8
• Grease Appl - Solenoid L9
• Vise Stop - not used
• DSR OK - DS12
• Eng. Wat. Temp - DS13
Machine Information

Inputs—Switches: (S)

• Water - Water control switch S10 press and release

• Full Flow - switch S10 press and hold
• Seat - Operator presence switch S11
• Rot Speed - High/Low rotation speed switch S12
• RJS Button 1 - On right joystick S13
• RJS Button 2 - On right joystick S17
• RL. Test - RL test/fault switch S19
• Key Switch - Key switch S4
• RJS Button 3 - On right joystick S14
• Grease - Grease switch S15
• D/PB Switch - Drill out/pullback switch S16

2-16
D20x22 Navigator HDD Service Controllers A1 and A2

Key to Fault Codes

Fault codes refer to outputs from the controller to a device such as a solenoid
or indicator light. 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 is listed in the fault code window.

When the code appears, it means that device—or the wiring to that device—
is faulty. There is either 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.

Engine Bay
Controller A1
Code Device
A fuel solenoid L7
B starter motor M1
C rod loader retract solenoid L18
D water full flow solenoid L9
E rod loader extend solenoid L10
F drill/transport mode solenoid L11

Machine Information
G thrust/pullback mode solenoids L12 and L13
H water and ball valve solenoids L8 and L14
I rotation speed solenoid L15
J brake release solenoid and transport cooling solenoid L16 and L17
L PMP2 EDC in + direction
N PMP2 EDC in - direction
O PMP1 EDC in + direction
P PMP1 EDC in - direction
Console Controller
A2
Code Device
A vise enable solenoid L1
B rear vise rotate solenoid L2
C oil pressure warning indicator DS6
D remote lockout acknowledge to remote lockout receiver A4
E water flow indicator light DS7
F remote lockout stop mode indicator light DS8
G remote lockout test mode indicator light DS9
H remote lockout run mode indicator light DS10
I DSR OK indicator light DS11
J high coolant temperature indicator light DS12
L front vise clamp solenoid L3
N rear vise clamp solenoid L4
O grease solenoid L6
P not used
0, 1 or 2 used during test mode

2-17
 Controllers A1 and A2 D20x22 Navigator HDD Service

Controller LED Output Grouped According to Function

Since most functions of the machine are controlled through the controllers,
the LEDs on the faceplate make a logical starting point for troubleshooting
most problems.

When troubleshooting machine functions, monitor the LEDs located on the

face plate of the engine and console controllers. They are divided as follows:

Power Distribution The Power LEDs (input) on both controllers indicate that voltage is reaching
LEDs the controller(s).

If so, circuit breaker CB1 is closed, and the contacts of the main power relay
K2 are closed. Also, the ground disconnect switch S1 is closed, and the
controller apparently has a good connection to ground.
Machine Information

2-18
D20x22 Navigator HDD Service Controllers A1 and A2

Engine LEDs The Fuel LED (output) on engine bay controller A1 indicates the controller
is sending voltage to the fuel solenoid L10.

The Starter LED (output) on engine bay controller A1 indicates the

controller is sending voltage to the coil of the start relay K1.

The Oil Pres. LED (output) on console controller A2 indicates the controller
is sending voltage to the low oil pressure warning light DS14 on the console.

The Eng. Wat. Temp. LED (output) on console controller A2 indicates the
controller is sending voltage to the high coolant temperature warning light
DS13 on the console.

The Eng. Oil Pre. LED (input) on engine bay controller A1 indicates the
controller is receiving voltage from the engine oil pressure switch S24.

The W. Temp. Hi LED (input) on engine bay controller A1 indicates the

controller is receiving voltage from the coolant temperature switch S26.

The Key Switch LED (input) on console controller A2 indicates the controller
is receiving voltage from the START position terminal on the key switch S4.

Machine Information
An “A.” in the fault window of engine bay controller A1 indicates a fault for
fuel solenoid L10.

A “B.” in the fault window of engine bay controller A1 indicates a fault for
start relay K1.

A “C.” in the fault window of console controller A2 indicates a fault for the oil
pressure warning light.

A “J.” in the fault window of console controller A2 indicates a fault for the
high coolant temperature warning light.

2-19
 Controllers A1 and A2 D20x22 Navigator HDD Service

Thrust/Pullback or The D/T Mode LED (output) on engine bay controller A1 indicates the
Left Track LEDs controller is sending voltage to solenoid L14 to shift the machine into Drill
mode.

Thr. EDC+ and Thr. EDC- LEDs (output) on engine bay controller A1
indicate the controller is sending voltage to the EDCs of PMP2 to send flow
forward (+) or backward (-) through the loop.

The Brake LED (output) on engine bay controller A1 indicates the controller
is sending voltage to solenoids L20 and L21 to release the park brakes.

The F. Slow and R. Slow LEDs (input) on engine bay controller A1 indicate
that the controller is receiving voltage from the proximity switches S20
(front) or S22 (rear). This indicates the position of the gearbox carriage on
the rack.

The F. Stop and R. Stop LEDs (input) on engine bay controller A1 indicate
that the controller is receiving voltage from the proximity switches S21
(front) or S23 (rear). These indicate the gearbox carriage has reached the
end of the rack.

The Anti-Crash LED (input) on engine bay controller A1 indicates the

Machine Information

controller is receiving voltage from proximity switches S29 (front) and S30
(rear). These indicate whether or not the rod loader arms are extended into
the path of the gearbox carriage. Green light indicates rod loader arms are
in the retracted position (proximity switches are closed).

The Seat LED (input) on console controller A2 indicates the controller is

receiving voltage from the seat switch S11.

An “F.” in the fault window of engine bay controller A1 indicates a fault for
drill/transport solenoid L14.

A “J.” in the fault window of engine bay controller A1 indicates a fault for the
brake release solenoid L20.

A “L.” or an “N.” in the fault window of engine bay controller A1 indicates a

fault for the EDC of PMP2.

2-20
D20x22 Navigator HDD Service Controllers A1 and A2

Rotation or Right Rot. EDC+ and Rot. EDC- LEDs (output) on engine bay controller A1
Track LEDs indicate the controller is sending voltage to the EDCs of PMP1 to send flow
forward (+) or backward (-) through the loop.

The Rot. Speed LED (output) on engine bay controller A1 indicates the
controller is sending voltage to solenoid L19.

The Rot. Speed LED (input) on console controller A2 indicates the controller
is receiving voltage from the high/low rotation speed switch S12.

An “I.” in the fault window of engine bay controller A1 indicates a fault for
the rotation speed solenoid L19.

An “O.” or a “P.” in the fault window of engine bay controller A1 indicates a

fault for the EDC of PMP1.

NOTE: Since the rotation pump drives the right track motor, the Seat LED
(input) and Brake LED (output) are also involved. The seat switch and the
brake solenoid are discussed in chapter 6.

Machine Information

2-21
 Controllers A1 and A2 D20x22 Navigator HDD Service

Controller LEDs The Rd. Ld. Extend LED (output) on engine bay controller A1 indicates the
Associated with controller is sending voltage to solenoid L13. This solenoid shifts the valve
PFC Pump that controls movement of the rod loader arms.
Functions
The T/P Mode LED (output) on engine bay controller A1 indicates the
controller is sending voltage to solenoids L15 and L16. The solenoids operate
valves that control whether the rod loader arm cylinders operate first,
followed by the lift cylinders, or vice versa.

The Water & B.V. LED (output) on engine bay controller A1 indicates the
controller is sending voltage to solenoids L18 and L17. These solenoid shift
valves that operate the water pump, and the water on/off ball valve.

The Rd. Ld. Retract LED (output) on engine bay controller A1 indicates the
controller is sending voltage to solenoid L11. This solenoid shifts the valve
that controls movement of the rod loader arms.

The Water LED (output) on console controller A2 indicates the controller is

sending voltage to drilling fluid indicator light DS9 on the console.

The Vise LED (output) on console controller A2 indicates the controller is

sending voltage to solenoid L1. This solenoid shifts the valve that enables
Machine Information

the front and rear vise.

The UV Rotate LED (output) on console controller A2 indicates the

controller is sending voltage to solenoid L2. This solenoid shifts the valve
that operates the rear vise rotate cylinder.

The LV. Clamp LED (output) on console controller A2 indicates the

controller is sending voltage to solenoid L6. This solenoid shifts the valve
that operates the front vise clamping cylinder.

The UV. Clamp LED (output) on console controller A2 indicates the

controller is sending voltage to solenoid L8. This solenoid shifts the valve
that operates the rear vise clamping cylinder.

The Grease Appl. LED (output) on console controller A2 indicates the

controller is sending voltage to solenoid L9. This solenoid is on the greaser
valve.

The Rd. Ld. Stop LED (input) on engine bay controller A1 indicates the
controller is receiving voltage from the rod loader manual/auto switch S28.

The DB2 LED (input) on engine bay controller A1 indicates the controller is
receiving voltage from the UP/OUT position of switch S25.

The DB3 LED (input) on engine bay controller A1 indicates the controller is
receiving voltage from the DOWN/IN position of switch S27.
Continued on next page...

2-22
D20x22 Navigator HDD Service Controllers A1 and A2

The PB2 LED (input) on engine bay controller A1 indicates the controller is
receiving voltage from the OUT/UP position of switch S27.

The PB3 LED (input) on engine bay controller A1 indicates the controller is
receiving voltage from the IN/DOWN position of switch S25.

The Water On/Off LED (input) on console controller A2 indicates the

controller is receiving voltage from switch S10.

The RJS Button 1 LED (input) on console controller A2 indicates the

controller is receiving voltage from switch S13.

The RJS Button 2 LED (input) on console controller A2 indicates the

controller is receiving voltage from switch S17.

The RJS Button 3 LED (input) on console controller A2 indicates the

controller is receiving voltage from switch S14.

The Grease LED (input) on console controller A2 indicates the controller is

receiving voltage from switch S15.

The T/P LED (input) on console controller A2 indicates the controller is

Machine Information
receiving voltage from switch S16.

An “A.” in the fault window of console controller A2 indicates a fault for the
vise enable solenoid L1 is drawing more or less power than expected.

A “B.” in the fault window of console controller A2 indicates a fault for the
rear vise rotate solenoid L2.

An “L.” in the fault window of console controller A2 indicates a fault for the
front vise clamp solenoid L6.

An “N.” in the fault window of console controller A2 indicates a fault for the
rear vise clamp solenoid L8.

An “O.” in the fault window of console controller A2 indicates a fault for the
grease apply solenoid L9.

A “C.” in the fault window of engine bay controller A1 indicates a fault for
the rod loader extend solenoid L13.
Continued on next page...

2-23
 Controllers A1 and A2 D20x22 Navigator HDD Service

A “D.” in the fault window of engine bay controller A1 indicates a fault for
the water full flow solenoid L12.

An “E.” in the fault window of engine bay controller A1 indicates a fault for
the rod loader extend solenoid L13.

A “G.” in the fault window of engine bay controller A1 indicates a fault for
the drill/transport mode solenoids L15 and L16.

An “H.” in the fault window of engine bay controller A1 indicates a fault for
the water flow and ball valve solenoids L18 and L17.

The RL. Radio LED (input) on console controller A2 indicates the controller
is receiving voltage from the remote lockout transceiver module A4,
indicating the presence of the radio signal from the handheld transmitter.

A “D.” in the fault window of console controller A2 indicates a fault for

remote lockout receiver A4

An “F.” in the fault window of console controller A2 indicates a fault for the
remote lockout stop mode indicator DS9.
Machine Information

A “G.” in the fault window of console controller A2 indicates a fault for the
remote lockout test mode indicator DS10.

An “H.” in the fault window of console controller A2 indicates a fault for the
remote lockout run mode indicator DS11.

2-24
D20x22 Navigator HDD Service Hydraulic Valves

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
(1) on top of coil (2).
3
2. Slide coil off spool valve (3).
If double coil slide both coils 1
off spool valve.
NOTE: Inspect spool valve for
any damages.

Reverse removal steps when

installing coils. Torque hex nut 2
to specification or to 5 ft-lb (6.8
Nm) if no other specification is

Machine Information
given. Do not overtighten.

2-25
 Hydraulic Valves D20x22 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

2
from any dirt or contaminants.
2. Loosen large hex nut (1) body on
valve and unscrew valve from
manifold (2). 1

NOTE: Observe orientation of the O-

rings (3) and backup washers (4).
Machine Information

3. Inspect valve for damage and 3

ensure no external contaminants
are present.
4. Inspect manifold cavity for burrs or
other irregularities which could
damage O-rings during installation.
4
5. Install new O-rings and backup 1
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 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.

FUNCTIONS/CIRCUITS/COMPONENTS
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
 Functions/Circuits/Components D20x22 Navigator HDD Service

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

• Engine ENG1 and Pump Drive Assembly A18

• Battery BT1
• Ground Disconnect Switch S1
• Glow Plug 105-Amp Circuit Breaker CB1
• 50-Amp Circuit Breaker CB2
• Fuses F1–F7
• Relays K1–K6
• Alternator ALT1
• Ignition Switch S4
• Engine Oil Pressure Switch S24
• Engine Coolant Temperature Switch S26
• Starter Motor M1
• Fuel Solenoid Coil L10
• Tachometer/Hourmeter GA5
Power

• Seat Switch S11

• Strike Alert Horn AD1
• Remote Lockout Horn AD2
• Emergency Stop Switches
• Front E-Stop Switch S3
• Rear E-Stop Switch S2

3-2
D20x22 Navigator HDD Service Functions/Circuits/Components

Component Locations
Fuel Pump Drive
Engine Temp Filter
Switch Assembly
S26 FL5 Engine
A18 Controller
A1

Power
PMP1 PMP3
PMP2
Rotation/Right Implement Drive
Thrust/Pullback/ Track Pump
Oil ENG1 S1 Left Track
Filter CB1
Engine Ground Disconnect
Glow Plug Switch
Fuse

A19
Air Cleaner
Assembly

ALT1
Alternator

3-3
 Functions/Circuits/Components D20x22 Navigator HDD Service

Drill Rotation
Drill Out/Pullback Pressure Gauge
Pressure Gauge
Drilling Fluid GA2 GA3
Pressure Gauge
GA1
Power

Fuel Gauge GA4

Tachometer/
Hourmeter GA5

Light Switch S5

Ignition
Switch S4

Strike
Alert Horn AD1

S19 A2 Console Controller

Remote Lockout
Alarm Cancel
S16 Drill Out/Pullback Switch

AD2 Remote Lockout Horn

S9
Alarm Cancel Button

DS15 S8
Strike Alert Test Button
Indicator Light

3-4
D20x22 Navigator HDD Service Functions/Circuits/Components

S2
Rear Emergency
Shutoff Switch

S3
Front Emergency
Shutoff Switch

Power

3-5
 Functions/Circuits/Components D20x22 Navigator HDD Service

Troubleshooting
Before performing any troubleshooting or testing on a electrical circuit or
component, perform a pretest inspection of the machine (see below). Often
problems can be solved by doing a walk-around inspection of the machine
and looking for obvious problems.

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 wires on the power wires
that supply electrical circuit components.
Power

• 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.

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.

3-6
D20x22 Navigator HDD Service Functions/Circuits/Components

Specifications
Listed below are specifications for components in this chapter.

Electrical System • Nominal circuit voltage - 12 volts DC

Battery 950 CCA12-volt BCI group size 31

Circuit Breaker • CB1 - 105-Amp

• CB2 - 50-Amp

Fuse Ratings • F1 - 15-Amp

• F2 - 5-Amp
• F3 - 10-Amp
• F4 - 10-Amp
• F5 - 10-Amp
• F6 - 5-Amp
• F7 - 10-Amp
Engine Model - Caterpillar 3054C

Maximum Power -86 hp (64 kW) at 2400 rpm (intermittent)

Power
77 hp (57 kW) at 2200 rpm (continuous)

Fuel type/capacity - diesel, 35 gal (133 L)

Oil capacity - 1.85 gal (7 L)

Maximum engine inclination - 30° all directions

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 - 42-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.

3-7
 Engine D20x22 Navigator HDD Service

ENGINE
The D20x22 HDD is powered by a Caterpillar diesel engine rated for 86 hp
(64 kW) at 2400 rpm (loaded).

The engine supplies the pump drive assembly installed on the rear of the
engine with power.

Engine Service
The Caterpillar engine is covered under Caterpillar’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 Caterpillar industrial engine repair facility.

Engine Maintenance
Refer to the D20x22 Maintenance Manual for information on regular engine
Power

maintenance schedules and procedures.

3-8
D20x22 Navigator HDD Service Engine

Engine Start Circuit

FUSE
switched +12 volts
F1
IGNITION SWITCH S4

SWITCH MAIN POWER

S2 RELAY K2

SWITCH
S3 TACHOMETER

STARTER
A2
RELAY STARTER
A1 K1 MOTOR

Power
Required Operating The components listed below must be positioned as follows to complete
Conditions START circuit:

• Ground disconnect switch S1 must be closed.

• ALL joysticks must be in NEUTRAL position.
• Emergency stop switches S2 and S3 must be pulled out.

Operation When required operating conditions are met:

• A 12-volt DC voltage path which begins at the battery BT1 supplies

voltage to the fuse panel. This voltage travels through a 15A fuse F1, and
passes through emergency switches S2 and S3 if they are closed. When
ignition switched is activated, voltage travels to the main power relay
K2, tach GA5, and through both controllers to the starter motor.

3-9
 Engine D20x22 Navigator HDD Service

Key Switch S4 at OFF

The battery BT1 is a 12-volt DC wet cell battery that delivers 950 cold
cranking amps to start the engine, or to run accessory items.

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.

The exception is the battery charger A5 used to charge the remote lockout
transmitter battery. The charger is connected to the positive terminal of the
battery through fuse F2.

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 main power relay K2.
• fuse F1, which, if good, allows voltage to the rear emergency stop switch
S2.
Power

Key Switch S4 at RUN or ACC

If both the front and rear emergency stop switches S2 and S3 are closed,
when the key switch S4 is moved to RUN, it energizes the coil of the main
power relay K2. The contacts of K2 close, delivering voltage to:

• fuses F3, F4, F5, F6, and F7

• the engine bay controller A1
• the console controller A2

3-10
D20x22 Navigator HDD Service Battery Charging Circuit

Fuse F1 supplies voltage to ignition switch S4 through the front and rear
stop switches.

Fuse F2 supplies voltage to the Remote Lockout battery charger.

Fuse F3 supplies voltage to fuel gauge GA4, throttle control switches S6 and
S7, front and rear throttle relays K6 and K7, water flow meter, and water
motor speed pickup B3.

Fuse F4 supplies voltage to auxillary power jacks J4 and J5.

Fuse F5 supplies voltage to the alternator ALT1, and provides voltage to

work lights switch S5.

Fuse F6 supplies voltage to Strike Alert module A3.

BATTERY CHARGING CIRCUIT

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

Power from fuse F5 crosses the alternator diode D1 and connects to the

Power
alternator at terminal D. 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 W on the alternator delivers an input signal to the tachometer.

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

3-11
 Testing the Circuits D20x22 Navigator HDD Service

TESTING THE CIRCUITS

GROUND DISCONNECT
SWITCH S1

+ - >>
301-BK
>>
BATTERY BT1 CIRCUIT BREAKER CB1

300-BK
100-RD 100-RD
>>
412-OR
>>
REAR STOP S2
F2 F1 >> MAIN
IGNITION SWITCH S4 >> POWER
120-RD RELAY
>> RUN K2
>>
>>
TO REMOTE
>> >>
LOCKOUT BATTERY 122-RD
CHARGER >> >> 112-OR

125-OR
124-RD
>> 260-DK GN F3
Power

FRONT STOP S3 116-OR

F4
113-OR
F5
114-OR
F6

125-OR 125-OR
to CONTROLLER A2 to CONTROLLER A1

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

Measure Battery Voltage

1. 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.

3-12
D20x22 Navigator HDD Service Testing the Circuits

Check for Power at Controllers and Remote Lockout Charger

to A1
contacts
CB2 K2 to A2
S1 BT1
to F3 through F6
F1 S2 S3 S4 K2
coil

F2 TO REMOTE
LOCKOUT CHARGER
1. Close ground disconnect switch S1 and verify that both emergency stop
switches S2 and S3 are closed (button pulled up).
2. Turn key switch S4 to RUN.
3. Look at power LEDs on the faceplates of both controllers. 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 LEDs are glowing, and charging indicator is
glowing.

If power LEDs are glowing, CB2 is closed and K2 is working and

Power
energized, so fuse F1 is good, and fuses F3 through F6 have power to
their input sides. Continue at "Test Fuses," page 3-16 to test individual
fuses F3 through F6.

If neither of the power LEDs are glowing, follow the steps under Test
Fuses, "Test Fuses," page 3-16. If one glows and the other does not,
continue at step 5.

If the charging indicator is glowing, fuse F2 is good. If not, test fuse F2 as

described on "Test Fuses," page 3-16.

3-13
 Testing the Circuits D20x22 Navigator HDD Service

One Power LED Both controllers are connected with four plugs, two on each side. When
Dark viewed from the controller’s faceplate, the plugs are connected as follows:

On A1 On A2
Upper left—plug P201 Upper left—plug P331
Lower left—plug P202 Lower left—plug P332
Upper right—plug P203 Upper right—plug P333
Lower right—plug 204 Lower tight—plug 334

4. On the controller with the

dark Power LED, disconnect P201
upper left plug from the
controller, when viewed from
the faceplate side. This is
plug 201 on engine bay K2
controller A1, and plug 331
on console controller A2.
5. Test continuity from pins 1
and 2 on the plug to the
terminal of the orange wire
#125 at relay K2. Also test
from pin 12 to the terminal
of black wire #300 of the
Power

ground disconnect switch S1.

Expected result: Continuity.
If so, contact Vermeer service department. The controller itself may be
faulty.

If not, use the harness diagrams to localize the fault in any

discontinuous wire. Repair or replace the faulty harness segment.

3-14
D20x22 Navigator HDD Service Testing the Circuits

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 Caterpillar engine
manual (for 3054-C engine) 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 113 from fuse F5 to the light DS1. If open, repair
or replace the faulty wire or harness segment.
• Test continuity in wire 276 from the DS1 to the D 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
Caterpillar service facility to have it rebuilt or repaired.

Power
113-OR
from FUSE F5 to worklights switch S5
401-WH
W to tachometer
276-BR 100-RD
D ALT1 B+ to BT1 + terminal

3-15
 Testing Components D20x22 Navigator HDD Service

TESTING COMPONENTS
Test Fuses
1. Open engine bay doors and open fuse panel cover.
2. Set multimeter to read DC voltage in the 40-volt range. Connect black
probe to either terminal of the ground disconnect switch S1.
3. Each fuse has two small metal tabs sticking out of the face of the fuse.
On each fuse, place the red probe on each tab and compare resulting
voltages. Test circuit breaker CB2 first. If it is open, fuses F3 through F6
will not have voltage.
Expected result: On each fuse, the tabs will each have battery voltage, ±
10%. If so, fuse holder has voltage and fuse is good.

If one side of the fuse has voltage, and the other shows none, fuse is
blown. Replace the 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 circuit breaker CB2 is good, but fuses F3 through F6 are not getting
voltage, relay K2 may be faulty. See "Testing Breaker CB1 and Main Power
Power

Relay K2," page 3-17.

If F1 has voltage, but F2 does not, F3 does not or F4 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 3-21.

If no fuses have voltage, test continuity across S1. Test continuity of

wires from S1 to negative terminal of battery and to frame.

3-16
D20x22 Navigator HDD Service Testing Components

Testing Breaker CB1 and Main Power Relay K2

1. With the black probe connected to a terminal at the ground disconnect
switch S1, read voltage with red probe at each terminal of the circuit
breaker CB1.
Expected result: Battery voltage on both posts. If so, CB1 has voltage
and breaker is closed—continue below.

If there is voltage at one post and not the other, the breaker is open.
Press the breaker to reset it, and test again. If it does not reset, replace
the breaker CB1 (see"Breaker CB1," page 3-22 ). If it resets, you need to
determine why it tripped, see "Reason CB1 Tripped," page 3-18.

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

2. Turn key switch S4 to OFF. Measure voltage at the terminals on main

power relay K2.
Expected result: One of the orange wires should indicate battery voltage,
± 10%. This is wire 412. The other orange wire is number 125.

3. Turn key switch S4 to RUN and read the voltage at relay K2 terminal of
wire 125.

Power
Expected result: Battery voltage, ± 10%. If so, the relay K2 is working. If
not, the relay may be defective, or there may be faults in the harness, or
key switch S4. Continue below.

4. Pull out dark green wire #260 from the relay and measure voltage from
the blade on the wire to ground.
Expected result: Battery voltage, ± 10%. If so, the relay K2 has voltage to
the coil. Continue below.

If not, test both emergency stop switches S1 and S2 ("Testing S2 and S3,"
page 3-19) and test key switch S4 ("Testing Switch S4," page 3-20). If the
switches are good, wire 120-RD, wire 122-RD, 124-RD or wire 260-DK
GN is faulty. Isolate and repair or replace the faulty wire.

Continued on next page...

3-17
 Testing Components D20x22 Navigator HDD Service

5. Pull out black wire #300 from the relay and test for continuity to ground
from the blade on the wire.
Expected result: Continuity. If so, power relay K2 is faulty. Replace K2
(see"Relay K2," page 3-23 ).

If not, repair or replace the faulty wire or harness segment for wire 300-
BK.

Reason CB1 Tripped Breaker CB1 feeds power to four other fuses and the two controllers A1 and
A2. CB1 is rated for 60 amps.

The four fuses it feeds are rated for a total of 35 amps.

The two controllers operate a total of 14 drivers, and each driver can take up
to 3 amps, for a total of 42 amps. Added to the 35 possible amp draw through
the four fuses, this would be 77 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.
Power

A more normal situation is a short to ground in wire 125-OR or 412-OR.

Wire 412-OR runs only from the breaker to the relay K2, so it can be
inspected for any missing insulation or other causes of shorting to the frame.

For wire 125-OR, 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 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 inspect harness for worn insulation and
replace or repair the faulty section.
fuse box stud 1

125-OR 125-OR 125-OR

>>
single wire
connector
from engine
bay to console
K2 pin1 pin1
pin2 pin2
connector A connector A
at engine at console
bay controller controller

3-18
D20x22 Navigator HDD Service Testing Components

Testing S2 and S3
Emergency stop switch S2 is located at the transport station. You can access
its terminals by opening the door to the remote lockout transmitter dock.
Remove transmitter to give you room to work.

Emergency stop switch S3 is located on the support arm for the right
joystick at the drill station. You can access its terminals by removing the
four bolts holding the joystick in place, and gently pulling out the joystick.

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.

Power

3-19
 Testing Components D20x22 Navigator HDD Service

Testing Switch S4
With the drill station control
panel removed, and the harness
disconnected from key switch S4, B
B
test continuity from the B blade
on the switch to the other blades A1 I1 I1 A1
while turning the key through its S
S
positions.
A2 I2 I2 A2
If results do not match those
given below, replace switch. See Harness connector Switch face
"Ignition Switch S4," page 3-24.

Testing continuity of the switch from terminal B to terminal:

• S, continuity when in START, otherwise open.

• A1, continuity when in ACC, otherwise open.
• A2, continuity when in ACC and RUN, otherwise open.
• I1, continuity when in RUN and START, otherwise open.
• I2, continuity when in ACC and RUN, otherwise open.
Power

3-20
D20x22 Navigator HDD Service Component Repair

COMPONENT REPAIR
Fuse Panel
Remove 1. Open engine bay doors.
2. Remove plastic snap-on cover from the fuse panel.
3. Remove the four mounting screws
and washers (1). 1
4. Push fuse panel back into the
mounting bracket so that it can be
pulled out of its mounting location
to better access the wires.
5. Label all wires going into the back
of the fuse panel.
6. Remove the two power wires from
back of fuse panel. They are the
ones attached with nuts.

7. Remove LINE wires from back of

panel for each fuse. This requires
removing the fuse and pushing a

Power
pair of wires or small pointed tools
into the access holes (2) provided. 2
This will compress the release tabs
on the wire connector (3) so it can
be pulled out the back of the fuse
panel.
2

Continued on next page...

3-21
 Component Repair D20x22 Navigator HDD Service

Install 8. Connect power wires removed

during step 5.
9. Insert LINE wires into the
appropriate sockets until they
engage with a click. The
corresponding fuse may need to be
pulled out of its socket while
installing the LINE wire. Ensure all
fuses are returned to the correct
sockets in the panel when finished. 3
10. Return panel to its mounting
position and install mounting
screws and washers removed during step 2. Ensure plastic cover is
tethered to one of the screws.
11. Snap plastic cover back in place.

Breaker CB1
1. Open engine bay doors.
Power

2. Label and remove electrical wiring (1) from breaker CB1.

3. Remove the two mounting screws
(2) and nuts (3) and remove breaker
CB1 from the machine.
2 3
Reverse removal steps to install
breaker CB1.

CB1

3-22
D20x22 Navigator HDD Service Component Repair

Relay K2
NOTE: Relays K1 and K2 are shown below. They are identical. When
replacing K2, remove the nuts, bolts, and wires from K2.

1. Open engine bay doors.

2. Label and remove electrical wiring (1) from relay K2.
3. Remove the two mounting screws
(2) and nuts (3) and remove relay K1
K2 from the machine. 2
3
Reverse removal steps to install relay
K2.

K2

Power

3-23
 Component Repair D20x22 Navigator HDD Service

Emergency Stop Switches S2 or S3

Replace 1. Access back of the panel containing the switch.
2. Unplug switch from the harness.
S2
3. Unscrew plastic knob from the
switch.
4. Loosen and remove retaining ring
(1).
5. Push switch through the panel.
1

To install new switch, follow reverse of

above instructions.

1
Power

S3

Ignition Switch S4
1. Access rear of the control panel.
2. Unplug connector from the back side
of the switch.
3. On the front side of the control panel,
unscrew retaining ring around the
barrel of the switch. Pull switch out
from the back side of the panel.
Reverse removal steps to install switch
S4.

3-24
D20x22 Navigator HDD Service Component Repair

Battery Disconnect Switch S1

Replace 1. Open engine bay doors.
S1
2. Label and remove electrical
wiring from switch S1.
3. Loosen jam nut, remove washer,
and slide switch out from mount.
Reverse removal steps to install
switch S1.

Power

3-25
This page intentionally left blank.
D20x22 Navigator HDD Service Overview

Chapter 4: Hydraulic Fluid Distribution

OVERVIEW
The Hydraulic Fluid Distribution 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.

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

Hydraulic Fluid Distribution

Electrical:

• Nominal circuit voltage - 12 volts DC.

Hydraulic:

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

• Pumps PMP1 & PMP2 normal output flow - variable to 31 gpm (117 L/
min).
• Pump PMP2 charge pressure setting 313 psi (21.5 bar).
• Pump PMP3 normal output flow - variable to 20 gpm (76 L/min.).
low pressure compensator setting 250 psi - (17.2 bar)
high pressure compensator setting 3200 psi - (220 bar)

Functions/Components
The following functions are included in this chapter:

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

4-1
 Overview D20x22 Navigator HDD Service

The following components are discussed in this section:

• Pump PMP1
• Pump PMP2
• Implement Drive Pump PMP3
• Charge Filter FL3
• Hydraulic Tank RES1 including:
• Return Filters FL1 & FL2
• Fluid Level Indicator GA6
• Oil Cooler HE1
Hydraulic Fluid Distribution

4-2
D20x22 Navigator HDD Service Overview

Component Locations
CHARGE PUMP
FILTER CHARGE PRESSURE
THRUST/PULLBACK
FL3 VALVE ASSEMBLY DIAGNOSTIC PORT
A7

Hydraulic Fluid Distribution

PMP2 PMP1 PMP3
THRUST/PULLBACK/ ROTATION/
FL1 LEFT TRACK RIGHT TRACK PUMP

FILTER
RES1
HYDRAULIC FL2
TANK
FILTER

4-3
 Overview D20x22 Navigator HDD Service

Hydraulic Hose Connections - Fluid Supply and Return

OIL COOLER
HE1
TRACK DRIVE
MOTORS

DRILL/TRANSPORT
VALVE A3

ROD LOADER ROTATION MOTOR MH1

VALVE A1
WATER
Hydraulic Fluid Distribution

CONTROL
A2 TRANSPORT
FLUSH VALVE
A18 CHARGE
FILTER
FL3
TRACK VISE VALVE
BRAKE A13
A8

HYDRAULIC GREASER
TANK RES1 VALVE
MANIFOLD
A 21

PUMP ASSEMBLY WATER SHUTOFF

MANIFOLD A24 STAKEDOWN
VALVE ASSEMBLY
A10

WATER
PUMP MOTOR RACK/STABILIZER
MH9 VALVE A11

4-4
D20x22 Navigator HDD Service Troubleshooting

TROUBLESHOOTING

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.

Reference Diagrams

Hydraulic Fluid Distribution

A large format 11x17″ foldout of the complete hydraulic schematic is located
in the Addendum section in the back of the manual.

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.
• 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 tests on hydraulic components will be listed in the
manual.

4-5
 Troubleshooting D20x22 Navigator HDD Service

Pretest Inspection

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 such as:

• Broken, kinked, collapsed, loose, or leaking hoses and fittings on supply,

pressure, and return to hydraulic components.

• Low fluid level in hydraulic tank. Low fluid can cause erratic behaviors
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.
Hydraulic Fluid Distribution

If obvious signs of problems are not found, then more exhaustive checks
must be carried out.

If there are problems 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
• external leakage

If excess heat and/or external leakage is generated while operating, see "Oil
Cooling," page 4-18.

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

4-6
D20x22 Navigator HDD Service Troubleshooting

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

1. Check fluid
level on FL4
indicator GA6
FL5
of RES1. The
level should be
visible in the
indicator
glass.
FL1
2. If not, filter FL2
new fluid
through a
5-micron filter
before adding
it to the fluid
tank RES1.

Hydraulic Fluid Distribution

3. Refer to
Machine
Information
chapter, "Fuel
RES1
and GA6
Lubricants,"
page 2-11 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...

4-7
 Troubleshooting D20x22 Navigator HDD Service

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 screeching noise is coming from one or more

pumps, continue with step 6. If it is determined that 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.
Hydraulic Fluid Distribution

Repair or replace as necessary. If nothing is found, continue.

7. Inspect supply suction screens FL1 and FL2 for clogs. The suction
screens must be totally clean. Clean or replace as necessary.
8. Inspect charge filter
FL3. Charge filter FL3
is used in the closed-
loop of the Drill
Rotation function. If
the filter is dirty and
becomes restricted,
charge flow will bypass
the filter element and
flow to tank. Charge
pressure will be
reduced.
9. If no problem is found,
a pump may be
experiencing excessive
internal leakage, refer
to "Oil Supply," page 4-
10 for information on
the various pumps.

Continued on next page...

4-8
D20x22 Navigator HDD Service Troubleshooting

NOTE: A noisy relief valve will have a steady high-pitched screeching or

screaming noise. The drill rotation closed-loop hydraulic system has relief
valves integral to pump PMP2.

Hydraulic Fluid Distribution

4-9
 Oil Supply D20x22 Navigator HDD Service

OIL SUPPLY
ROTATION
MOTOR THRUST
MOTORS

VALVE MANIFOLD A6

TRACK
Hydraulic Fluid Distribution

DRIVE
MOTORS
VALVE
MANIFOLD
A7

VALVE MANIFOLD A9

VALVE
MANIFOLD
PMP2 A8

PMP1
CHARGE
PUMP

RES1

Continued on next page...

4-10
D20x22 Navigator HDD Service Oil Supply

PMP1 & PMP2 Hydrostatic Loop

Outgoing Fluid The charge pump on PMP2 draws fluid from the tank RES1, pulling through
the strainer in the tank.

Charge pump flow is forced through the charge filter FL3 to the low pressure
side of the hydrostatic loops, and to the servos controlling the pumps. As
pressure in the low side of the loop reaches 313 psi (21.5 bar), the fluid
passes over the charge relief valve to the tank. Charge pump flow is also
supplied to valve assembly A8 to send pilot signals to shift the machine from
Transport mode to Drill mode, or vice versa.

Returning Fluid - During drill operations, the thrust motors are not used continuously, so they
Drill Mode generate relatively little heat. There are no case drains in these motors and
the oil simply cycles from pump PMP2 to the motors MH2, MH3, and MH4
and back.

Hydraulic Fluid Distribution

In contrast, the rotation motor does a lot of work and correspondingly more
heat is created. Oil from low pressure side of rotation loop is routed through
the hot oil shuttle valve DV29. The amount of flow through this valve is
limited by a fixed orifice. It then crosses a check valve and is routed to oil
cooler HE1.

Should the oil cooler become plugged and flow is restricted, a bypass valve
opens at 50 psi (345 kPa) to send the hot oil directly to the tank.

The hot oil removed from the loop is replaced by cool oil from the tank,
delivered by the charge pump.

Returning Fluid - During transport operations, case drains on track motors MH5 and MH6
Transport Mode supply a small amount of hot fluid from the motors to oil cooler HE1. From
there, fluid passes through return filter FL4 and goes back to tank RES1.

Also, when the track drive is in use, PFC pump PMP3 flow is directed to the
oil cooler by valve DV30 to help cool the hydraulic fluid.

4-11
 Oil Supply D20x22 Navigator HDD Service

Charge Pump
Operation The charge pump is a gerotor pump that has a displacement of 1.40 cid (22.9
cc) and is directly driven by the same shaft as PMP2. The charge pump
turns at the same speed as the engine crankshaft, so at high idle (2600 rpm),
it theoretically produces 15.75 gpm (50 L/min), dropping to 15.54 gpm (49 L/
min) when machine is running under load at 2400 rpm.

Flow from this pump goes to charge the hydrostatic loop, or goes over the
pressure relief valve to the tank. Flow passes through charge filter before
being added to loops. Cool fluid added to loops replaces hot fluid that is lost
through internal leakage, or removed by the hot oil shuttle valve SV2.

Pressure from the charge pump supplies pressure to manifold A8 which

controls drill/transport shift, rotation speed shift, and track brakes.
Hydraulic Fluid Distribution

4-12
D20x22 Navigator HDD Service Oil Supply

Charge Pump Inlet 1. Disconnect charge

Restriction pump inlet hose
Measurement (1). Plumb in a
T-fitting and
connect a 30″ Hg
vacuum gauge to
the fitting.
2. Refill charge
pump inlet hose
with hydraulic
fluid and
reconnect charge
pump inlet hose 1
to the fitting and
the pump.
3. Connect a 600 psi
test gauge to the
charge pressure test port on the charge filter.

Hydraulic Fluid Distribution

4. Without starting the engine, use the key switch to jog the engine until
the charge pressure begins to rise.
5. Start engine and run it at the lowest possible speed until charge
pressure reaches 300 psi or more. Then run engine at 2400 rpm.
6. Have an assistant run the controls to move gearbox carriage forward and
back as you observe vacuum gauge in FORWARD (thrust), in REVERSE
(pullback) and in NEUTRAL (stopped).
Expected result: When the oil is warm (100°F/38°C or greater) the gauge
should not indicate more than 5″ Hg. When the oil is cold, it should not
indicate more than 10″ Hg. If it does, change sump strainer.
NOTE: To remove vacuum gauge at the conclusion of the test, follow steps 1
through 6 again, but remove the T-fitting and vacuum gauge in step 1. Steps
4 and 5 are required to safely start up the pump whenever any of its hoses
have been disconnected and reconnected. To remove charge pressure gauge,
shut down, unscrew gauge and replace dust cap on the test port.

4-13
 Oil Supply D20x22 Navigator HDD Service

Charge Pressure Charge pressure should be 313 psi, ± 20 psi (21.5 bar, ± 1.4 bar) If higher,
Measurement change the pressure relief valve PV4 (see "Adjusting Charge Pressure Relief
Valve PV4," page 4-29). If lower, there are several possible faults that could
cause it to be lower.

• The charge pump may be producing inadequate flow, possibly due to an

inlet restriction.
• The charge filter FL3 may be clogged or partially clogged. If the pressure
differential across the filter is more than 25 psi (172 kPa), a check valve
opens, drawing charge pump flow to tank.
• The charge pressure relief valve PV4 may be opening at a lower
pressure.
• There may be large amounts of cross port leakage in the valves in
assembly A8, allowing charge pump flow to drain to tank.
• If low only in Drill mode, the hot oil shuttle valve in rotation motor MH1,
or valve DV1 in manifold A7, may be stuck open, allowing charge flow to
drain to tank.
• If low only in Transport, the ground drive motors MH5 and MH6 may be
Hydraulic Fluid Distribution

leaking excessively, outstripping the charge pump’s ability to supply the

low side of the loop.

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 test port
on manifold A8.
2. Have an assistant sit in the seat and start the machine following the
normal starting procedure, and run the engine at idle while you inspect
and verify that there are no leaks where the test gauge is connected to
the test port.
Continued on next page...

4-14
D20x22 Navigator HDD Service Oil Supply

3. Run engine at 2400 rpm. Have the assistant sit in the seat, and then
stand up from the seat. Note the pressure indicated on the test gauge
while assistant is in the seat and out of the seat.
Expected result: 313 psi, ± 20 psi (21.5 bar, ± 1.4 bar). The pressure may
drop briefly, but it must recover to this range.

When the seat switch is closed (seat occupied), the machine is in Drill
mode. When the seat switch is open (seat empty) the machine is in
Transport mode.

If the gauge indicated within the correct range in both modes, continue
at step 4.

If the pressure was less than allowed in the Transport mode only (seat
empty), continue by testing for excess flow from the track drive motors
MH5 and MH6. See "Measuring Case Drain Flow," page 5-20.

If the pressure was less than allowed in the Drill mode only (seat
occupied), continue by testing for flow from the drain line from the

Hydraulic Fluid Distribution

rotation motor MH6, and the shuttle valve DV1 in manifold A7 (see page
"Drill/Transport Valve Assembly A7," page 7-9).

If the pressure was less than allowed in both modes, first, replace the
charge filter FL3 and repeat step 3. If charge pressure remains low,
continue by testing for flow from manifold A8 ("Testing Pilot Valve
Assembly A8 for Cross Port Leakage," page 5-18). If the manifold A8 does
not seem to be the problem, replace the charge pump.

4. With the engine speed at 2400 rpm, observe the gauge as the assistant
operates the controls to do the following:
• Move rotation gearbox up and down the rack.
• Run rotation motor in both directions.
• Run track motors in forward and reverse.
5. 313 psi, ± 20 psi (21.5 bar, ± 1.4 bar). Pressure may drop briefly, but it
must recover to this range. If so, the charge circuit appears to be
operating normally.

If not, troubleshoot by measuring inlet restriction to the charge pump

("Charge Pump Inlet Restriction Measurement," page 4-13). If the inlet
restriction is within limits, replace charge pump ("Charge Pump
Replacement," page 4-23).

4-15
 Oil Supply D20x22 Navigator HDD Service

PFC Pump PMP3

Supply Fluid in tank RES1 is drawn though filter FL to PFC pump PMP3. The
pump delivers flow on demand to a number of implement circuits. Those
functions which receive oil by means of PMP3 include:

• Stakedown
• Stabilizer/Rack Angle
• Vise
• Mud Pump
• Rod Loader
• Tracking Cooler Flow Valve

Return Return flow from the control valves in the different implement circuits is
combined, and flows through a return filter FL to the tank RES1.
Hydraulic Fluid Distribution

Assuming the fluid level in the tank is correct, the fluid has time to cool
(transfer heat to tank walls) and for air and contaminants to settle out
before being drawn back into the PFC pump or pmp2 charge pump.

4-16
D20x22 Navigator HDD Service Oil Filtering

OIL FILTERING
With Functions Operating or At Rest
Normal Operation The fluid is filtered constantly during normal operation or with no functions
actuated. The following components include:

• Two suction strainers FL1 and FL2 are installed inside the hydraulic oil
tank and protects the system from dirt particles that may reside in the
hydraulic fluid when adding to the tank RES1.
• The 10-micron fill screen FL3 is installed in the fill tube, preventing
foreign material from entering the hydraulic oil tank RES1 when adding
oil.
• The 10-micron return filters FL4 & FL5 filters the fluid as it is returned
to the tank.
• The charge filter FL3 filters the fluid in the charge circuit of the
hydrostatic loop used in the drill rotation function.
• The sight gauge GA6 installed on the fluid tank gives the operator a

Hydraulic Fluid Distribution

visual reference of the fluid level. The fluid should be visible in the sight
glass when the machine is at rest.

FL5

FL4

FL1
FL2

SR3

RES1
GA6
FL3

4-17
 Oil Cooling D20x22 Navigator HDD Service

OIL COOLING
Oil Cooler HE1
Normal Operation All hydraulic functions on the machine share the hydraulic fluid in tank
RES1. When a function is actuated:

• Oil is routed to the inlet of cooler HE1 where it is cooled before returning
to the tank RES1.
Hydraulic Fluid Distribution

4-18
D20x22 Navigator HDD Service Hydraulic Fluid Sampling

Tracking Cooler Flow Valve Assembly A18

TO BRAKE RELEASE L20
TO GROUND
A18
TO IMPLEMENT
HYDRAULIC
CIRCUITS

TRACKING
RACK ENABLE
COOLER
SWITCH S31
VALVE DV30,
SOLENOID L21

HE1
PMP3

Hydraulic Fluid Distribution

The tracking cooler flow valve DV30 diverts oil flow from pump PMP3 to the
oil cooler when activated by solenoid L21.

When the machine is in Transport mode and either track drive joystick is
moved out of NEUTRAL, the controller sends power to energize both brake
release solenoid L20 and solenoid L21 (see exception, below). When
energized, solenoid L21 opens the tracking cooler valve DV30, sending flow
from PFC pump PMP3 to the cooler. Since PMP3 is a pressure-compensated
pump, it responds to the drop in pressure by going to full-stroke, sending
about 17 gal (64 L) of fluid through the oil cooler each minute.

The exception is when the rack angle adjustment lever is moved out of
NEUTRAL. The lever opens normally closed switch S31, that breaks the
circuit which supplies power to solenoid L21. This allows the rack angle to
be adjusted while the machine is being transported.

HYDRAULIC FLUID SAMPLING

Sampling hydraulic fluid should be performed as part of a preventive
maintenance program. Analyzing hydraulic fluid condition may prevent
future hydraulic problems.

4-19
 Hydraulic Fluid Sampling D20x22 Navigator HDD Service

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 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, oxidation, or contamination.

Draw a sample and compare it to a sample of new oil. It should appear clean,
clear and amber in color. A milky haze or smoky appearance indicates there
is water present. If so, replace oil and filter. Refer to the D20x22
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).
Hydraulic Fluid Distribution

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
• 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
Continued on next page...

4-20
D20x22 Navigator HDD Service Hydraulic Fluid Sampling

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

Hydraulic Fluid Distribution

Fluid Sample
Collection Points

FILL CAP
STRAINER

DIAGNOSTIC PORT

RES1
HYDRAULIC TANK

To sample open-loop circuits, take the sample directly from the oil tank at
the fill cap.

Cleanliness Approval Criteria:

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

Continued on next page...

4-21
 Hydraulic Fluid Sampling D20x22 Navigator HDD Service

• 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
SR1 should also be cleaned or replaced. Refer to the D20x22 Maintenance
Manual for instructions.
• If a sample taken from the drill rotation closed loop is above ISO code 18/
16/13, high pressure closed-loop filtration should be installed and
operated for 15 minutes.
• If sampling shows oil is still above ISO code 18/16/13, the hydraulic fluid,
charge and return filters should be replaced. Suction screen SR1 should
also be cleaned or replaced. Refer to the D20x22 Maintenance Manual for
instructions.

Adjusting Relief PV4

The charge pressure relief valve is adjusted by adding or removing shims.
Correct number and thickness of shims are installed at the pump
manufacturer. If charge pressure needs adjustment, contact Vermeer Service
Hydraulic Fluid Distribution

department for instructions.

4-22
D20x22 Navigator HDD Service Hydraulic Fluid Sampling

Bypass Valve Adjustment

The bypass valves are SHOWN FROM ABOVE
opened if the machine (EDCs are not shown)
needs to be towed a short bypass valves
distance. Ensure that both
bypass valves are closed if
the machine has been
towed.

1. Place a 5/8″ wrench on

the hex on the bypass
valve.
engine
2. With moderate hand PMP2 PMP1 PMP3
(not shown)
pressure on the
wrench, attempt to SHOWN FROM RACK SIDE
tighten the hex (rotate (EDCs are not shown)
clockwise). PMP1 bypass valve

If it tightened, it was

Hydraulic Fluid Distribution

partially open. If it would
not tighten, it was closed.

engine
PMP3 PMP1 PMP2
(not shown)

Charge Pump Replacement

The charge pump on this model of drill cannot be purchased as a separate
unit. If charge pump fails, replace pump PMP1/PMP2. See next page.

4-23
 Hydraulic Fluid Sampling D20x22 Navigator HDD Service

PFC Pump PMP3 High and Low Pressure Compensator Adjustment

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. Connect pressure check

gauge assembly (with dual 7
gauges), Vermeer P/N
67566001 to the M2 port (6)
1
on top of the pump. This will
show system pressure.
5
Hydraulic Fluid Distribution

6
2. Connect a T-fitting and a
2
diagnostic fitting to the case
drain line (7). Connect a 100 4
psi test gauge to the
diagnostic fittings. This
gauge will show case 3
pressure.
3. Load sense line (1) leads to
the water pump flow control
valve assembly A13 on the
inside wall of the engine bay. Disconnect line at A13 and plumb in a T-
fitting connected to a 600 psi gauge. This gauge will show load sense
pressure.
4. Attach magnetic thermometer to the hydraulic tank, or use a laser
pyrometer to check hydraulic fluid temperature. If possible fluid
temperature should be 100°F (38°C) for this adjustment. If necessary,
start machine and operate rotation or thrust/pullback function to warm
the fluid.
Continued on next page...

4-24
D20x22 Navigator HDD Service Hydraulic Fluid Sampling

5. Have wrenches ready to loosen the setscrews (2) and (3) and adjust the
adjustment screws (4) and (5).
6. Have an assistant run engine at 2400 rpm.
7. Observe system pressure gauge and load sense pressure gauge. Subtract
load sense pressure reading from system pressure reading.

The expected value is 250 psi,± 50 psi. If so, continue at step 9.

Otherwise, continue below.
8. Loosen setscrew (2) and turn load sense spool adjustment screw (5).
Turn it in to raise pressure and turn it out to decrease it. When system
pressure minus load sense pressure is 250 psi, hold adjustment screw in
position and tighten setscrew. Torque setscrew to 6–8 ft-lb, or 7–11 Nm.

One full rotation of the adjustment screw is approximately equal to 170

psi (12 bar).
9. If the dual gauge pressure
check gauge assembly (P/N 7
1

Hydraulic Fluid Distribution

6756601) is connected at the
M2 port (6), continue below.
Otherwise, shut down and
replace 600 psi gauge at M2
5 6
with a 5000 psi gauge.
10. Have the assistant fully 2
extend or fully retract the 4
rack angle cylinder to
deadhead the cylinder. The
assistant must hold control 3
lever in the deadhead
position during steps 11 and
12.
11. With cylinder deadheaded,
observe the system pressure gauge and the case drain gauge. Subtract
case pressure from the system pressure.

The expected value is 3000 psi, ± 50 psi (207 bar ± 3.5 bar). If so,
compensator is properly adjusted; continue at step 13. If not, continue
below.
Continued on next page...

4-25
 Hydraulic Fluid Sampling D20x22 Navigator HDD Service

12. Loosen setscrew (3) and turn compensator adjustment screw (4). Turn it
in to raise pressure and turn it out to decrease it. When system pressure
minus case pressure is 3000 psi (207 bar), hold adjustment screw in
position and tighten setscrew. Torque setscrew to 6–8 ft-lb, or 7–11 Nm.

One full rotation of the adjustment screw is approximately equal to 500

psi (35 bar).
13. Shut down engine and remove gauges and reconnect hoses. Torque plugs
and hoses as follows:
• plug at M2 port (6) to 26 ft-lb (35 Nm)
• case drain hose to fitting in PMP3 to 38 ft-lb (51 Nm)
• load sense line to fitting in A13 to 9.5 ft-lb (12.8 Nm)
Hydraulic Fluid Distribution

4-26
D20x22 Navigator HDD Service Component Repair

COMPONENT REPAIR
When replacing hydraulic components, do not allow contaminants to enter
the circuit.

• 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.

Hydraulic Fluid Distribution

• 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.
• 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.

4-27
 Component Repair D20x22 Navigator HDD Service

PMP1/PMP2 Charge Checks and High Pressure Relief 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. Shut down engine.

2. Remove charge check and
1 2
pressure relief valve hex
plug.
• (1) for port A
Hydraulic Fluid Distribution

• (4) for port B

• (3) for port C
• (2) for port D engine right side

3 4
3. Remove spring and check
poppet or valve cartridge
from the housing. Inspect
valve and mating seat in the
housing for damage or
foreign materials. It will be
necessary to replace housing
if the seat is damaged. left side engine
4. Reinstall valve cartridge,
spring, and plug with O-ring into the housing. Torque the plug from 30–
70 ft-lb (41–95 Nm).

4-28
D20x22 Navigator HDD Service Component Repair

Adjusting Charge Pressure Relief Valve PV4

1. Shut down machine.
2. Remove charge relief hex
1
plug.
3. Remove spring and poppet
from the housing. Do not
alter the shims or
interchange parts with
another valve. Inspect
poppet and mating seat in engine right side
the end cap for damage or
foreign material.
4. Reinstall poppet, spring and plug with shims and O-ring into the
housing. Torque plug from 30–70 ft-lb (41–95 Nm).

Hydraulic Fluid Distribution

4-29
 Component Repair D20x22 Navigator HDD Service

PMP1/PMP2 Tandem Pump Replacement

NOTE: Due to the number of hoses that must be disconnected and correctly
routed when reconnected, it is strongly recommended that all hoses are
labeled prior to disassembly. Take notes, make sketches or take photographs
prior to and during disassembly to ensure correct routing for reassembly.

1. Drain the hydraulic tank.

2. For better access, remove rod box.
3. Remove left engine side shield.
4. Open doors on the right side of the engine bay.
5. Remove screw holding the knob to the shaft of the flow control valve FC1
on A13 and remove knob. Also, remove the two bolts holding the mud
flow control manifold A13 to the front shield of the engine bay.
6. Support top shield of the engine bay and unbolt front shield of the engine
bay. Move it about 4″ (10 cm) forward. This may require disconnecting
wires to engine bay controller and/or the fuse panel. If so, carefully label
Hydraulic Fluid Distribution

all connectors to simplify reassembly.

7. Disconnect inlet hose from the fitting on PFC pump PMP3. Also,
disconnect pressure hose from fitting in port B and disconnect load sense
line from the fitting in port LS. Plug or cap all open hose ends and ports.
8. Support PFC pump PMP3 as you loosen and remove the two bolts
holding PMP3 to PMP1. Remove PFC pump. Also, locate and remove the
O-ring between PMP3 and PMP1. Plug or cap all open hose ends and
ports.
9. Label and remove hoses connected to the charge filter assembly. Plug or
cap all open hose ends and ports.
10. Remove fluid filter assembly from the top of PMP2. Plug port.
11. Label and disconnect the four lines leading to the shuttle valves for the
transducers. Plug or cap all open hose ends and ports.
12. Support tandem pump PMP1/PMP2. Remove the two bolts holding the
pump support bracket to the engine flywheel cover.
13. Remove inlet hose from the fitting on PMP2. Remove hoses from the
fittings in ports D and C in PMP1.
Refer to illustration on next page.

Continued on next page...

4-30
D20x22 Navigator HDD Service Component Repair

FL3

Hydraulic Fluid Distribution

PMP2

PMP1

CHARGE
PRESSURE

INLET LS

PRESSURE

PMP3
INLET

Continued on next page...

4-31
 Component Repair D20x22 Navigator HDD Service

14. Remove hoses from the fittings in ports A and B in PMP2. Remove
charge pressure hose leading to manifold A8. Plug or cap all open hose
ends and ports.
15. Support tandem pump while loosening and removing two bolts holding
the face of PMP2 to the flywheel cover. Remove pump.
16. Remove pump support bracket from pump.
17. Transfer fittings to the new pump. Oil fitting threads and cap fittings as
they are installed to minimize contamination. Torque as follows:
• hose fitting into ports A, B, and C to 61 ft-lb (83 Nm).
• hose fitting into port D to 87.5 ft-lb (119 Nm)
• hose fitting into port for charge pressure hose to 46 ft-lb (62 Nm).
• fitting to charge filter to 38 ft-lb (52 Nm).
• fitting for charge filter relief line (next to charge filter fitting) to 31.5
ft-lb (43 Nm).
• four fittings for lines leading to transducer shuttle valves to 12.5 ft-lb
(17 Nm)
Hydraulic Fluid Distribution

• bolt for pump support bracket to 20 ft-lb (27 Nm)

18. Apply grease to the splines on the pump drive shaft. Align splines and
slide into coupling in flywheel. Support tandem pump and install
mounting bolts. Torque mounting bolts to 90 ft-lb (122 Nm).
19. Install bolts through pump support bracket into flywheel cover. Torque to
58 ft-lb (79 Nm).
20. When connecting hoses, snug connection with a wrench, but do not
overtighten. Reconnect hoses for:
• the four lines to the shuttle valves for the transducers.
• ports A, B, C and D.
• charge pressure line leading to manifold A8.
• charge filter relief line.

21. Fill charge filter with filtered oil and install on pump PMP2. Do not
overtighten the connection.
22. Replace O-ring removed in step X. Coat new O-ring with clean oil or
vaseline and install it.
23. Support PFC pump PMP3 and slide it into PMP1 while aligning splines.
Be careful when bringing the mating surfaces together to avoid pinching
O-ring.
Continued on next page...

4-32
D20x22 Navigator HDD Service Component Repair

24. Reconnect hoses to PMP3. Do not overtighten.

25. Install rear shield.
26. Install manifold A13 on rear shield and install handle on the flow control
valve.
27. Install remaining shields.
28. Refer to Returning System to Service.

Returning System to 1. Refill tank to proper level with new fluid that has been filtered through a
Service 5-micron absolute filter.
2. To prevent engine start when cranking to achieve charge pressure,
disconnect electrical connection to engine fuel solenoid L7.
3. Attach a 600 psi test gauge to the test port on manifold A8.
4. Have an assistant crank the engine while you watch the test gauge. Do

Hydraulic Fluid Distribution

not crank longer than 30 seconds and wait at least one minute before
cranking again.
5. When gauge indicates charge pressure is rising, reconnect solenoid L7
and start engine. Increase engine speed and observe pressure gauge.

If pressure indicated is not 313 psi, ± 10 psi (21.5 bar ± 2 bar), inspect for
any leakage. Repair leaks if found. Otherwise, correct size or number of
charge pressure adjustment shims may not have been installed at pump
manufacturer. Contact Vermeer Service department for advice.

4-33
 Component Repair D20x22 Navigator HDD Service

Servicing Hydrostatic Circuits

Hydrostatic drive components are precision-built to very close tolerances
and operate at very high pressures. Cleanliness is extremely important
when servicing a hydrostatic 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
Hydraulic Fluid Distribution

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.
• 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
hydraulic oil.
• Fill all disconnected hoses with new filtered oil during reassembly.
• Install the filter assembly in the circuit using the proper fittings. Install
filter assembly in the return side of the circuit being flushed. Ensure
flow arrow (1) indicates correct flow direction when the function is
activated. Do not reverse oil flow direction when flushing the circuit.
Refer to individual circuit drawings to determine oil flow direction and
hose connections
Continued on next page...

4-34
D20x22 Navigator HDD Service Component Repair

TO PUMP

FROM ACTUATOR

Hydraulic Fluid Distribution

• Disconnect external control input signal (linkage for manual
displacement control, or electrical connections for electric displacement
control) from the pump until after initial start-up. This will allow the
pump to remain in NEUTRAL position.
• Crank engine without allowing it to start until charge pressure is 25–50
psi (172–345 kPa). This can be accomplished by removing the power wire
from the fuel solenoid. This will keep the engine from starting.
NOTE: Do not crank engine for more than 30 seconds at a time to prevent
the starter from overheating. Allow the starter to cool for several minutes
between attempts to build charge pressure.

• Turn ignition switch to START to crank the engine. When charge

pressure of 25–50 psi (172–345 kPa) is established, return the ignition
switch to OFF and reconnect fuel solenoid power wire.
• Start engine.
• Run engine at idle setting until charge pressure reaches 300 psi.
• Take an oil sample from the closed loop whenever replacing components.

4-35
 Component Repair D20x22 Navigator HDD Service

Filter Components
3

1
2
8

5
7
6 6
7 4
3

5 2
Hydraulic Fluid Distribution

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

4-36
D20x22 Navigator HDD Service Component Repair

PMP3 Replacement
NOTE: Due to the number of hoses that must be disconnected and correctly
routed when reconnected, it is recommended that all hoses are labeled prior
to disassembly.

1. Drain hydraulic tank.

2. For better access, remove rod box.
3. Remove left engine side shield.
4. Open doors on the right side of the engine bay.
5. Remove screw holding the knob to the shaft of the flow control valve FC1
on water control valve manifold A13 and remove knob. Also, remove the
two bolts holding the manifold to engine bay shielding.
6. Support engine bay top shield and unbolt engine bay front shield. Move
it about 4″ (10 cm) forward. This may require disconnecting wires to
engine bay controller and/or the fuse panel. If so, label all connectors to
simplify reassembly.

Hydraulic Fluid Distribution

7. Disconnect inlet hose from the fitting on PFC pump PMP3. Also,
disconnect pressure hose from fitting in port B and disconnect load sense
line from the fitting in port LS. Plug or cap all open hose ends and ports.
8. Support PFC pump PMP3 as you loosen and remove the two bolts
holding PMP3 to PMP1. Remove PFC pump. Also, locate and remove
O-ring between PMP3 and PMP1. Plug or cap all open hose ends and
ports.
Continued on next page...

4-37
 Component Repair D20x22 Navigator HDD Service

9. Transfer hose fittings to replacement pump. Oil fitting threads and

torque fittings as follows:
• inlet port fitting to 107.5 ft-lb (145.7 Nm)
• pressure port fitting to 117.5 ft-lb (159.3 Nm)
• T-fitting (into pressure port fitting) to 31.5 ft-lb (42.7 Nm)
• reducer fitting (from tee into smaller tee) to 38 ft-lb (52 Nm)
• load sense port fitting to 38 ft-lb (52 Nm)
10. Replace O-ring removed in step 8. Coat new O-ring with clean oil or
petroleum jelly and install it.
11. Support PFC pump PMP3, align splined shaft, and slide it into PMP1 so
the splines align. Ensure O-ring is in place when bringing the mating
surfaces together.
12. Reconnect hoses to PMP3. Do not overtighten.
13. Install rear shield.
14. Install mud flow manifold A13 on rear shield and handle on the flow
Hydraulic Fluid Distribution

control valve.
15. Install remaining shields.

4-38
D20x22 Navigator HDD Service Component Repair

EDCs for PMP1 and PMP2

1. Disconnect harness from the EDC.
2. Locate and remove the four
mounting screws that hold the
EDC body to the pump casing.
1
Watch as you lift EDC from the
pump. A spool hangs from the
EDC. Around this spool is a
sleeve. The sleeve will remain in
the pump. Use a vise grip to lift
the old sleeve out of the cavity in
the pump.

3. The new EDC is shipped with

Hydraulic Fluid Distribution

an attached spool and sleeve
assembly. Remove sleeve (2)
2
from the valve. With the notch
in the sleeve facing down and
toward the pump shaft, place
sleeve in the pump valve bore
until the attached snap ring
bottoms out.

4. Ensure O-rings (3) are in place

on the new EDC. There is one
larger O-ring and two smaller 3
O-rings.
5. Carefully guide EDC spool into
the pump sleeve until four bolt
holes are aligned to the pump
mounting holes. There is only
one possible alignment.
NOTE: Any damage or nicks to the
spool while installing could cause
control to bind and produce erratic
operation.

Continued on next page...

4-39
 Component Repair D20x22 Navigator HDD Service

6. Put two short mounting screws (1/4-20 x 3/4″) through bosses on the side
of valve. Put two long screws (1/4-20 x 2.5″) through valve body. Torque
four screws in a cross pattern starting with the screw closest to the pilot.
Torque to 10 ft-lb (16 Nm).
NOTE: Improper torquing may cause control to bind, causing erratic
operation.

7. Reconnect harness to the EDC.

8. Perform "Nulling the EDC," page 4-41.

Adjusting Pump
Swashplate
NEUTRAL Position
Hydraulic Fluid Distribution

2 1

1. Remove plugs from port G and port F and install a low pressure line (500
psi/35 bar minimum) (1) between the two.
2. Disconnect small pressure lines from pump and install pressure gauges
10,000 psi (690 bar) (2) in the system pressure gauge ports.
Continued on next page...

4-40
D20x22 Navigator HDD Service Component Repair

3. Start engine and slowly accelerate to operating RPM.

4. Remove protective cap and loosen
servo lock nut (1) while holding servo
adjustment screw (2) until the two
system pressure gauge readings are
equal.
5. Turn servo adjustment screw until
one of the system pressure gauges
starts to increase. Noting the amount
of rotation, turn servo adjustment
screw counterclockwise until the
other system pressure gauge starts 1
to increase.
2
6. Turn servo adjustment screw
clockwise half the amount of rotation noted above.
7. While holding the servo adjustment screw from turning, torque the servo
lock nut to 13 to 18 ft-lb (17.6 to 24.4 Nm). Stop engine, install a new

Hydraulic Fluid Distribution

protective cap, remove servo cross-port line.

Nulling the EDC

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.

Continued on next page...

4-41
 Component Repair D20x22 Navigator HDD Service

1. Install a 500 psi test gauge

at the servo port (1).
2. Install another 500 psi test
gauge in the servo port
directly opposite from (1). 1
3. Loosen lock nut on the null
adjustment screw (2).
4. Unplug EDC from the
harness. 2
5. Start machine and run it at
low idle. Allow system to
warm up for a few minutes. Slowly increase engine speed to 2400 rpm.
6. Using an Allen wrench, rotate null adjustment screw until both gauges
show the same amount of pressure.
7. Rotate adjustment screw one way or the other until gauge shows an
increase in pressure. Note location of the Allen wrench handle in relation
Hydraulic Fluid Distribution

to the adjusting nut. (Example: Handle is at the “1:00 clock” position.)

8. Rotate adjustment screw the opposite way until the other gauge shows
an equal increase in pressure. Count the turns and note location of the
Allen wrench handle in relation to the adjusting nut. (Example: Handle
is at the “7:00 clock” position.)
9. Turn Allen wrench back the other way one half distance. (Example: Turn
it 3/4 turn if distance from first to second mark was 1-1/2 turns.)
Tighten lock nut and reconnect EDC to the harness. Remove gauges and
replace cap screws.

Testing Transducers B4 and B5

1. Remove transducer from manifold in question.
2. Install hand pump supply hose with gauge to transducer. Apply pressure
to the transducer as listed in expected results below.
3. Apply voltage and ground to transducer leads and use multimeter to
check voltage at wire 731-PK for thrust (B5) and wire 738-GY for
rotation (B4).
Expected result: 500 psi = 1.2–1.46V, 1000 psi = 1.75–1.85V, 1500 psi =
2.1–2.2V, 2000 psi = 2.45–2.55V, 2500 psi = 2.9–3.5V.

4-42
D20x22 Navigator HDD Service Component Repair

Replacing Transducers B4 and B5

1. Disconnect
transducer from
harness.
2. Unscrew
transducer from
straight fitting in
shuttle valve.
Steps 3 through 6
B4
apply if replacing
shuttle valve. If
replacing transducer
only, skip ahead to step
7.

3. Disconnect lines
from fittings on
shuttle valve.

Hydraulic Fluid Distribution

4. Unbolt shuttle
valve from mount. B5
Temporarily bolt
other shuttle valve
to mount while
preparing new
shuttle valve.
5. Remove fittings
from the old shuttle
valve and install in the new shuttle valve.
• Elbow fittings go into ports A, B and G. Torque the elbow fittings to 9.5
ft-lb (12.9 Nm).
• Straight fitting goes into bottom port. Torque the fitting to fitting to 19
ft-lb (26 Nm).
6. Reassemble and bolt shuttle valve to spacer, other shuttle valve and the
mounting plate. Torque nuts on the bolts to 10 ft-lb (14 Nm).
7. Screw transducer into straight fitting in bottom of shuttle valve. Torque
transducer to 9.5 ft-lb (12.9 Nm).
8. Connect transducer to electrical harness.

4-43
 Component Repair D20x22 Navigator HDD Service

Pump PMP3 Replacement

1. Refer to steps 1–8 of "PMP1/PMP2 Tandem Pump Replacement," page 4-
30 for removal. For installation, refer to step 23 of the same section.
2. Refer to "Returning System to Service," page 4-33.
Hydraulic Fluid Distribution

4-44
D20x22 Navigator HDD Service Overview

Chapter 5: Ground Drive

OVERVIEW
This chapter consists of the functions and components necessary for the left
and right track drive functions.

Functions/Components
Functions The following functions are included in this chapter:

• Left Track
• Right Track
• Track Brakes
• Track Drive Cooling Circuit

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

• Hydraulic Fluid Distribution

• Drill/Transport Valve Assembly A7
• Pilot Valve Assembly A8
• Pump PMP1
• Pump PMP2
• Right Track Motor MH5
• Left Track Motor MH6

5-1
 Overview D20x22 Navigator HDD Service

Component Locations
Ground Drive

Track/Brake Valve Drill/Transport

Assembly A8 A7 Valve Assembly

5-2
D20x22 Navigator HDD Service Overview

EDC Left Track EDC

EDC Right Track EDC

PMP1 Rotation/Right
Track Drive

Rear Emergency
Stop
S2

PMP2
Thrust/Pullback/
Left Track Drive

S7

Ground Drive
Throttle
Switch

MH5
Right Track
Drive Motor
MH6
Left Track
Drive Motor

5-3
 Overview D20x22 Navigator HDD Service

Hose Connections

PRESSURE
TRANSDUCER B4

FILTER FL3
MANIFOLD A8

PRESSURE
TRANSDUCER
B5
Ground Drive

TANK
RES1

VALVE
ASSEMBLY
A7

RIGHT
MOTOR
MH5 LEFT MOTOR
MH6

OIL COOLER
HE1

5-4
D20x22 Navigator HDD Service Charge Pressure Circuit

Transport Mode During Transport mode, the controller powers up solenoid L20 which
releases the brakes when a control handle is moved. The software in the
controller also limits the maximum voltage to the pump EDC to 6.6 vDC, or
55%. This limits the output of the pump to 55% of full displacement, or 1.55
in3. At 2400 rpm, this displacement results in 3720 in3/min of theoretical
flow. This is a piston pump, expected to be 97% efficient, so 3608 in3 is the
expected output.

The track motors displacement is 2.68 in3. With 3608 in3 per minute of flow
it will theoretically turn at 1346 rpm. The track motors are piston motors
considered to be 97% efficient, resulting in 1305 expected rpm. The track
motor turns a 30.9 reduction gearbox, so it is expected to turn the track
drive sprocket at 42.2 rpm.

CHARGE PRESSURE CIRCUIT

The charge pump is a gerotor pump that has a displacement of 1.40 cid (22.9
cc) and is directly driven by the same shaft as PMP2. The charge pump
turns at the same speed as the engine crankshaft, so at high idle (2600 rpm),
it theoretically produces 15.75 gpm (50 L/min), dropping to 15.54 gpm (59 L/

Ground Drive
min) when the machine is running under load at 2400 rpm.

CHARGE FILTER FL3

TRACK/
BRAKE
VALVE
A8

PRESSURE
SUCTION SCREEN RELIEF
FL1
Continued on next page...

5-5
 Charge Pressure Circuit D20x22 Navigator HDD Service

Flow to the pump is drawn through suction screen FL1 located in tank
RES1. Flow from the pump supplies oil to charge the two hydrostatic loops,
or goes over pressure relief valve PV4 to the tank. Charge flow passes
through charge filter FL3 before being added to the loops. Cool fluid added to
the loops replaces hot fluid that is lost through internal leakage, or removed
by the hot oil shuttle valve DV1.

When both loops are full,

transport/drill

rotation motor
pilot to shift

pilot to shift
pressure builds in the charge

park brake
circuit until it opens relief valve

release
PV4 at 313 psi (21.5 bar). This
pressure is available to manifold
A8. There it can be used to shift
the machine from Transport to A8
Drill mode, release the park
brakes and to shift the rotation
motor speed.

Charge pump pressure, and a

small amount of flow, is also
used by the EDC (electric
displacement control). The
Ground Drive

EDCs in pumps PMP1 and

PMP2 move the servo pistons which control pump output.

5-6
D20x22 Navigator HDD Service Charge Pressure Circuit

Drill/Transport Valve Assembly A7

Operation - Right Flow from either port of PMP1 goes to Drill/Transport Valve Assembly A7
Track and passes the valves DV2 or DV3. These are pilot-operated valves that
direct flow to either the right track motor MH5 or the rotation motor MH1.

When the seat is unoccupied, solenoid L14 of DV8 prevents pilot signal from
shifting the valves from Transport mode to Drill mode. When the seat is
occupied, or a joystick control is out of NEUTRAL position, solenoid L14
receives a signal from engine bay controller A1 and pilot pressure from A8
shifts DV4 and DV5 allowing oil to flow to thrust/pullback motors if all
interlocks are satisfied.

Operation - Left Flow from either port of PMP2 goes to Drill/Transport Valve Assembly A7
Track and passes through valves DV4 or DV5. These are pilot-operated valves that
direct the flow either to the left track motor MH6 or to the three thrust
pullback motors MH2, MH3, and MH4.

When the seat is unoccupied, solenoid L14 of DV8 prevents pilot signal from
shifting the valves from Transport mode to Drill mode. When the seat is
occupied, or a joystick control is out of NEUTRAL position, solenoid L14
receives a signal from engine bay controller A1 and pilot pressure from A8
shifts DV2 and DV3 allowing oil to flow to the rotation motor if all interlocks

Ground Drive
are satisfied.

A7 MH4 MH5

DV1
DV4 DV5

DV2 DV3

to PMP2 A port from Port DS on A8

to PMP2 B port from Port BR on A8

to PMP1 A port

to PMP1 B port

5-7
 Brake Release Circuit D20x22 Navigator HDD Service

BRAKE RELEASE CIRCUIT

rotation motor
When the machine is shut down,

transport/drill

pilot to shift
pilot to shift
or when running in Drill mode,

park brake
a spring-applied brake at the

release
track drive gearbox prevents the
gearbox shaft from turning. The
springs each apply a force
equivalent to 260 psi (17.9 bar)
to the side of a piston holding A8
the brakes ON.
L14 L19 L20
When the seat is empty (seat DC8 DC9 DC10
switch S13 open) and either of
the transport station joysticks is
moved, the engine bay controller
sends voltage (via pin B5) to the
brake release solenoid L20, on
manifold A8.

Solenoid L20 shifts valve DC10 (on A8) to send charge pressure to the brake
Ground Drive

pistons. Provided charge pressure is greater than 260 psi (17.9 bar), it
overcomes spring pressure and the pistons move to release the brakes.

Troubleshooting
Troubleshooting procedures are given in this chapter for each functions
operating modes. Each procedure begins by performing a pretest inspection
of the machine (see following page).

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 "Machine Performance," page 5-11.

5-8
D20x22 Navigator HDD Service Brake Release Circuit

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.

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

Mechanical

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

Electrical

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 wires 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...

5-9
 Brake Release Circuit D20x22 Navigator HDD Service

Hydraulic

Check hydraulic components for any obvious problems 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 can cause
erratic behaviors in hydraulic circuits. Correct level is between the two
lines on dipstick. If needed, add new fluid that has been filtered through
a 10-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 problem is fixed.
Ground Drive

5-10
D20x22 Navigator HDD Service Brake Release Circuit

Machine Performance
If there are malfunctioning components in other functions, they may have an
affect on Stabilizer and Stakedown function operation.

Therefore, the preferred way to troubleshoot any faults that occur in these
functions is to operate all machine functions and document the performance
of the working actuators.

Make note of any functions not operating normally based on the normal
operation given in each chapter for that function. Comparing the results
with the normal operation given for each mode of a particular function will
help to isolate the problem.

Check machine performance, and 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 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:

Ground Drive
• See "Engine," page 3-8
• Shared hydraulic components (See "Troubleshooting," page 4-5)
2. If problems are noted in the Ground Drive, Thrust/Pullback, and
Rotation functions, and all other functions of the machine are operating
normally, the hydraulic components common to just these functions
should be investigated, including:
• "PMP1 & PMP2 Hydrostatic Loop," page 4-11
• "Drill/Transport Valve Assembly A7," page 5-7
• "Pilot Valve Assembly A8," page 5-16
3. If problems are noted in the Ground Drive function only and all other
machine functions are operating normally, the hydraulic components
common to just these functions should be investigated, including:
• "Drill/Transport Valve Assembly A7," page 5-7
• "Pilot Valve Assembly A8," page 5-16
• "Track Drive Motors MH5 & MH6," page 5-19

5-11
 Brake Release Circuit D20x22 Navigator HDD Service

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.

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

Electrical:

• Nominal circuit voltage - 12 volts DC

Hydraulic:

• Pump PMP1 & PMP2 normal output flow - variable to 31 gpm (117 L/
min)
• Pump PMP1 & PMP2 charge pressure relief setting - 313 psi (21.6 bar)
• Pump PMP1 & PMP2 high pressure compensator PV9 setting - 3335 psi
(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 4-19 and follow instructions.

5-12
D20x22 Navigator HDD Service Ground Drive Circuit

GROUND DRIVE CIRCUIT

FV1
DV1 MH5 MH6

A7
DV4 DV5

DV2 DV3

EDC EDC DV8 DV9

PV7

L14 L20

Ground Drive
GA2

PMP1
PMP2

Continued on next page...

5-13
 Ground Drive Circuit D20x22 Navigator HDD Service

IMPORTANT: Always check level of fluid in tank. Low fluid can contribute
to a number of hydraulic problems. If it is low, add clean fluid that has been
pumped through a 5-micron filter to bring fluid up to proper level. New fluid,
direct from drum or bulk tank, has accumulated contaminates while stored
in drum or tank. Always filter new fluid before adding it to a hydraulic
system.

As oil moves through the loop, it heats up. Some oil leaks into cases of pump
and motor through the clearances between moving parts.

Oil in case of pump and track motor is drained away to tank. In thrust/
pullback motors, cases drain internally to low pressure side of loop.

To replace hot oil taken from loop, charge pump draws cool oil out of tank,
pushes it through high pressure filter, and adds it to low pressure side of
loop.

Any contamination in oil will cause wear and other damage to pump and
motor(s) in use. As they wear, clearances between moving parts in both
pump and motors will increase, allowing more oil to pass out of loop into the
cases. Thus, monitoring case drain flow of pump and track motor will give a
general indication of wear.
Ground Drive

5-14
D20x22 Navigator HDD Service Ground Drive Circuit

Troubleshooting/ If faults are noted in Rotation, Thrust/Pullback or Ground Drive functions:

Testing
NOTE: First, ensure there are no obvious controller faults on both the
engine controller A1 as well as the console controller A2.

1. If all three functions are operating abnormally, pump PMP1 and PMP2
should be tested first. Check charge pressure of pump PMP2. Refer to
"Oil Supply," page 4-10 for troubleshooting information on tandem pumps
PMP1 & PMP2. If fault can be isolated to only the ground drive circuit,
continue.
2. If both tracks do not move when the seat is unoccupied and transport
levers are moved, seat switch S11 could be stuck in the closed position.
Inspect console controller seat LED. If LED is lit when seat is not
occupied, the switch may be broken. Inspect wiring and replace switch if
necessary. Refer to "Seat Switch S11," page 5-29. If switch is OK, proceed.
3. If either left, right, or both tracks are operating abnormally, the problem
could be linked to pilot pressure supplied by the pilot valve assembly A8.
If A8 is allowing oil to flow to A7, track drive functions with either be
degraded or inoperable. Refer to "Pilot Valve Assembly A8," page 5-16. If
problems continue, proceed.
NOTE: If coils which control pilot valve assembly A8 remains energized, oil

Ground Drive
is not reaching the track drive motors MH4 and MH5. Instead oil is most
likely flowing to rotation and thrust/pullback circuits, as well as activating
the park brake.

4. Examine valves DV2–DV5 to determine if valves are stuck. Replace if

necessary. Refer to "Drill Transport Valve Assembly A7," page 5-33 for
repair information.

5-15
 Ground Drive Circuit D20x22 Navigator HDD Service

Pilot Valve Assembly A8

Operation Pilot control valve assembly A8 controls whether the D20x22 Navigator is in
Transport mode, or Drill mode. The presence of an operator in the seat
determines the direction of flow coming out of drill/transport valve assembly
A7.

When an operator is present in the seat and seat switch S11 is closed, coil
L14 of DV8, coil L20 of DV9, and coil L19 of DV10 are not energized. Flow
from valve DV8 will shift valves DV2 and DV3 to supply oil to the drill
rotation motor, and DV4 and DV5 to supply oil to thrust/pullback motors
MH2, MH3, and MH4. DV9 allows oil to pass through DV5 and releases the
brakes.

If operator is not present and seat switch S11 remains open, coils L14 and
L20 are not energized. DV8 will not supply pilot pressure to A7, thus
allowing the track motors to receive flow. DV9 will not supplying oil to the
brakes, allowing the tracks to move.

The top schematic shows Ground Drive mode when the seat is unoccupied
and coils are not energized. The bottom schematic shows flow when seat is
occupied, and coils L14 and L20 energized.
Ground Drive

To Drill/Transport To Parking
Valve Assembly A7 Brake

From Charge
Pump
L14 L20 L19
DV8 DV9 DV10

To Drill/Transport To Park
Valve Assembly A7 Brake

From Charge
Pump
L14 L20 L19
DV8 DV9 DV10

+12V from Pin B5

of Engine Controller A1

5-16
D20x22 Navigator HDD Service Ground Drive Circuit

Troubleshooting/ If faults are noted in the Ground Drive function, and all other machine
Testing functions are normal:

1. Disconnect solenoid
L14 on manifold A8.
2. Set multimeter to A8
measure resistance
and place probes on
contacts at jack J215
on solenoid L14.

Expected Result: 9.8

ohm, ± 1.0 ohm. If so, Charge Pressure
continue. If not refer Test Port
to "Pilot Valve
Assembly A8," page 5-
32 and replace
solenoid L14.
DV9
3. Measure voltage from L20 DV10
pin P215-1 to P215-2. L19 DV8
Read voltage when L14

Ground Drive
drill seat is occupied
and empty.

Expected Result: 12 volts DC, ± 1.2 v DC when occupied, zero when

empty. If so, continue.

If not, test continuity of P215-1 (wire #709 purple) to engine bay

controller A1 at P204-5.
4. Shut down machine. Connect a 500 psi pressure gauge to charge
pressure test port. Restart machine and run engine to 2400 rpm.

Expected Result: 313 psi, ± 30 psi (21.5 bar, ± 2 bar). If so, replace valve
DV9. Refer to "Pilot Valve Assembly A8," page 5-32.

For any value less than 313 psi (21.5 bar), adjust charge pressure to
proper setting of 313 psi (21.5 bar). Refer to "Adjusting Charge Pressure
Relief Valve PV4," page 4-29.

5-17
 Ground Drive Circuit D20x22 Navigator HDD Service

Testing Pilot Valve The spools sliding back and forth in their bores can wear and allow greater
Assembly A8 for than allowed loss of pressure from the pressurized port of the valves to the
Cross Port Leakage tank ports. If this leakage is great enough, it can reduce charge pressure.

Before doing this test, carefully note the charge pressure. Connect a 500 psi
test gauge to the test port on manifold A8, start the machine and note the
charge pressure with the seat empty, and with it occupied. This test is only
used if the charge pressure is too low (below 313 psi, ± 10 psi) at operating
speed in both Transport and Drill mode.

IMPORTANT: This test will lock the machine into Drill mode, but it will
also prevent the parking brakes from being released. Do not attempt to
move the machine during this test.

1. Label harness connectors for the three solenoids on the manifold.

Disconnect solenoids from the harness.
Disconnect hose to tank leading
from A8, and cap the hose, and
the tank port in the manifold.
A8
2. Start machine and observe
Ground Drive

charge pressure at operating

speed. charge pressure
test port
Expected result: 313 psi, ±
10 psi. If so, replace
manifold A8 and the valves
in it. You may retain the
solenoids currently used.
L16 L15 L11
Refer to "Pilot Valve
Assembly A8," page 5-32. hose to tank

If not, the valves and

manifold A8 do not appear to be the cause of the low charge pressure.

3. Shut down, remove caps and reconnect the tank hose to A8. Also
reconnect solenoids to the harness.

5-18
D20x22 Navigator HDD Service Ground Drive Circuit

Track Drive Motors MH5 & MH6

Operation The track drive function on the D20x22 is powered by hydraulic pumps
PMP1 and PMP2. PMP1 supplies power for rotation, as well as powers the
right track motor MH5. PMP2 supplies power for thrust/pullback, as well as
powers the left track motor MH2.

The speed of these motors is dependant upon the operator’s input into the
track drive controls. These are proportional controls, thus allowing more oil
to flow to the motor as lever is pushed farther forward or backward.

Ground Drive

5-19
 Ground Drive Circuit D20x22 Navigator HDD Service

Measuring Case If charge pressure measurements indicate low charge pressure only in the
Drain Flow transport, excess internal leakage in of one or both track motors may be the
cause.

The case drain lines from TO PMP2 INLET TO PMP3

MH5 and MH6 join at a T- INLET
fitting near the motors. The
combined flow leads back to B9 and B10
the tank RES1. CASE DRAIN
PMP3 FROM A13
CASE DRAIN
1. Connect a 10-gpm flow PMP1
meter in the case drain FROM A9 CASE DRAIN

line just above where it FROM B13

connects to the case
drain line from PMP3. FROM FL4,
Ensure flow arrow on the A8 and PRL1
flow meter points toward
the tank.
FROM HE2
2. Connect charge pressure
test gauge to the charge
pressure test port. (See FL5
Ground Drive

FL6
"Charge Pressure
Measurement," page 4-
14.)
1. Ensure engine starting and warm-up procedures have been performed.
2. With engine running, use phototach to verify engine speed of 2,400 ± 100
rpm.
3. Enable Remote Lockout.
4. Lower stabilizer all the way down using control switches at the rear
control panel.
5. At rear control panel, operate rack angle control lever, to lower rack until
both tracks are completely clear of ground/floor.
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.
Continued on next page...

5-20
D20x22 Navigator HDD Service Right Track Function

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
stabilizer.
9. Observe and record charge pressure gauge. Observe and record flow
meter.
10. Shut down machine. Use pyrometer to measure the temperature of the
right and left track motors at the point where the case drain hoses are
attached to the motors.
11. Remove flow meter and pressure gauge.
12. Analyze results.

Analysis of Case If both motors are in identical condition (equal amounts of wear), case drain
Flow Test for MH5 flow, charge pressure reduction and heat accumulation will be nearly
and MH6 identical.

When turning right or left, case drain flow indicated should be slightly more

Ground Drive
than one half the indicated flow when operating both tracks. If case drain
flow when turning left is substantially more than when turning right, the
right motor is apparently worn substantially more than the left motor.

When operating right or left track, charge pressure should be approximately

equal to moving both. If charge pressure drops when operating either the
left or right track that side motor is leaking.

Heat is generated by leakage. If the pressure dropped significantly more

when turning one track than when turning the other, the warmer motor is
leaking more than the cooler one.

If the case drain flow is even between the two motors, but the combined flow
is more than 2.3 gpm (9.5 L/min), replace both motors MH5 and MH6. See
"Track Drive Motors MH5 & MH6," page 5-30.

RIGHT TRACK FUNCTION

Track Forward Mode
Required Operating • Seat switch must be open ( seat unoccupied).
Conditions • Engine running at full throttle.
• Ground drive control handle pushed FORWARD.

5-21
 Right Track Function D20x22 Navigator HDD Service

Operation When required operating conditions are met:

• Motor MH5 turns clockwise, rotating right track forward.

NOTE: If track Forward mode does not operate as expected, see following
troubleshooting.

Troubleshooting/ Before beginning any troubleshooting or testing procedures, perform the

Testing "Pretest Inspection," page 5-9. If nothing obvious is found continue.

1. In order to ensure the fault is isolated to just the Forward mode, the
technician should operate all machine functions and observe the
actuators as discussed in "Machine Performance," page 5-11.
2. If any functions other than track FORWARD or REVERSE function are
faulty, continue troubleshooting the components based on the possible
results given. If all other machine functions are operating normally,
continue with step 3.
3. If problem is limited to the track drive function, motors MH5 or MH6,
Ground Drive

pilot valve assembly A8, drill transport valve assembly A7, or the motor
brakes have most likely malfunctioned.
NOTE: Hydraulic component testing is based on volumetric efficiency.
Testing 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.

4. If machine will not shift to Transport mode, determine whether one

track will move or nether track will move. If both tracks fail, continue to
"Failure of Both Tracks," page 5-24. If only one track fails, refer to"Tracks
Operating in Single Direction," page 5-25. If machine does shift to
TRANSPORT, continue.
Continued on next page...

5-22
D20x22 Navigator HDD Service Right Track Function

5. If one track motor speed is operating slower than the other, machine will
be unable to track in a straight line. Switch transport joysticks by
unplugging them and plugging the right joystick into the jack for the left
joystick, and vice versa. You can reach these connectors through the
compartment used for storing the handheld transceiver for the Remote
Lockout system.
6. Drive machine again, but remember the left stick now controls the right
track and vice versa. Remember to reconnect joysticks correctly when
test is complete.

If machine still tracks off to same side, problem is either with track drive
motor or pump. If so, continue. If machine now curves opposite way, the
problem is either with joystick or EDC. Continue, and test joystick.
7. Disconnect 4-pin connector at base of joystick and attach 4 pin
connectors of breakout box to joystick plug and harness jack. Turn key
switch on and sit in seat.
8. Measure voltage from 2 to 3 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),
zero volts DC when fully back and 5 volts DC when fully forward. If so,

Ground Drive
joystick appears to operating normally.

If there is no voltage, go to step 4.

If there is voltage, but it does not vary with stick position as described,
replace joystick. Refer to "Transport Joysticks," page 5-35.

9. 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 harness
drawings in the back of the book. Test continuity of the wires for 2 and 3
on the breakout box to the jack and plug connected to the controller. If
continuity is good, replace joystick. Refer to "Transport Joysticks," page 5-
35. If not, repair or replace faulty wire or harness segment.

10. If joystick tests out, replace EDC on pump for slow turning track. Refer
to "EDCs for PMP1 and PMP2," page 4-39.
11. Reconnect joysticks properly and shut down machine. Label hoses that
connect to P1 top and bottom and P2 top and bottom ports.
12. Switch hoses from pumps to manifold A7 so that PMP1 and PMP2 are
supplying opposite track drive motor. Drive machine again but
remember left stick now controls right track and vice versa. Remember
to reconnect hoses correctly when test is complete.
Continued on next page...

5-23
 Right Track Function D20x22 Navigator HDD Service

13. If machine still tracks same way, problem is in track drive motor. Replace
by referring to "Track Drive Motors MH5 & MH6," page 5-30.

If machine tracks opposite way, problem is in either PMP1 or PMP2.

Replace the tandem pump stack. Refer to "PMP1/PMP2 Tandem Pump
Replacement," page 4-30.

Failure of Both 1. Examine “Seat” LED on face of console controller and “Brake” LED on
Tracks face of engine bay controller. With key switch S4 turned to RUN, sit in
the seat, then stand up and observe effect on LEDs.

Expected Result: Seat LED will glow when seat is occupied, and be dark
when seat is empty. If so, skip to step 6. If not, continue.

Brake LED will glow when seat is empty, and be dark when seat is
occupied. If so, continue below. If not, continue to "Track Brakes Release,"
page 5-27.
2. Disconnect seat switch S11 from harness and test continuity across
Ground Drive

switch when seat is empty and occupied.

Expected Result: Continuity when occupied, open when empty. If so,

continue. If not, replace seat switch. Refer to "Seat Switch S11," page 5-
29.
3. Measure DC voltage with red probe on orange wire #112 to seat switch,
and ground black probe to chassis.

Expected Result: 12 volts DC, ±1.2v DC. If so, continue. If not, trace wire
112 back to fuse box. Locate and correct continuity problem.
4. Disconnect plug P331 from controller A2 in console. Test continuity from
pin P331-11 to white wire #202 at seat switch connection.

Expected Result: Continuity. If so, contact Vermeer service and advise

them that the controller is not responding to seat switch.

If not, repair or replace faulty wire.

5. Find “D/T Mode” LED on face of controller A1. With key switch S4
turned to RUN, sit in seat, then get out of the seat and observe effect on
LED.

Expected Result: D/T Mode LED will glow when seat is occupied, and be
dark when seat is empty. If so, continue. If not, contact Vermeer service
and advise them that controller is not responding to seat switch.
6. Refer to "Pilot Valve Assembly A8," page 5-16.

5-24
D20x22 Navigator HDD Service Right Track Function

Failure of Single 1. Refer to step 4 of "Pilot Valve Assembly A8," page 5-16.
Track
2. If problem is affecting only left track, replace valves DV2 and DV3. If
only right track is affected, replace DV4 and DV5. Refer to "Drill Transport
Valve Assembly A7," page 5-33 for repair information.
3. If replacing valves does not solve problem, perform pressure/flow test on
pump PMP2.

Tracks Operating in 1. Determine if this affects only one or both track motors. Also, test thrust/
Single Direction pullback and rotation circuits to determine if these functions are affected
as well. If both motors are operating in a single direction, continue.
2. Check console controller and ensure “Seat” LED is dark.
3. Check engine bay controller and ensure “D/T Mode” LED is dark.
4. Check fault window of engine bay controller while trying to operate
transport function.
• An “F.” indicates a fault in Drill/Transport mode solenoid L14, or in
wiring leading to solenoid.

Ground Drive
• An “L.” or a “N.” indicates a fault in EDC on PMP2 or wiring leading to
it.
• An “O.” or a “P.” indicates a fault in EDC on PMP1 or wiring leading to
it.
5. Refer to "EDCs for PMP1 and PMP2," page 4-39.
6. Check charge check valve and high pressure relief valve on the
malfunctioning pump. Refer to "PMP1/PMP2 Charge Checks and High
Pressure Relief Valves," page 4-28.
7. Shut down machine and swap the two and see if non-functioning
direction changes. If so, replace malfunctioning valve.

Track Reverse Mode

Required Operating • Seat switch open (seat must be unoccupied).
Conditions • Engine running at full throttle.
• Control handle pulled back.

5-25
 Left Track Function D20x22 Navigator HDD Service

Operation When required operating conditions are met:

• Motor MH5 turns counterclockwise rotating right track in Reverse.

NOTE: If track Forward mode does not operate as expected, refer to
"Troubleshooting/Testing," page 5-22.

LEFT TRACK FUNCTION

Track Forward Mode
Required Operating • Seat switch must be open (seat unoccupied).
Conditions • Engine running at full throttle.
• Control handle pushed FORWARD.

Operation When required operating conditions are met:

Ground Drive

• Motor MH6 turns clockwise rotating left track forward.

NOTE: If track Forward mode does not operate as expected, refer to
"Troubleshooting/Testing," page 5-22.

Track Reverse Mode

Required Operating • Seat switch must be open (seat unoccupied).
Conditions • Engine must be running at full throttle.
• Control handle must be pulled back.

Operation When required operating conditions are met:

• Motor MH6 turns counterclockwise, rotating left track in reverse.

NOTE: If track Reverse mode does not operate as expected, refer to
"Troubleshooting/Testing," page 5-22.

5-26
D20x22 Navigator HDD Service Track Drive Circuit Cooling

TRACK DRIVE CIRCUIT COOLING

Whenever the machine is in Transport mode and either track drive joystick
is moved out of NEUTRAL, the controller energizes solenoid L21. When
energized, solenoid L21 opens the tracking cooler valve SV2, sending full
flow from the PFC pump PMP3 to cooler. This results in cooler fluid in the
tank, so the charge pump has cooler fluid to provide to the two hydrostatic
loops.

The exception is when the rack angle adjustment lever is moved out of
NEUTRAL. The lever opens a normally closed switch S31, that breaks the
circuit for L21. This allows an operator to adjust the rack while moving the
machine. This can be helpful when driving the machine off of or onto a
trailer or truck bed.

To ensure tank has plenty of cool oil to supply the loop charge pumps, PFC
pump PMP3 is used to send oil through the oil cooler HE2 when the park
brakes are released.

Solenoid L20 releases the park brake by shifting brake valve DV9 to send
charge pressure to the proper ports on the track motors. The same electrical
signal that energizes L20 also energizes L21.

Ground Drive
L21 shifts SV2 to allow flow from PMP3 through the cooler to the tank.
Since PMP3 is a pressure-compensated pump, it responds to the drop in
pressure by going to full-stroke, sending about 17 gal (64 L) of fluid through
the oil cooler each minute.

The transport dump override switch S31 is normally closed. It is mounted

inside the valve assembly used to adjust rack lift. If the operator needs to
operate rack lift when loading or unloading the machine from a truck or
trailer, moving the rack lift lever will open S31, cutting off cooling flow and
making pressure and flow available to rack angle circuit.

TRACK BRAKES RELEASE

Required Operating • Seat must be unoccupied
Conditions • Rear transport controls moved from NEUTRAL

5-27
 Track Brakes Release D20x22 Navigator HDD Service

Operation When the seat

switch S11 is open
(operator not
present in seat),
and rear joystick
control is moved
from NEUTRAL MH5 MH6
engine bay
controller A1
sends a signal to
coil L20 of DV9
within the pilot
valve assembly
A8. This signal
energizes L20,
thus shifting DV9
and directing oil
to release brakes.
Ground Drive

To A7

L14 L20

5-28
D20x22 Navigator HDD Service Component Repair

COMPONENT REPAIR
Seat Switch S11
The operator presence switch S11 is built into the bottom seat cushion of the
seat. In order to inspect and replace this switch:

1. Unplug harness connector.

2. Refer to parts book diagram to remove the seat from pedestal.
3. To install new seat and switch, follow reverse of above instructions.

Charge Pump
The charge pump on this model of drill cannot be purchased as a separate
unit. If charge pump fails, replace pump PMP1/PMP2.

Ground Drive
PMP1/PMP2 Tandem Pump Adjustments
Refer to "PMP1/PMP2 Charge Checks and High Pressure Relief Valves," page
4-28.

EDCs for PMP1 and PMP2

Refer to "EDCs for PMP1 and PMP2," page 4-39

Transducers B4 & B5 for PMP1/PMP2

Refer to "Replacing Transducers B4 and B5," page 4-43

PMP1/PMP2 Tandem Pump Replacement

Refer to "PMP1/PMP2 Tandem Pump Replacement," page 4-30.

5-29
 Component Repair D20x22 Navigator HDD Service

Track Drive Motors MH5 & MH6

Motors MH5 and MH6 are identical. MH5 drives the right track and MH6
drives the left track. The following procedure works for either motor.

MH5

MH6

3
1
Ground Drive

Continued on next page...

5-30
D20x22 Navigator HDD Service Component Repair

1. Label all three hoses for ports A, B, and the case drain port.
2. Disconnect case drain line hose at the elbow fitting. Cap the line. Allow
motor case to drain to a catch pan, then plug elbow fitting.
3. Disconnect hoses to 45° fittings or elbow fittings in ports A and B. Cap
the lines. Plug fittings.
4. Support motor and remove the two bolts holding it to the frame.
5. Remove and inspect O-ring. If not nicked or pinched, it may be reused.
6. Remove fittings from old motor. Install in new motor. Torque fittings for
A and B ports to 46 ft-lb (62 Nm). Torque case drain fitting to 20.5 ft-lb
(27.8 Nm).
7. Coat O-ring with clean oil and install on motor. Slide motor into gearbox.
8. Apply Loctite 277 to threads of bolts and install. Snug bolts evenly and
torque to 90 ft-lb (122 Nm).
9. Attach case drain line and torque to 28.5 ft-lb (38.6 Nm)
10. Attach hoses to A and B ports and torque to 38 ft-lb (52 Nm).
11. Refer to "Returning System to Service," page 4-33.

Ground Drive

5-31
 Component Repair D20x22 Navigator HDD Service

Pilot Valve Assembly A8

Solenoid Coils L19, These are located on pilot valve
L20, and L21 assembly A8.

Locate correct solenoid or valve. A8

Remove shields as needed for
access.

1. Loosen and remove hex nut

on bottom of coil.
2. Slide coil off spool valve. If
double coil slide both coils off
spool valve.
NOTE: Inspect spool valve for
any damage.

Reverse removal steps when

installing coils.

Torque valves as follows:

Ground Drive

A8
• all solenoids to 5 ft-lb (7
Nm).
• DV8, DV9 and DV10 to 20
ft-lb (27 Nm).

DV8
DV9 DV10 L14
L20 L19

5-32
D20x22 Navigator HDD Service Component Repair

Drill Transport Valve Assembly A7

Valves DV1, DV2, These are located on drill
DV3, DV4, and DV5 transport valve assembly A7. A7

Locate correct valve or solenoid.

Remove shields as needed for
access.

Remove valves from manifold

and inspect for obvious signs of
damage or contamination.
Replace O-rings, seals, and
washers if necessary. When DV1
finished, replace valves in
manifold.

Ground Drive
Torque valves as follows: A7
A7

• DV1 to 30 ft-lb (41 Nm)

• DV2 and DV3 to 50 ft-lb (68 DV2
Nm)
DV3
• DV4 and DV5 to 35 ft-lb (47
Nm)

DV4
DV5

5-33
 Component Repair D20x22 Navigator HDD Service

Directional Valve 1. Remove valve from manifold and check for

DV1 visual damage.
2. Replace O-ring (1) if necessary.
3. Screw valve back into manifold and torque
to 24–26 ft-lb (32.5–35.3 Nm).

1
Ground Drive

Directional Valves 1. Remove valve from manifold and check for

DV2 & DV3 visual damage.
2. Replace O-rings (1) and backup washers
(2) if necessary. 1
3. Screw valve back into manifold and torque
to 50 ft-lb (67.7 Nm).

1 2

5-34
D20x22 Navigator HDD Service Component Repair

Directional Valves 1. Remove valve from manifold and check for

DV4 & DV5 visual damage.
2. Replace O-rings (1) and backup washers
(2) if necessary. 1
3. Screw valve back into manifold and torque
to 35 ft-lb (47 Nm).

1 2

Ground Drive
Transport Joysticks
1. Open the door to the storage compartment for the handheld remote
transmitter.
2. Disconnect harness from the joystick base.
3. Unscrew knob and joystick as a unit from the base and pull it up out of
the dust boot.
4. Working from inside the transmitter compartment, remove the four
screws holding the joystick base to the mount.
To install new joystick, reverse steps above.

5-35
This page intentionally left blank.
D20x22 Navigator HDD Service Overview

Chapter 6: Thrust/Pullback

OVERVIEW
This chapter consists of information about components necessary for the
thrust/pullback function.

Functions/Components
Functions • Thrust (High-Speed and Low-Speed)
• Pullback (High-Speed and Low-Speed)
• Pressure Monitoring

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

• Hydraulic Fluid Distribution Components

Thrust/Pullback
• Pump PMP2
• Drill/Transport Valve Assembly A7
• Pilot Valve Assembly A8
• Thrust/Pullback Valve Assembly A6
• Thrust/Pullback Motors MH2, MH3 and MH4
• Thrust/Pullback Pressure Gauge GA4
• Pressure Transducer B5

6-1
 Overview D20x22 Navigator HDD Service

Component Locations

Pilot Valve Drill/Transport

Thrust/Pullback

Assembly A8 Valve Assembly A7

B5
Pressure
Transducer

6-2
D20x22 Navigator HDD Service Overview

EDC Left Track EDC

Engine
End
EDC Right Track EDC

PMP1
Rotation/Right
Track Pump

PMP2
Thrust/Pullback/
Left Track Pump

Thrust/Pullback
Thrust/Pullback
GA4 Pressure Gauge GA4

6-3
 Overview D20x22 Navigator HDD Service
Thrust/Pullback

MH2
Thrust/Pullback MH3
A6 Valve Assembly A6 Thrust/Pullback MH4
Motors

6-4
D20x22 Navigator HDD Service Overview

Hose Connections

Thrust/Pullback
Transducer B5

Pilot Valve
Assembly A8 Charge Pump
Filter FL3

Pump
PMP2

Pump
PMP1

Oil Tank

Thrust/Pullback
RES1

Drill/Transport
Valve Assembly A7

Thrust/Pullback
Valve Assembly A6

MH2
MH3
MH4
Thrust/Pullback
Motors

Oil Cooler
HE1

6-5
 Overview D20x22 Navigator HDD Service

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 following page).

Often problems can be solved by 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 "Machine
Performance," page 6-9.
Thrust/Pullback

6-6
D20x22 Navigator HDD Service Overview

Pretest Inspection
If faults occur, do the following visual checks to inspect for obvious signs of
failure before any exhaustive troubleshooting or testing is performed.

Mechanical

Inspect the mechanical linkages, cables, and connectors from joystick

controllers and control valves. Look for damage, misalignment, and
improper adjustment.

Electrical

Inspect electrical circuits for clues to 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 wires on the power wires
that supply circuit components.
• Check all ground connections on the machine and chassis for tight
connections. Cleaning harness connections or ground connections can

Thrust/Pullback
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.

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.

Continued on next page...

6-7
 Overview D20x22 Navigator HDD Service

Check hydraulic circuits for any failures such as:

• Broken, kinked, loose, or leaking hoses or fittings that connect hydraulic

components.
• Check level of 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

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

6-8
D20x22 Navigator HDD Service Overview

Machine Performance
Possible problems may occur in the Thrust/Pullback functions that are
directly related to problems in other functions. These other faults may not be
readily apparent because those particular functions are not currently being
operated.

The preferred way to troubleshoot problems that occur in this function is to

operate all the machine functions and document the performance of working
actuators.

Make note of any functions not operating normally based on the theory
given in each chapter for that function. Comparing the results with the
normal operation given for each mode of a particular function will help to
isolate the problem.

After checking the performance of all machine functions, if the problem can
be 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 problems are noted when operating all the machine actuators, it would

Thrust/Pullback
indicate a circuit or component that is common to all the actuators is
most likely faulty. The following components should be investigated:
• See "Engine," page 3-8.
• See hydraulic fluid distribution components.

2. If faults are noted in the Thrust/Pullback and Ground Drive functions,

the following should be investigated:
• See "PMP1 & PMP2 Hydrostatic Loop," page 4-11.
• See "Drill/Transport Valve Assembly A7," page 7-9.
• See "Pilot Valve Assembly A8," page 6-13.
3. If faults are noted in only the Thrust/Pullback functions and all other
functions are OK, the hydraulic components common to just these
functions should be investigated, including:
• See "Thrust/Pullback Valve Assembly A6," page 6-17.

6-9
 Overview D20x22 Navigator HDD Service

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: 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.

Specifications
Listed below are the electrical and hydraulic specifications for the Drill and
Thrust/Pullback functions.
Thrust/Pullback

Electrical:

• Joystick control voltages

Input - Red wire - 5.5 volts DC
Ground - Black wire
Output - Yellow wire - Maximum fully forward - 4.5 volts DC, fully back -
0.5 volts DC, centered - 2.5 volts DC
• Nominal circuit voltage - 12 volts DC
Hydraulic:

• Pump PMP2 normal output flow - variable to 31 gpm (117 L/min).

• Pump PMP2 charge pressure relief setting - 313 psi (21.6 bar).
• Pump PMP2 high pressure compensator PV4 setting - 3335 psi (230 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 4-19 and follow instructions.

6-10
D20x22 Navigator HDD Service Thrust/Pullback Circuit

THRUST/PULLBACK CIRCUIT
MH2

MH3

MH4

A6 L4
DV6

L3 L5

DV28 DV7

A7 A8

Thrust/Pullback
DV4 DV8
DV5 DV9
L14
L20

EDC
PV7

PV5

GA2

PMP2
PV6
Pressure/Return Charge PV4
Charge Pressure Pump

Continued on next page...

6-11
 Thrust/Pullback Circuit D20x22 Navigator HDD Service

Pump PMP2
Operation PMP2 is a bi-directional, variable displacement pump that can deliver up to
2.81 cid (46.0 cc) per revolution. It is driven directly by the engine at 2600
rpm high idle, pulling down 2400 rpm under load, delivering 31 gpm (110.5
L/min).

Actual flow volume is controlled by the angle of the swashplate inside the
pump. The swashplate can also reverse direction of flow through the loop.

The swashplate angle is controlled by a servo piston. The position of the

servo piston is controlled by an EDC. It uses pressure from the charge pump
to move the servo piston, according to electrical inputs from the engine bay
controller A1.

Charge Pump The charge pump is a gerotor pump that has a displacement of 1.40 cid (22.9
cc) and is directly driven by the same shaft as PMP2. The charge pump
turns at the same speed as the engine crankshaft, so at high idle (2600 rpm),
it theoretically produces 15.75 gpm (50 L/min), dropping to 15.54 gpm (49 L/
min) when machine is running under load at 2400 rpm.

Flow from this pump goes to charge the hydrostatic loops, or goes over the
Thrust/Pullback

pressure relief valve to tank. Flow passes through charge filter before being
added to loops. Cool fluid added to loops replaces hot fluid that is lost
through internal leakage, or removed by the hot oil shuttle valve SV2.

When both loops are full, pressure builds in charge pressure circuit until it
opens relief valve PV4 at 313 psi (21.5 bar). This pressure is available to
pilot valve assembly A8. There it can be used to shift machine from
Transport to Drill mode, release the park break, and shift rotation motor
speed.

Charge pump pressure, and a small amount of flow, is also used by the two
EDC units to move servo pistons that control flow from PMP1 and PMP2.

6-12
D20x22 Navigator HDD Service Thrust/Pullback Circuit

Pilot Valve Assembly A8

Operation Pilot control valve assembly A8 controls whether the machine is in
Transport mode, or Thrust/Pullback mode. The presence of an operator in
the seat determines the direction of flow coming out of the drill/transport
valve assembly A7.

If an operator is NOT present and seat switch S11 remains open, coils L14
and L20 are not energized. DV8 and DV9 remain closed thus keeping the
machine in Transport mode.

When an operator is present in the seat and seat switch S11 is closed, coil
L14 of DV8, and coil L20 of DV9, are energized. When this occurs, oil flows to
the pilot operated valves DV2, DV3, DV4, and DV5. This pilot pressure
shifts the valves, supplying oil to the thrust/pullback and rotation functions.

The top schematic shows Ground Drive mode when the seat is not occupied
and coils are not energized. The bottom schematic depicts the circuit when
the seat is occupied.

To Drill/Transport

Thrust/Pullback
Valve Assembly A7 To Brake

From Charge
Pump
L14 L20 L19
DV8 DV9 DV10

To Drill/Transport
Valve Assembly A7 To Brake

From Charge
Pump
L14 L20 L19

+12v from Pin D5 of A1 DV8 DV9 DV10

+12v from Pin B5 of A1

Continued on next page...

6-13
 Thrust/Pullback Circuit D20x22 Navigator HDD Service

MH4

HE1
MH5

MH6

A6

A7
Thrust/Pullback

DV1

DV2 DV3 DV4 DV5

frome PMP2 A port

from PMP2 B port

A8
from Charge Pump

from pin B5 on A1

L14 DV8
Troubleshooting If faults are noted in thrust/pullback and rotation functions:

1. With seat occupied, test for voltage at coil L14.

• Expected Result: +12V DC from Pin D5 of controller A1.
2. If no voltage is present, check seat switch S11. Refer to "Seat Switch
S11," page 5-29.
Continued on next page...

6-14
D20x22 Navigator HDD Service Thrust/Pullback Circuit

3. If problem is not corrected when coils have voltage, test resistance of

coils L14 and L20.
• Expected Result: Resistance should measure 7–9 ohms @ 68°F (20°C). If
necessary, refer to component repair section for "Pilot Valve Assembly
A8," page 5-16.
4. If coils L14 and L20 have acceptable voltage and resistance, and thrust/
pullback function is not operating properly, check valves for
contamination or damage. Refer to component repair for "Drill/Transport
Valve Assembly A7," page 7-9.

Drill/Transport Valve Assembly A7

Operation Flow from either port of pump PMP2 goes to drill/transport valve assembly
A7 and passes through valves DV4 or DV5. These are pilot-operated valves
that direct flow either to left track motor MH6 or to thrust/pullback motors
MH2, MH3, and MH4.

When the operators seat is occupied, solenoid L14 of DV8 contained in the
pilot valve assembly A8 provides pilot signal to shift DV4 and DV5, allowing

Thrust/Pullback
the machine to shift from Transport mode to Drill mode. When unoccupied,
solenoid L14 is not energized and DV8 cuts off pilot pressure to A7, thus
allowing flow to the track motors.

6-15
 Thrust/Pullback Circuit D20x22 Navigator HDD Service

Troubleshooting/ If faults are noted in rotation, thrust/pullback, or ground drive functions:

Testing
NOTE: First, ensure there are no obvious controller faults on both the
engine controller A1, as well as the console controller A2.

1. If all three functions are operating abnormally, pumps PMP1 and PMP2
should be tested first. Refer to "Oil Supply," page 4-10 for troubleshooting
information on tandem pumps PMP1 & PMP2. If fault can be isolated to
only the thrust/pullback circuit, continue.
2. If rotation and thrust/pullback circuits do not work when the seat is
occupied, seat switch S11 could be stuck in open position. In order to test
the circuit for seat switch S11, refer to steps 1–5 of "Failure of Both
Tracks," page 5-24.
3. If seat switch is defective, replace. Refer to "Seat Switch S11," page 5-29.
If switch is OK, proceed.
4. If rotation, thrust/pullback, or both functions are operating abnormally,
the problem could be linked to pilot pressure supplied by the pilot valve
assembly A8. If A8 is not allowing oil to flow to A7, thrust/pullback and
rotation functions will be inoperable. Refer to "Pilot Valve Assembly A8,"
page 6-13. If pilot valve assembly A8 appears to be OK, proceed.
Thrust/Pullback

NOTE: If coils which control pilot valve assembly A8 do not energize when
an operator is present in the seat, oil is not reaching the rotation motor MH1
or thrust/pullback motors MH2, MH3, and MH4. Instead, oil is most likely
flowing to the track drive motors.

5. Examine valves DV2–DV5 for contamination or damage. Refer to "Drill

Transport Valve Assembly A7," page 6-25 for repair information.

6-16
D20x22 Navigator HDD Service Thrust/Pullback Circuit

Thrust/Pullback Valve Assembly A6

Operation The thrust/pullback valve assembly A6
controls whether the carriage operates in
either Low Speed or High Speed mode. This is
done by manipulating flow to the motors which
will either allow rotation (Low-Speed mode) or
freewheel (High-Speed mode) of MH3, the
middle carriage motor.

Flow is manipulated by three solenoid

activated directional valves, DV28 (coil L3),
DV6 (coil L4), and DV7 (coil L5). When
operating in Low-Speed mode, these coils are
D7 DV6 DV28
not energized and pressurized oil flows
through all three motors, propelling the L5 L4 L3
carriage.

When operating in High-Speed mode, the coils are energized. DV28 and DV7
shift closed diverting oil around them. DV6 shifts open allowing oil to flow
through, allowing MH3 to free-wheel, rather than being propelled.

Thrust/Pullback
NOTE: When front vise is clamped during rod changing, coils L3, L4, and
L5 are automatically energized and the carriage moves in High-Speed mode
in order to expedite rod loading.

Troubleshooting/ If a problem with thrust/pullback function occurs, and it can be traced to the
Testing thrust/pullback valve assembly A6, take the following actions:

1. If thrust/pullback does not shift into High Speed mode when high-speed
carriage switch S14 is activated, test voltage and resistance at coils L3,
L4, and L5.

Expected Result: 12 volts DC ± 1.2 volts and 7-9 ohms at 68°F (20°C).
2. If accurate voltage and resistance are present, examine DV28, DV6, and
DV7 and replace if necessary. Refer to "Thrust/Pullback Valve Assembly
A6," page 6-17.

6-17
 Thrust/Pullback Function D20x22 Navigator HDD Service

THRUST/PULLBACK FUNCTION
LOW Speed

MH2

MH3

MH4

L4
From Pin C7
of A1

L3 DV6 L5
L5

DV28 DV7
To To
Rotation Rotation
Motor MH1 Motor MH1
Thrust/Pullback

To Park Break

From Port A From Port B From From Pin B5

From Port C From Port D Charge
of PMP1 of PMP2 of PMP2 of A1
of PMP1 Pump
Pressure/Return
Charge Pressure

6-18
D20x22 Navigator HDD Service Thrust/Pullback Function

HIGH Speed

MH2

MH3

MH4

A6 L4
From Pin C7
of A1

L3 DV6 L5

DV28 DV7

To To
Rotation Rotation
Motor MH1 Motor MH1

Thrust/Pullback
DV8
DV9
L21 L20

From Port C From Port D From Port A From Port B From From Pin B5
of PMP1 of PMP1 of PMP2 of PMP2 Charge of A1
Pump
Pressure/Return
Charge Pressure

6-19
 Thrust/Pullback Function D20x22 Navigator HDD Service

Thrust Mode
Required Operating To operate Thrust mode:
Conditions
• Operator must be seated at drill
controls.
• Remote Lockout system must be in
normal Run mode.
• Engine must be running at full
throttle.
• Thrust/pullback joystick must be
pushed forward.

S12

Operation When required operating conditions are met:

Thrust/Pullback

• Motors MH2 and MH4 will rotate, moving the gearbox down the rack. In
Low mode, MH3 will also rotate.
• Motor MH3 will freewheel (when in High mode only).
• Drill rod string will thrust forward.

Pressure relief valve PV5 and PV6 protect the circuits from over-
pressurization. If pressure in the thrust or pullback circuits reaches 3335 psi
(230 bar), the valve will open and direct fluid to the oil tank.

NOTE: If the Thrust mode does not operate as expected, see the following
troubleshooting.

6-20
D20x22 Navigator HDD Service Thrust/Pullback Function

Troubleshooting/ Before beginning any troubleshooting or testing procedures, perform the

Testing "Pretest Inspection," page 6-7. If nothing obvious is found, continue.

1. In order to ensure the fault is isolated to just the Thrust mode, the
technician should operate all machine functions and observe the
actuators as discussed in "Machine Performance," page 6-9.
2. If any functions other than the thrust function are faulty, continue
troubleshooting based on the possible results given. If all other machine
functions are operating normally, continue.
3. If carriage speed is less than normal, motor and pump wear or a faulty
EDC may be the issue. Shut down machine and reverse connectors so
that the plug to PMP1 EDC now goes to PMP2 EDC and vice versa.
4. Start machine and use other joystick to run the carriage back and forth.
Put pump and motors under load by thrusting or pulling on the drill
string. Use rotation stick to operate carriage, but buttons on thrust/
pullback stick are still used to operate vises and rod loader. Reconnect
EDCs properly after completing test. If carriage is still slow, the problem
is hydraulic. Continue with step 8. If the carriage speed becomes correct,
the problem is either the joystick or the EDC. Continue to next step.
5. Disconnect 4-pin connect at base of joystick and attach 4-pin connectors

Thrust/Pullback
of the breakout box to joystick plug and harness jack. Turn key switch to
the ON position and sit in seat.
6. Measure voltage from 2 to 3 on breakout box while moving joystick
slowly forward and slowly backward.

Expected result: 2.5 volts DC when joystick is centered, 0.5 volts DC

when fully back, and 4.5 volts DC when fully forward. If so, joystick is
operating properly.
7. Measure voltage with black probe grounded to chassis and red probe at 1
on breakout box.

Expected result: 12 volts DC. If so, test continuity of wires for 2 and 3 on
breakout box to jack and plug connected to controller. If continuity is
good, replace joystick. If not, replace faulty wire or harness segment.
8. If loss of pressure is indicated on pressure gauge GA4, the main relief
valves PV5 and PV6 in PMP2 maybe stuck open, out of adjustment, or
internal leakage in the pump may be the problem. If so, continue.
9. Remove and inspect the cartridge valves in pump PMP2 for damage or
contamination. Repair or replace any faulty components. If OK,
continue.
10. Test motors MH2, MH3 and MH4. Refer to the Industrial Dealerships
Technician’s Shop Manual (Vermeer P/N 105400V80) for information on
testing hydraulic motors.
Continued on next page...

6-21
 Thrust/Pullback Function D20x22 Navigator HDD Service

NOTE: An individual motor should be replaced if shaft speed is below 215

rpm when tested. If so, repair or replace motor(s). Refer to component repair
section in this chapter.

Pullback Mode
Required Operating To operate Pullback mode:
Conditions
• Seat must be occupied.
• Remote Lockout must be in normal Run mode.
• Engine must be running at full throttle.
• High/low rotation switch S12 on right joystick must be activated (High
mode only).
• Thrust/pullback joystick must be pulled back.
Thrust/Pullback

Normal Operation When required operating conditions are met:

• Motors MH2 and MH4 will rotate to guide the gearbox up the rack. In
Low mode, MH3 will also rotate.
• Drill rod string will pull back.

Pressure relief valve PV8 protects the circuits from over-pressurization. If

pressure in the thrust or pullback circuits reaches 3500 psi (241 bar), the
valve will open and direct fluid to the oil tank.

NOTE: If the Pullback mode does not operate as expected, see the following
troubleshooting.

6-22
D20x22 Navigator HDD Service Thrust/Pullback Function

Troubleshooting/ Before beginning any troubleshooting or testing procedures, perform the

Testing "Pretest Inspection," page 6-7. If nothing obvious is found, continue.

1. To determine whether the fault is isolated to just the Pullback mode,

operate all machine functions and observe the actuators as discussed in
"Machine Performance," page 6-9.
2. If any functions other than the pullback function are faulty, continue
troubleshooting based on the possible results given. If all other machine
functions are operating normally, continue.
3. If carriage speed is less than normal, motor and pump wear or a faulty
EDC may be the issue. Shut down machine and reverse connectors so
that plug to PMP1 EDC now goes to PMP2 EDC and vice versa.
4. Start machine and use other joystick to run the carriage back and forth.
Put pump and motors under load by thrusting or pulling on the drill
string. Use rotation stick to operate carriage, although buttons on thrust/
pullback stick are still used to operate vises and rod loader. Reconnect
EDCs properly after completing test. If carriage is still slow, the problem
is hydraulic. Continue with step 8. If the carriage speed changes, the
problem is either the joystick or the EDC. Continue to next step.
5. Disconnect 4-pin connect at base of joystick and attach 4-pin connectors

Thrust/Pullback
of the breakout box to joystick plug and harness jack. Turn key switch on
and sit in seat.
6. Measure voltage from 2 to 3 on breakout box while moving joystick
slowly forward and slowly backward.

Expected result: 2.5 volts DC when joystick is centered, zero volts DC

when fully back, and 5 volts DC when fully forward. If so, joystick is
operating normally.
7. Measure voltage with black probe grounded to chassis and red probe at 1
on breakout box.

Expected Result: 12 volts DC. If so, test continuity of wires for 2 and 3 on
breakout box to jack and plug connected to controller. If continuity is
good, replace joystick. If not, replace faulty wire or harness segment.
8. If loss of pressure is indicated on pressure gauge GA4, the main relief
valve PV8 in valve assembly A4 maybe stuck open or misadjusted, or
internal leakage in the valve may be the problem. If so, continue.
9. Remove and inspect the cartridge valves in thrust/pullback valve
assembly A4 for damage or contamination. Refer to component repair
procedures in this chapter. Repair or replace any faulty components.
Continued on next page...

6-23
 Component Repair D20x22 Navigator HDD Service

10. Test motors MH2, MH3 and MH4 for internal leakage. Refer to the
Vermeer Industrial Dealerships Technician’s Shop Manual (Vermeer P/N
105400V80), for information on testing hydraulic motors.
NOTE: An individual motor should be replaced if shaft speed is below 215
rpm. If so, replace motor(s). Refer to motor repair procedure in this chapter.

COMPONENT REPAIR
Charge Pump
The charge pump on this model of drill cannot be purchased as a separate
unit. If charge pump fails, replace pump PMP1/PMP2. See next page.

PMP1/PMP2 Tandem Pump Adjustments

Refer to "PMP1/PMP2 Charge Checks and High Pressure Relief Valves," page
Thrust/Pullback

4-28.

EDCs for PMP1 and PMP2

Refer to "EDCs for PMP1 and PMP2," page 4-39.

Transducers B4 & B5 for PMP1/PMP2

Refer to "Replacing Transducers B4 and B5," page 4-43.

PMP1/PMP2 Tandem Pump Replacement

Refer to "PMP1/PMP2 Tandem Pump Replacement," page 4-30.

Pilot Valve Assembly A8

Refer to "Pilot Valve Assembly A8," page 5-32.

6-24
D20x22 Navigator HDD Service Component Repair

Drill Transport Valve Assembly A7

Refer to "Drill/Transport Valve Assembly A7," page 7-9.

Thrust/Pullback

6-25
 Component Repair D20x22 Navigator HDD Service

High Speed Carriage Valve Assembly A6

Solenoid Coils L3, These are located on thrust/pullback valve assembly A6.
L4, and L5
Locate correct solenoid or valve. Remove shields as needed for access.

1. Disconnect electrical connections from solenoid coils.

2. Label and disconnect hoses from fittings.
3. Remove valve assembly from carriage.
4. Loosen and remove hex nut on bottom of coil.
5. Slide coil off spool valve and remove valve spool from manifold.
NOTE: Inspect spool valve for any damage and replace if necessary.

Reverse removal steps when installing coils.

Torque valves as follows:

• all solenoids to 5 ft-lb (7 Nm).

• DV28, DV6 and DV7 to 20
Thrust/Pullback

ft-lb (27 Nm).

A6

DV7
L5
DV28 DV6
L3 L4

6-26
D20x22 Navigator HDD Service Motors MH2, MH3, and MH4

MOTORS MH2, MH3, AND MH4

Remove 1. Remove rod box for
access to gearbox
carriage.
2. Label hoses and
disconnect them from
all motors on the
gearbox carriage
(including the rotation 6
motor). Install dust
caps on hoses and
motor ports.
3. Unbolt hose carrier
from the gearbox
carriage and fold it out 1
of the way.
4. Remove four bolts (1) 2
and washers (2) from
the base of each motor.

Thrust/Pullback
Lift motor straight up.
5. Remove retaining bolt
(3), and washer (4)
from end of motor
shaft and remove
pinion gear (5). 5
6. Remove hose adapter
fittings (6) from motor. ox
earb
4 g
w ard
to
3

Continued on next page...

6-27
 Motors MH2, MH3, and MH4 D20x22 Navigator HDD Service

Install 1. Slide pinion gear (1)

onto splines of new
motor. Apply Loctite
277 to threads of
retaining bolt (2) and
install bolt and washer
(3). Torque bolt to 195
ft-lb (264 Nm).
7
2. Position motor so
rectangular tag (4) on
top end is toward
4
gearbox.
3. Apply Loctite 277 to
bolt (5) threads.
5
Install bolts, washers
(6) and motor. Torque
bolts to 90 ft-lb (122 6
Nm).
4. Fill case of motor with
new hydraulic fluid
Thrust/Pullback

that has been filtered

through a 5-micron
filter.
5. Install hose adapter 1
fittings (7) and torque
to 38 ft-lb (52 Nm).
x
3 rbo
6. Attach hose carrier gea
ard
and hoses. tow
2
7. Torque hose
connections to:
• thrust/pullback motor fittings to 67.5 ft-lb (91.5 Nm).
• rotation motor A and B port fittings to 67.5 ft-lb (91.5 Nm).
• 1/4 inch hose to elbow on rotation motor to 9.5 ft-lb (12.9 Nm).
• 3/8 inch hose to tee on rotation motor to 19 ft-lb (29 Nm).

8. Refer to "Returning System to Service," page 4-33.

6-28
D20x22 Navigator HDD Service Motors MH2, MH3, and MH4

Drill Joysticks A19 & A20

The joysticks mounted on either side of the seat are identical, except for the
middle switch on the right joystick. Each is mounted to a flat plate, and the
plate and joystick together are mounted to the pedestal.

1. Disconnect harness connectors from joystick.

2. Remove four bolts holding joystick mounting plate to pedestal.
3. Remove four screws holding joystick to mounting plate.
To install new joystick, reverse above steps.

Thrust/Pullback

6-29
This page intentionally left blank.
D20x22 Navigator HDD Service Overview

Chapter 7: Drill Rotation

OVERVIEW
The Drill Rotation consists of the functions/components necessary to rotate
the drill string while drilliing out or backreaming.

Functions/Components
Functions • High-Speed Rotation
• Low-Speed Rotation
• Rotation loop cooling circuit

Components The function covered in this section includes the following components:

• Hydraulic Fluid Distribution Components

Drill Rotation
• Rotation Motor MH1
• Drill Transport Valve Assembly A7
• Pilot Valve Assembly A8
• Torque Limiter Valve Assembly A9
• Pump PMP1
• Pressure Transducer B4

7-1
 Overview D20x22 Navigator HDD Service

Component Locations A9

Charge
Filter

PMP1

FL2 B4
Charge Filter
Pressure Transducer
Drill Rotation

GA3
Rotation
Pressure Gauge

MH1 Rotation Motor

7-2
D20x22 Navigator HDD Service Overview

Hose Connections

Rotation
Transducer B4
Charge Pump
Filter FL3 Pump
PMP1

Pilot Valve
Assembly A8

Oil Tank
RES1

Drill Rotation
Torque Limiter
Rotation Valve Assembly A9
Motor MH1

Oil Cooler
HE1

7-3
 Overview D20x22 Navigator HDD Service

Schematic

HE1

COOLER HE1
DRILL/
ROTATION MOTOR TRACK
MH1 VALVE
DV8, SOL.
L14
TO RIGHT TRACK
TO RIGHT MOTOR A PORT
TRACK MOTOR
B PORT

TORQUE
LIMITER
VALVE
DV29
RIGHT
JOYSTICK
Drill Rotation

FUSE F3
LEFT
JOYSTICK

PUMP PMP1 PUMP

PMP2

ROTATION
PUMP EDC

PRESSURE
TRANSDUCER B4

7-4
D20x22 Navigator HDD Service Overview

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 below).

Often problems can be solved by 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 "Machine
Performance," page 7-6.

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

Drill Rotation
Inspect the mechanical connectors from controller and control valve 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 wires 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. They will often smell like burned insulation.

Continued on next page...

7-5
 Overview D20x22 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 such as:

• Broken, kinked, loose, or leaking hoses and fittings

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

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 problem has been corrected.

Machine Performance
The preferred way to troubleshoot problems that occur in this function is to
operate all the machine functions and document the performance of working
actuators.

Make note of any functions not operating normally based on the theory
given in each chapter for that function. Comparing the results with the
normal operation given for each mode of a particular function will help to
isolate the problem.

After checking machine performance, if the problem can be 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.

Continued on next page...

7-6
D20x22 Navigator HDD Service Overview

Possible Results 1. If problems 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 functions and components should be
investigated:
• See "Engine," page 3-8.
• Shared hydraulic components. See hydraulic fluid distribution chapter.
2. If faults are noted in the Drill Rotation and Ground Drive functions, the
following should be investigated:
• See "PMP1 & PMP2 Hydrostatic Loop," page 4-11.
• See "Drill/Transport Valve Assembly A7," page 7-9.
• See "Pilot Valve Assembly A8," page 6-13.
3. If faults are noted in only the rotation function, and all other functions
are OK, investigate the following:
• See "Thrust/Pullback Valve Assembly A6," page 6-17.
• See "Rotation Motor MH1," page 7-15.

Drill Rotation
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 tests on hydraulic components will be listed in
the manual.

7-7
 Overview D20x22 Navigator HDD Service

Specifications
Listed below are the electrical and hydraulic specifications for the Drill
Rotation function.

Electrical: • Joystick control voltages

Input - Red wire - 5.5 volts DC
Ground - Black wire
Output - Yellow wire - Maximum fully forward - 4.5 volts DC, fully back -
0.5 volts DC, centered - 2.5 volts DC
• Nominal circuit voltage - 12 volts DC.
• Torque limiter valve solenoid coil L7 - 4.5 ohms @ 68°F (20°C).

• Pressure transducer B4 - 500 psi = 1.2–1.46V, 1000 psi = 1.75–1.85V,

1500 psi = 2.1–2.2V, 2000 psi = 2.45–2.55V, 2500 psi = 2.9–3.5V

Hydraulic: • Pump PMP1 normal output flow - variable to 31 gpm (117 L/min) @ 2600
rpm.
• Pump PMP1 charge pressure relief setting - 313 psi (21.6 bar).
• Pump PMP1 multifunction valves PV2 and PV3 high pressure
Drill Rotation

settings - 3335 psi (230 bar).

• Torque limiter valve assembly A9 relief valve PV1 pressure
setting - 2000 psi (138 bar).
• Vise switch S10 pressure setting - 1850 psi (128 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 4-19, and follow instructions.

Hydrostatic Loop - PMP1 & PMP2

Refer to "PMP1 & PMP2 Hydrostatic Loop," page 4-11.

7-8
D20x22 Navigator HDD Service Overview

Drill/Transport Valve Assembly A7

Operation - Drilling Flow from either port of pump PMP1 goes to manifold A7 and passes the
Mode valves DV2 or DV3. These are pilot-operated valves that direct flow to either
the right track motor MH or the rotation motor MH1.

When the seat is unoccupied, solenoid L14 prevents pilot signal from
shifting the valves from Transport mode to Drill mode. When the seat is
occupied, solenoid L14 receives a signal from engine bay controller A1 and
pilot pressure from A8 shifts DV2 and DV3 allowing oil to flow to rotation
motor if all interlocks are satisfied.

To Port A on To Port B on
Rotation Motor MH1 Rotation Motor MH1

to Oil Cooler HE1

A7

Drill Rotation
DV1

DV4 DV5

DV2 DV3

From PMP1 D port From PMP1 C port

PMP2 Charge Pressure From Pilot Valve

Assembly A8

7-9
 Overview D20x22 Navigator HDD Service

Troubleshooting/ If faults are noted in Rotation, Thrust/Pullback or Ground Drive functions:

Testing
NOTE: Ensure there are no obvious controller faults on both the engine
controller A1 as well as the console controller A2.

1. If all three functions are operating abnormally, pump PMP1 and PMP2
should be tested first. Refer to "Oil Supply," page 4-10 for troubleshooting
information on tandem pumps PMP1 & PMP2. If fault can be isolated to
only the ground drive circuit, continue.
2. If rotation and thrust/pullback function are both inoperable when the
seat is occupied, seat switch S11 could be defective. Replace switch if
necessary. Refer to "Seat Switch S11," page 5-29. If switch is OK, proceed.
3. If rotation, thrust/Pullback, or both functions are operating abnormally,
the problem could be linked to pilot pressure supplied by the pilot valve
assembly A8, or charge pressure supplied to valve assembly A7 from
charge pump PMP2. If A8 is not allowing oil to flow to A7, thrust/
pullback and rotation functions will be inoperable. Refer to "Pilot Valve
Assembly A8," page 5-16 for troubleshooting information. If A8 tests OK,
continue to step 4.
NOTE: If coils which control pilot valve assembly A8 do not energize when
an operator is present in the seat, oil is not reaching the rotation motor MH1
Drill Rotation

or thrust/pullback motors MH2, MH3, and MH4. Instead, oil is most likely
flowing to track drive motors.

4. Examine valves DV2–DV5 to determine if valves are stuck. Replace if

necessary. Refer to "Drill Transport Valve Assembly A7," page 5-33 for
repair information.

7-10
D20x22 Navigator HDD Service Overview

Pilot Valve Assembly A8

Operation - High Pilot control valve assembly A8 controls whether the machine is in
Speed Rotation Transport or Drill mode. It is also responsible for shifting the speed of the
rotation motor based on operator inputs. The presence of an operator in the
drill control seat determines the direction of flow coming out of the drill/
transport valve assembly A7.

When seat switch S11 is closed, and a drill control joystick is move out of
neutral, coil L14 of DV8 is energized. DV8 allows oil to pass through DV2
and DV3 to reach the rotation motor MH1. DV8 allows oil to pass through
DV4 and DV5 in order to reach thrust/pullback motors MH2, MH3, and
MH4.

When coil L19 of DV10 is energized, rotation motor MH1 is shifted from Low
speed mode to HIGH speed mode. Schematic below shows pilot valve
assembly in drill mode with rotation motor shift valve DV10 shifted for High
mode.

To Rotation
To Valve Assembly A7 Motor MH1

Drill Rotation
From Charge
Pump

L14 L20 L19

DV8 DV9 DV10

+12v from Pin D5

of Controller A1

+12v from Pin A5

of Controller A1

7-11
 Overview D20x22 Navigator HDD Service

Troubleshooting/ If there are faults with both thrust/pullback and rotation functions and/or
Testing machine appears not to be switching from Drill to Transport mode, refer to
"Troubleshooting," page 6-14.

If faults are noticed when shifting rotation gearbox from High speed mode to
Low speed mode:

1. Check controllers.
• If console controller A2 shows “Rot. Speed LED” glowing, rotation
speed switch S12 is in HIGH position, or switch and/or wiring is faulty.
• If engine bay controller A1 shows “Rot. Speed LED” glowing, controller
is sending an output to shift rotation motor to High mode.
• Check fault code window of engine bay controller A1. If an “I” is shown,
wiring to rotation speed solenoid L19 is apparently shorted to a source
of power.
If faults are noticed when shifting rotation gearbox from Low speed mode to
HIGH speed mode:

1. Verify front vise is not clamped. The rotation speed will not shift to high
if the console controller is recieving input from front vise clamp switch.
Drill Rotation

2. Check controllers.
• If console controller A2 shows “Rot. Speed LED” dark, rotation speed
switch S12 is in LOW position, or switch and/or wiring is faulty.
• If engine bay controller A1 shows “Rot. Speed LED” dark, controller is
not sending an output to shift rotation motor to HIGH.
• Check fault code window of engine bay controller A1. If an “I” is shown,
wiring to rotation speed solenoid L19 is apparently shorted to a ground
or wiring to solenoid is faulty. If so, continue.
3. Verify that transport brakes will release and machine will shift from
transport to drill.

If so, continue to next step. If not, check charge pressure. "Charge

Pressure Measurement," page 4-14.
4. Locate L19 and DV10 which is in the center of pilot valve assembly A8.
Disconnect solenoid at J/P 214, and measure voltage to solenoid.

Expected result: 12 volts DC, ±1.2 v DC. If so, continue below. If not,
conduct continuity tests of blue wire #739 between solenoid at P214-1
and controller at P201-5 and black wire #300 between solenoid at P214-2
and ground at P201-12. Repair or replace faulty wire.
5. Remove retaining nut holding solenoid to center valve and slide solenoid
off. Disconnect plug and jack J/P213 for brake release solenoid. Remove
its retaining nut and slide it onto center valve. Install retaining nut and
connect to harness plug P214.
Continued on next page...

7-12
D20x22 Navigator HDD Service Overview

6. Restart machine and see if rotation motor will now shift into HIGH.

If so, solenoid was faulty. Replace solenoid. If not, continue.

7. Shut down machine, Refer to "Pilot Valve Assembly A8," page 5-32, for
instructions on replacing solenoid valves.
NOTE: All three valves must be installed before restarting engine.

8. Restart and see if rotation motor MH1 will shift to High.

If so, valve was faulty, replace it. If not, continue.

9. It is possible that drain line (1) for the 2-speed spool within the motor is
clogged, resulting in spool being hydraulically locked in Low.

Shut down. Remove hose, inspect and reinstall.

10. Restart and see if rotation motor will shift to High. If not, replace motor.

Torque Limiter Valve Assembly A9

Drill Rotation
Operation The machine is equipped with a
torque-limiter valve assembly
A9 which protects the drill rod
from overtightening when
L7
adding rod to the drill string. A9
consists of two valves; SV1 and SV1
PV1.

PV1 has a pressure rating of

2000 psi. By restricting the
pressure to 2000 psi to the PV1
rotation motor when operating
in clockwise direction,
overtorquing of the drill rod is
avoided.

SV1 is a solenoid operated valve,

controlled by coil L7. When the
operator rotates drill rod in
counterclockwise direction, coil
L7 is energized by controller A1
which allows oil to flow through
the valve freely.
A9

7-13
 Overview D20x22 Navigator HDD Service

Troubleshooting/ If it appears the machine is overtorquing rod joints:

Testing
1. Clamp front vise onto drill rod and watch rotation pressure gauge while
attempting to rotate rod.

Expected result: Pressure rises no higher than 2000 psi (138 bar). If so,
the torque limiter valve appears to be working normally. If pressure rises
above 2000 psi (138 bar), continue.
2. Test for acceptable voltage at solenoid coil L7 of SV1. If voltage is
acceptable, continue with step 2. If not, continue with step 3.

Expected result: 12 v DC, ±1.2 v.

3. Test resistance of coil L7. If OK, continue.

Expected result: 7-9 ohms at 68°F (20°C).

4. Remove and inspect coil L7 and SV1, as well as PV1. Refer to "Torque
Limiter Valve Assembly A9," page 7-25 for repair information.
Drill Rotation

7-14
D20x22 Navigator HDD Service Overview

Rotation Motor MH1

Speed Shift Circuit The rotation motor MH1 is a
to oil cooler and tank
2-speed, bi-directional motor
with an integral case flushing
B5
circuit. In Low speed, its
displacement is 30.7 in3 (503
cc). In High, the displacement
decreases by 1/3 to 20.5 in3
high pressure (336 cc).

side of loop
low pressure
side of loop
It is shifted from High to Low
speed by a pilot signal. The
pressure pilot signal comes from valve
reducing DV10 on pilot control valve
valve
assembly A8. When solenoid
L19 is energized by controller
to A7, to shift A1.
to drill mode
A8 The pilot signal shifts a valve
from
DV10 in the motor that shuts off flow
charge pump L19 from 1/3 of the pistons.

Drill Rotation
The spring side of the speed
shift valve is drained by the
from A1 case drain line to prevent it
from hydraulically locking in
the Low speed position.

Rotation Motor The motor also includes a hot oil shuttle that flushes oil through the case of
Flush Circuit the motor to the tank. This pushes heat out of the motor.

Pressure on the high pressure side of the loop shifts a shuttle valve to draw
fluid from the low pressure side of the loop. The low pressure side of the loop
is maintained at 313 psi (21.5 bar) by the charge pressure relief valve.

This oil flows across a pressure reducing valve built into the motor, which
keeps the pressure in the case within limits the shaft seals can withstand.
The oil flows into the bottom of the motor case, forcing hot oil in the case up
and out through a drain line attached to the top of the case. This hot oil
flows through the oil cooler and back to the tank. The charge pump replaces
the hot oil removed, with cool oil from the tank.

7-15
 Drill Rotation Function D20x22 Navigator HDD Service

DRILL ROTATION FUNCTION

Drilling/Backreaming High Mode

Low-Pressure Side of Loop

High-Pressure Side of Loop
Charge Pressure
Drill Rotation

Required Operating Drilling/backreaming in High mode:

Conditions
• Seat occupied (seat switch S11 activated)
• Remote Lockout system must be in normal RUN mode.
• Engine must be running at full throttle and rotation handle pulled
back.
• Switch S12 Rotation High/Low switch must be activated.

7-16
D20x22 Navigator HDD Service Drill Rotation Function

Operation Pump PMP1 provides flow through a closed-loop system which powers both
the right track motor as well as the rotation motor. In order for flow to reach
the rotation motor, a series of requirements must be met.

Operator must be present in the seat. Seat switch S11 closes and sends a
signal to the console controller A2. The console controller A2 relays the
signal to the engine controller A1 through the CAN (controller-area
network) which allows solenoids L14 of DV8 and L20 of DV9 within the pilot
valve assembly A8 to be activated.

When these two solenoids are activated, two things happen simultaneously.
Pilot pressure from DV8 shifts two valves within the drill/transport valve
assembly A7, allowing oil to reach the rotation motor MH1 as well as the
thrust pullback motors MH2, MH3, and MH4. Also, pilot pressure from A8
activates the track parking breaks.

When switch S12 is closed by the operator, pilot pressure from A8 also shifts
the rotation motor MH1 into High speed mode.

As an operator pulls the rotation joystick BACK, pump PMP1 EDC sends a
proportionate amount of oil to the rotation motor MH1. The farther the
handle is pulled BACK, the faster rotation speed.

Drill Rotation

7-17
 Drill Rotation Function D20x22 Navigator HDD Service

Troubleshooting/ 1. In order to ensure fault is isolated to just the thrust/pullback function,

Testing operate all machine functions and observe actuators as discussed in
"Machine Performance," page 7-6.
2. If any functions other than drill rotation are faulty, continue
troubleshooting based on possible results given. If all other machine
functions are operating normally, continue.
3. Listed below are common symptoms associated with closed-loop system
faults. Refer to appropriate troubleshooting for symptoms experienced:
NEUTRAL position is difficult or impossible to find:

1. Inspect connections discussed in "Pretest Inspection," page 7-5. If OK,

continue.
2. Inspect control valve components. If OK, continue.
Rotation Function is operating too hot:

1. Ensure oil level is adequate. If OK, continue.

2. Check charge pressure. Start engine and set throttle at full.
3. Ensure rotation drive control level is in NEUTRAL.
Drill Rotation

4. Ensure hydraulic oil is warmed to at least 100°F (38°C).

Continued on next page...

7-18
D20x22 Navigator HDD Service Drill Rotation Function

5. Observe gauge in NEUTRAL then stroke pump in FORWARD then

REVERSE.

Expected result: Pressure gauge should read 250–300 psi (17–21 bar) in
NEUTRAL. Pressure should initially drop when stroked in FORWARD
or REVERSE, then recover to slightly lower than NEUTRAL reading. If
pressure is not within specification in any of the positions, continue. If
OK, check system pressure. Refer to step 9.
6. Replace charge filter FL3. Refer to the machine Maintenance Manual for
information on replacing filter.
7. Check pressures. If still not OK, inspect charge pressure relief valve for
damage or contamination. If charge relief is OK, most likely pump PMP2
is worn internally beyond design specification. Replace pump PMP2 and
rotation motor MH1.
NOTE: Pump wear is caused by contamination and degradation of oil. Since
pump and motor in a closed loop circuit continuously recycle the same oil,
pump and motor wear at same rate. If leakage in a pump or motor
approaches or exceeds design specification, it is highly recommended that
motor and pump be replaced.

8. Check maximum rotation system pressure.

Drill Rotation
9. Remove hoses from rotation drive motor MH1. Plug hoses and cap
fittings.
10. Start engine and set throttle to full.
11. Ensure hydraulic oil is warmed to 100°F (38°C).
12. Deadhead system by pulling rotation drive lever BACK. Observe gauge
and note pressure reading.

Expected result: Pressure gauge should read 3250 psi (224 bar). If OK,
continue.
13. Remove caps and plugs; install hoses back on rotation drive motor MH1.
14. Test case drain flow of motor MH1.
15. If case drain flow exceeds maximum amount, replace pump PMP2 and
motor MH1.
Continued on next page...

7-19
 Drill Rotation Function D20x22 Navigator HDD Service

Rotation function operates in one direction only:

1. Inspect electrical connections discussed in "Pretest Inspection," page 7-5.

If OK, continue.
2. Inspect control valve components. If OK, continue.
3. Inspect EDC module. The engine bay controller A1 has LEDs for Rot.
EDC+ and Rot. EDC-. If these glow in response to joystick movement the
controller is sending voltage to the EDC. (These are the same LEDs used
for right track.)
4. Inspect system relief valve for damage or contamination. If OK,
continue.
5. Replace pump. Refer to "PMP1/PMP2 Tandem Pump Replacement," page
4-30.
Rotation function does not operate in either direction:

1. Ensure oil level is adequate. If OK, continue.

2. Inspect control valve components. If OK, continue.
3. Refer to troubleshooting section of "Pilot Valve Assembly A8," page 7-11.
Drill Rotation

Rotation function response is slow or sluggish:

1. Shut down machine, unplug EDCs and reverse connectors so that plug to
PMP1 EDC now goes to PMP2 EDC and vice versa.
2. Start machine and use other joystick to rotate the drive chuck. Put pump
and motors under load by thrusting or pulling on the drill string. Use
thrust joystick to operate rotation. Reconnect EDCs properly after
completing test. If rotation is still slow, the problem is hydraulic.
Continue with step 8. If the rotation speed is corrected, the problem is in
the joystick. Continue to next step.
3. Disconnect 4-pin connector at base of joystick and attach 4-pin
connectors of the breakout box to joystick plug and harness jack. Turn
key switch on and sit in seat.
4. Measure voltage from 2 to 3 on breakout box while moving joystick
slowly forward and slowly backward.

Expected result: 2.5 volts DC when joystick is centered, 0.5 volts DC

when fully back, and 4.5 volts DC when fully forward. If so, joystick is
operating properly. If not, replace joystick control.
Continued on next page...

7-20
D20x22 Navigator HDD Service Drill Rotation Function

5. Measure voltage with black probe grounded to chassis and red probe at 1
on breakout box.

Expected result: 12 volts DC. If so, test continuity of wires for 2 and 3 on
breakout box to jack and plug connected to controller. If continuity is
good, replace joystick. If not, replace faulty wire or harness segment.
6. If rotation is still slow, problem is hydraulic. Since pump PMP1 and
motor MH1 cycle the same fluid back and forth, the pump and motor are
probably worn about the same amount.

If the problem appears to be in the pump, check for:

• Open bypass valve - verify it is turned in. Refer to "Bypass Valve

Adjustment," page 4-23.
• Insufficient charge pressure - check in NEUTRAL, FORWARD, and
REVERSE. Refer to "PMP1/PMP2 Charge Checks and High Pressure
Relief Valves," page 4-28.
• IF low in NEUTRAL and FORWARD/REVERSE, replace charge
pressure relief valve in pump. Refer to "Adjusting Charge Pressure

Drill Rotation
Relief Valve PV4," page 4-29. If charge pressure remains low, replace
the charge pump. Refer to "Charge Pump Replacement," page 4-23.
• Internal leakage in pump and motor - perform case pressure test on
pump. Refer to "Measuring Case Drain Flow," page 5-20.
7. If rotation speed is now correct, problem is either joystick or EDC. Test
joystick by referring to "Troubleshooting/Testing," page 6-21 for
instructions on testing joystick.
8. If joystick needs replaced, refer to "Drill Joysticks A19 & A20," page 6-29.
If joysticks are OK, refer to "EDCs for PMP1 and PMP2," page 4-39.

7-21
 Drill Rotation Function D20x22 Navigator HDD Service

Drilling/Backreaming Low Mode

Low-Pressure Side of Loop

High-Pressure Side of Loop
Charge Pressure
Drill Rotation

Required Operating Drilling/backreaming in Low mode:

Conditions
• Operator seat must be occupied (seat switch S11 activated)
• Remote Lockout system must be in normal RUN mode.
• Engine must be running at full throttle and rotation handle pulled
back.
• Switch S12 Rotation High/Low switch must be in Low.

7-22
D20x22 Navigator HDD Service Drill Rotation Function

Operation Pump PMP1 provides flow through a closed-loop system which powers both
the right track motor as well as the rotation motor. In order for flow to reach
the rotation motor, a series of requirements must be met.

First, an operator must be present in the seat. When the operator is seated,
seat switch S11 closes and sends a signal to the console controller A2. The
console controller A2 relays the signal to the engine controller A1 through
the CAN (controller-area network) which allows solenoids L14 of DV8 and
L20 of DV9 within the pilot valve assembly A8 to be activated.

When these two solenoids are activated, two things happen simultaneously.
Pilot pressure from DV8 shifts two valves within the drill/transport valve
assembly A7, allowing oil to reach the rotation motor MH1 as well as the
thrust pullback motors MH2, MH3, and MH4. Also, pilot pressure from A8
activates the track brakes.

When switch S12 is left open in low-speed mode, the rotation motor MH1
only receives 1/3 the amount of oil that it would if in HIGH speed mode.

As an operator pulls the rotation joystick back, pump PMP1 EDC sends a
proportionate amount of oil to the rotation motor MH1. The further the
handle is pulled back, the more rotation speed increases.

Drill Rotation
Troubleshooting/ Refer to "Troubleshooting/Testing," page 7-18.
Testing

7-23
 Rotation Loop Cooling Circuit D20x22 Navigator HDD Service

ROTATION LOOP COOLING CIRCUIT

When in Drill from MH1
mode, hot oil is case drain to MH1
from MH1
taken from the
loop by the
rotation motor
flush circuit and
by the auxiliary to cooler
cooling circuit. and tank

The rotation
motor MH1 has
a built-in loop
flushing circuit.
from PMP21 to PMP1
About 10% of the high pressure side low pressure side
from charge pump
flow through the
motor is drawn
off the low
pressure side of the motor and ported to the case of the motor. A case drain
in the top of the motor case leads away to the oil cooler HE1 and on to the
tank.
Drill Rotation

The auxiliary cooling circuit is provided by valve DV1 in manifold A7. It is

shifted by pressure in the high side of the loop to draw off oil from the low
pressure side of the loop.

The oil drains to the cooler and tank through a line that connects to the case
drain line coming from the rotation motor MH1.

The hot oil removed is replaced by cool oil added by the charge pump to
bring the low pressure side of the loop back up to 313 psi (21.5 bar)

COMPONENT REPAIR
PUMP PMP1
Refer to "PMP1/PMP2 Tandem Pump Replacement," page 4-30.

Pilot Control Valve Assembly A8

Refer to "Pilot Valve Assembly A8," page 5-32.

7-24
D20x22 Navigator HDD Service Component Repair

Drill Transport Valve Assembly A7

Refer to "Drill Transport Valve Assembly A7," page 5-33.

Torque Limiter Valve Assembly A9

L7

DV29

Drill Rotation
PV1

Manifold Removal 1. Mark all hoses to aid

in hookup once repair
is complete.
2
2. Disconnect solenoid.
Remove all hoses
from fittings on
manifold. Cap hoses.
3. Remove nuts (1),
bolts (2), and
washers (3) which
secures valve
manifold to bracket
inside engine bay.
4. Reverse removal
procedure to attach
3
manifold after repair.
1 3

Continued on next page...

7-25
 Component Repair D20x22 Navigator HDD Service

Shuttle Valve SV1 1. Remove nut (1) which secures coil to valve
and remove coil. 1

2. Remove valve from manifold and check for

visual damage.
3. Replace O-rings (2) and backup washer (3)
if necessary.
4. Screw valve back into manifold and torque
to 35 ft-lb (26.2 Nm).
5. Place coil on valve and secure with nut (1)
torqued to 5 ft-lb (6.8 Nm).

3
Drill Rotation

Relief Valve PV1 1. Remove valve from manifold and check for
visual damage.
2. Replace O-rings (1) and backup washer (2)
if necessary.
3. Screw valve back into manifold and torque
to 25 ft-lb (33.9 Nm).

7-26
D20x22 Navigator HDD Service Component Repair

Rotation Motor MH1

3 9 7

Drill Rotation
Removal 1. Mark all hoses to aid in hookup once repair is complete.
2. Remove 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.
Breakdown 5. Remove bolt (5) which secures gear (6) to motor shaft. Replace washers
(7) and spacer (8), and gasket (9) if necessary.

7-27
 Component Repair D20x22 Navigator HDD Service

Rotation Gearbox
5 7
8
6

17
22
21

16 20
15
14 19
13 18
12
11
9 4

1
2 3
10
Drill Rotation

Removal 1. Remove bolts (1) and washers (2) which secure gearbox to carriage (3).
2. Using a hoist, lift gearbox from machine and onto workbench.
3. Remove plugs (4) and drain oil into suitable container.
4. Remove drive chuck from shaft.
5. Remove motor from gearbox. Refer to "Rotation Motor MH1," page 7-27.
6. Remove bolts (5) and washers (6) which secure gearbox top cover (7) to
gearbox. Replace seal (8) if necessary.
7. Remove lock nuts (9) and lock washer (10) from shaft.
8. Remove and examine O-ring (11), seal sleeve (12), seal (13), cone
bearing (14), cup (15), gear spacer tube (16). Check items for damage
and replace if necessary.
9. Slide rotation shaft (17) from gearbox and lift gear (18) out of gearbox.
Examine gear for damage and replace if necessary.
10. Remove snap ring (19), cup (20), cone bearing (21), and seal (22) from
shaft. Examine and replace if necessary.
11. Reverse instructions to install gearbox.

7-28
D20x22 Navigator HDD Service Component Repair

Drill Rotation

7-29
 Component Repair D20x22 Navigator HDD Service
Drill Rotation

7-30
D20x22 Navigator HDD Service Component Repair

Drill Rotation

7-31
This page intentionally left blank.
D20x22 Navigator HDD Service Overview

Chapter 8: Stakedown

OVERVIEW
This chapter consists of the functions and components necessary for the left
and right stakedown functions.

There are two stakes which help anchor machine to ground so that pulling
and pushing on drill rod does not shift the machine forward or backward.
The right and left stakedown circuits are identical.

The stakes are augers which are screwed into the ground by motors MH7
(left stake) and MH8 (right stake). Cylinders CY1 (left stake) and CY2 (right
stake) assist by pushing auger in as motor rotates it. Both cylinders have
counterbalance valves that require pressure in opposite line to open flow
path from cylinder to tank.

Directional control valve DV11 controls left stakedown cylinder CY1. DV12
controls left stakedown motor MH7. DV13 controls right stakedown motor
MH8 and DV14 controls right stakedown cylinder CY2. These valves are
mounted together in the stakedown valve assembly A10. All are manually
operated.

Stakedown
To remove stakes from ground, levers are pulled in opposite direction.
Motors MH7 and MH8 rotate in opposite direction and cylinder retracts.

Functions/Components
Functions The following functions are included in this chapter:

• Right Stakedown
• Left Stakedown

8-1
 Overview D20x22 Navigator HDD Service

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

• Implement Pump PMP3

• Stakedown Valve A10 including:
• Control Valve DV11
• Control Valve DV12
• Control Valve DV13
• Control Valve DV14
• Stakedown Motors MH7 and MH8
• Stakedown Cylinders CY1 and CY2
• Counterbalance Valves CV26 and CV27

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

Electrical:

• Nominal circuit voltage - 12 volts DC.

• Drill/transport valve solenoid coils L4 and L5 - 4.3 ohms @ 68°F (20°C).

Hydraulic:

• Pump PMP3 normal output flow - variable to 20 gpm (76 L/min).

• Pump PMP3 low pressure compensator setting - 250 psi (bar).
• Pump PMP3 high pressure compensator setting - 3200 psi (217 bar).
• Control valve assembly A11 relief valve PV11 pressure setting - 3500 psi
(241 bar).

8-2
D20x22 Navigator HDD Service Overview

Component Locations

Implement
Pump
PMP3

Stakedown
Right Stakedown
Motor
Left
MH8 Stakedown
Cylinder
CY1

Right Stakedown
Cylinder
CY2

MH7
Left Stakedown
Motor

Left Stakedown Cylinder DV11

Left Stakedown Motor DV12

Right Stakedown Cylinder DV13

Right Stakedown Motor DV14

A10
Stakedown Control
Valve Assembly

8-3
 Overview D20x22 Navigator HDD Service

Hose Connections

Oil Tank
RES 1

Vise Valve
Assembly A13

Rod Loader Valve

Assembly A14

Implement
Pump PMP3
Stakedown

Counterbalance
Valve CV26

Left Stakedown
Motor MH7

Left Stakedown
Cylinder CY1

Counterbalance
Valve CV27
Stakedown Valve Right Stakedown
Assembly A10 Motor MH8

Right Stakedown
Cylinder CY2

8-4
D20x22 Navigator HDD Service Overview

Troubleshooting
Troubleshooting procedures are given in this chapter for each functions
operating modes. Each procedure begins by performing a pretest inspection
of the machine (see below).

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 "Machine Performance," page 8-7.

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.

Stakedown
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

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 wires 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.

8-5
 Overview D20x22 Navigator HDD Service

Hydraulic

Check hydraulic components for any obvious problems 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 can cause
erratic behaviors 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

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

8-6
D20x22 Navigator HDD Service Overview

Machine Performance
If there are malfunctioning components in other functions, they may have an
effect on Stabilizer and Stakedown function operation.

Therefore, the preferred way to troubleshoot any problems that occur in

these functions is to operate all machine functions and document the
performance of the working actuators.

Make note of any functions not operating normally based on the normal
operation given in each chapter for that function. Comparing the results
with the normal operation given for each mode of a particular function will
help to isolate the problem.

Check machine performance, and 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 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:

Stakedown
• Shared hydraulic components. See hydraulic fluid distribution chapter.
2. If problems are noted in the stakedown, water pump, and stabilizer
functions as well as the rack angle 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:
• Pump PMP3 refer to "Pump PMP3," page 8-10
• Tracking Cooler Valve Assembly A18
• Drill/Transport Valve Assembly A7 (see page 5-7)

8-7
 Overview D20x22 Navigator HDD Service

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.

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

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 4-19 and follow instructions.

8-8
D20x22 Navigator HDD Service Stakedown Hydraulic Circuit

STAKEDOWN HYDRAULIC CIRCUIT

CY1
CV26 MH7 CY2
MH8

CV26
CV27

A10

DV11 DV12 DV13 DV14

Stakedown
SV2

L21

PV8

PV9

HE1

PMP3

FL2 FL1

RES1

8-9
 Stakedown Hydraulic Circuit D20x22 Navigator HDD Service

Pump PMP3
Pump PMP3 is pressure-flow compensated (PFC), meaning that the
pressure from the valves in the load sense lines control the flow coming from
the pump. The load sense lines run to the pump from the pressure side of the
directional control valves operating the actuators. These pumps are
sometimes called load sense pumps.

Pump PMP3 is a variable displacement piston pump and the flow is

controlled by the pumps swash plate angle. This swash plate angle is
controlled by a control piston. Oil is ported to both sides of this piston, so the
piston moves up or down its cylinder according to the differing pressures on
either side of the piston. The compensator controls the pressure to the two
sides of the control piston.

High Pressure Mode When a hydraulic function is actuated either during stakedown, stabilizer,
vises, or drilling fluid functions:

• Pump PMP3 supplies pressure to stakedown valve assembly A10, rack

angle/stabilizer valve assembly A11, vise valve assembly A13, rod loader
Stakedown

valve A14 and water pump valve assembly A12.

• The pump compensator senses the demand for flow and adjusts the
pump displacement to increase the flow required at the pressure
required to operate the function, plus the 250 psi (17.3 bar) required to
operate the load sense spool in the pump. Load sense pressure to operate
the compensator is received from stakedown valve assembly A10, rack
angle/stabilizer valve assembly A11, water pump valve assembly A12,
and vise valve assembly A13.
• PMP3 will strive to maintain the flow required, under all working
conditions of the system.
• PMP3 will respond to the highest pressure of all the functions up to the
compensator limit of 3200 psi (220 bar) and provide flow required to
operate multiple functions.
If the load in the system produces hydraulic pressure that is equal to the
setting of the high pressure compensator, 3200 psi (220 bar), the pump will
go into high pressure standby mode until the load is overcome or the control
valves are returned to NEUTRAL.

Troubleshooting/ NOTE: If problems are noticed in the stabilizer/stakedown, vise, water, and
Testing rod loading functions, and all other functions are normal, pump PMP3
operation should be investigated first.

8-10
D20x22 Navigator HDD Service Stakedown Hydraulic Circuit

Compensator
The compensator is designed to limit pump output to 250 psi (low pressure
compensator setting) when flow is not needed, and to prevent the pump from
driving the pressure in the circuit above 3200 psi (high pressure
compensator setting.

Two spring-loaded spools in the compensator react to pressure at the pump

outlet, and one of the two also reacts to pressure in the circuit beyond the
directional control valve for the circuit.

These two spools are the high pressure compensator spool and the standby
pressure spool.

Pressure The high pressure compensator spool limits pressure in the circuit by
Compensator Spool varying the output of the pump. On this machine, pressure in the circuit is
limited to 3200 psi (220 bar). Once that pressure is reached, the pressure
compensator spool will cause the pump to produce only enough flow to
maintain that pressure.

This value is referred to as the high pressure standby value.

Stakedown

8-11
 Stakedown Hydraulic Circuit D20x22 Navigator HDD Service

Load Sense The load sense system matches pump

1
output to circuit demand. It does this
with pressure supplied by the load sense
lines from the function control valves.
When the directional control valves for
the functions are closed, load sense
pressure is drained to the tank. The
2
spring (1) moves the low pressure
compensator spool to cause the pump to
generate enough flow to maintain 250
psi (17 bar) at the pump outlet port B.

When a directional control valve is opened, the load sense line receives
pressure created by the load on the actuator side of the directional control
valve. This pressure, and the spring on the spool causes the pump to
generate enough flow to maintain a 250 psi (17 bar) pressure differential
across the directional control valve. This means the pump produces enough
flow to handle the load, plus 250 psi (17 bar).

If the load moves, the pressure required to keep it moving is maintained. If

the load resists movement, pressure is increased until it moves, or the pump
outlet pressure reaches the high pressure standby setting of 3200 psi (220
Stakedown

bar).

If resistance to movement decreases, pressure will decrease to 250 psi (17

bar) plus the pressure required to keep it moving.

When the actuator stalls, pressure will climb to 3200 psi (220 bar) as
controlled by spring (2).

If the directional control valve is closed again, the load sense lines will again
drain to tank (pressure becomes zero psi) and the pump will return to
producing standby pressure of 250 psi (17 bar).

8-12
D20x22 Navigator HDD Service Stakedown Hydraulic Circuit

Troubleshooting/ The circuits are designed to operate with compensator settings of 3200 psi
Testing (220 bar) on the compensator spool and 250 psi (17 bar) on the load sensing
spool.

To verify setting of compensator:

1. Start machine and run engine at 2400 rpm.

2. Watch water pump pressure gauge as an assistant raises or lowers rack.
Have assistant hold valve handle in raise or lower position after rack
cylinder stalls.

Expected result: When cylinder is fully extended or retracted (stalled),

gauge will indicate 3200 psi, ±50 psi (220 bar, ± 3.5 bar). This is
compensator spool setting. If it needs adjusted, refer to "PFC Pump PMP3
High and Low Pressure Compensator Adjustment," page 4-24.
3. Watch gauge as assistant moves valve handle back to NEUTRAL.

Expected result: When valve is at NEUTRAL position, gauge will

indicate 250 psi, ± 50 psi (17 bar ± 3.5 bar). This is load sense spool
setting. If it needs adjusted refer to "PFC Pump PMP3 High and Low
Pressure Compensator Adjustment," page 4-24.

Stakedown

8-13
 Stakedown Hydraulic Circuit D20x22 Navigator HDD Service

Stakedown Valve Assembly A10

Operation The Stakedown function is controlled by stakedown valve assembly A10.
The valve assembly is comprised of four manually controlled spool sections.
Two of these spool sections control stakedown cylinders, and the remaining
two spools control stakedown motor direction.

CY1 MH8
MH7
CY2

CV26
CV27
Stakedown

A10

DV11 DV12 DV13 DV14

The individual valve sections control the following functions:

• DV11 - Left Stakedown Cylinder

• DV12 - Left Stakedown Motor
• DV13 - Right Stakedown Cylinder
• DV14 - Right Stakedown Motor

NOTE: If all functions operate abnormally, see the following

troubleshooting.
Continued on next page...

8-14
D20x22 Navigator HDD Service Stakedown Hydraulic Circuit

Troubleshooting/ If all four functions are operating abnormally and all other machine
Testing functions are OK, it would indicate a component common to just these five
functions is most likely faulty.

Inspect stakedown valve assembly A10 including CV26 and CV27 for
damage or contamination. Refer to component repair section for information
on control valve and check valve repair.

Stake Out Mode

Required Operating To operate stake CY1
CY2
Conditions Out mode:

• Engine must MH7 MH8

be running at
full throttle. CV26
CV27
• Control
handle for
DV11 and
DV12 must be

Stakedown
pushed
forward (to
raise left
stake)
• Control DV11 DV12 DV13 DV14
handle for
DV13 and
DV14 must be DV30
pushed
forward (to
raise right L21
stake).

PMP3

8-15
 Stakedown Hydraulic Circuit D20x22 Navigator HDD Service

Operation When required operating conditions are met:

• Cylinder CY1 extends and motor MH7 turns counterclockwise, pulling

left stake up.
• Cylinder CY2 extends and motor MH7 turns counterclockwise, pulling
right stake up.
NOTE: If Stake Out mode does not operate as expected, see the following
troubleshooting.
Stakedown

8-16
D20x22 Navigator HDD Service Stakedown Hydraulic Circuit

Troubleshooting/ 1. Before beginning any troubleshooting or testing procedures, perform the

Testing "Pretest Inspection," page 8-5. If nothing obvious is found, continue.
2. In order to ensure the fault is isolated to just the stake In or Out mode,
the technician should operate all the machine functions and observe the
actuators as discussed in "Machine Performance," page 8-7.
3. 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 4.
4. Determine which actuator is 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 5. If
only the motor is faulty, go to step 6. If both are operating abnormally, go
to step 7.
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 Industrial Dealerships Technician’s
Shop Manual (Vermeer P/N 105400V80) for information on how to test these
components.

5. 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

Stakedown
seal system.
The cylinder will need to be replaced if any flow is measured when
deadheading with pump PMP3 high compensator setting of 3200 psi (220
bar). If so, repair or replace cylinder. Refer to component repair
information at the end of this chapter for information.
6. Test efficiency of motor. Excessive cross-port leakage can be caused by
damage or wear to internal components.
The motor will need to be replaced if shaft speed is below 135 rpm when
tested with pump PMP3 high compensator setting of 3200 psi (220 bar).
If so, repair or replace motor. Refer to component repair information at
the end of this chapter for information.
7. If both cylinder and motor are faulty, it may indicate that a common
component to both actuators has failed. Test sequence valves CV26 and
CV27.
The sequence valve will need to be replaced if a steady stream of fluid
pours from the outlet port when tested with mini-tester. Replace if faulty.
Refer to component repair information at the end of this chapter for
information. If OK, continue.

8-17
 Stakedown Hydraulic Circuit D20x22 Navigator HDD Service

Stake In Mode
Required Operating • Engine must CY2
Conditions be running at CY1 MH7 MH8
full throttle.
• Control
handle for
DV11 and
CV26 CV27
DV12 must be
pulled back (to
lower left
stake)
• Control
handle for
DV13 and
DV14 must be
pulled back (to
lower right DV11 DV12 DV13 DV14
stake)
DV30
Stakedown

L21

PMP3

Normal Operation • Cylinder CY1 retracts and motor MH7 will turn clockwise to screw left
stake into ground.
• Cylinder CY2 retracts and motor MH8 will turn clockwise to screw right
stake into ground.
• Lock Valves CV26 and CV27 allow stakedown cylinders CY1 and CY2 to
hold hydraulic pressure.

8-18
D20x22 Navigator HDD Service Stakedown Hydraulic Circuit

Troubleshooting/ If stake In mode does not operate as expected, see "Troubleshooting/Testing,"

Testing page 8-10.

PMP3

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.

Adjusting Load 1. Connect a pressure check

1 7
Sense Spool and gauge assembly (with dual
Compensator gauges), Vermeer P/N

Stakedown
Settings 67566001 to the M2 port (6)
on top of the compensator. 2
This gauge will show system 6
pressure. 5

2. Connect a T-fitting and a

diagnostic fitting to the case
4
drain line (7). Connect a 100
psi test gauge to the
diagnostic fittings. This
3
gauge will show case
pressure.
3. Load sense line (1) leads to
the water pump flow control
valve assembly A12 on the inside wall of the engine bay. Disconnect line
at A12 and plumb in a T-fitting connected to a 600 psi gauge. This gauge
will show load sense pressure.
4. Attach magnetic thermometer to the hydraulic tank, or use a laser
pyrometer to check hydraulic fluid temperature. Fluid temperature
should be 100°F (38°C) for this adjustment. If necessary, start machine
and operate hydraulic functions to warm the fluid.
Continued on next page...

8-19
 Stakedown Hydraulic Circuit D20x22 Navigator HDD Service

5. Have wrenches ready to loosen the setscrews (2) and (3) and adjust the
adjustment screws (4) and (5).
6. Have an assistant run engine at 2400 rpm, and operate one stakedown
motor. Stakedown augers must be up out of the ground and free to rotate.
Keep stakedown auger rotating through steps 7 and 8.
7. While stakedown motor is turning, observe system pressure gauge and
the load sense pressure gauge. Subtract the load sense pressure reading
from the system pressure reading.

The expected value is 250 psi,± 50 psi. If so, continue at step 9.

Otherwise, continue below.
8. Loosen setscrew (2) and turn compensator spool adjustment screw (5).
Turn it in to raise pressure and turn it out to decrease it. When system
pressure minus load sense pressure is 250 psi, hold adjustment screw in
position and tighten setscrew. Torque setscrew to 6–8 ft-lb (7–11 Nm).

One full rotation of the adjustment screw is approximately equal to 170

psi (12 bar).
9. If the dual gauge pressure
check gauge assembly (P/N 1 7
Stakedown

6756601) is connected at the

M2 port (6), continue below.
Otherwise, shut down and 2
replace 600 psi gauge at M2 5 6
with a 5000 psi gauge.
10. Have the assistant fully 4
extend or fully retract the
rack angle cylinder to
deadhead the cylinder. The
assistant must hold control
lever in the deadhead
position during steps 11 and 3
12.

11. With the cylinder deadheaded, observe the system pressure gauge and
the case drain gauge. Subtract case pressure from the system pressure.

The expected value is 3200 psi, ± 50 psi (207 bar ± 3.5 bar). If so,
compensator is properly adjusted; continue at step 13. If not, continue
below.
Continued on next page...

8-20
D20x22 Navigator HDD Service Stakedown Hydraulic Circuit

12. Loosen setscrew (3) and turn compensator adjustment screw (4). Turn it
in to raise pressure and turn it out to decrease it. When system pressure
minus charge pressure is 3000 psi (207 bar), hold adjustment screw in
position and tighten setscrew. Torque setscrew to 6–8 ft-lb, or 7–11 Nm.

One full rotation of the adjustment screw is approximately equal to 500

psi (35 bar).
13. Shut down and remove gauges and reconnect hoses. Torque plugs and
hoses as follows:
• plug at M2 port (6) to 26 ft-lb (35 Nm)
• case drain hose to fitting in PMP3 to 38 ft-lb (51 Nm)
• load sense line to fitting in A13 to 9.5 ft-lb (12.8 Nm)

Stakedown

8-21
 Component Repair D20x22 Navigator HDD Service

COMPONENT REPAIR
Replacing PMP3
NOTE: Due to the number of hoses that must be disconnected and correctly
routed when reconnected, it is strongly recommended that all hoses are
labeled prior to disassembly. Take notes, make sketches or take photographs
prior to and during disassembly to ensure correct routing for assembly.

1. Drain hydraulic tank.

2. For better access, remove rod box.
3. Remove left engine side shield.
4. Open doors on the right side of the engine bay.
5. Remove screw holding the knob to the shaft of the flow control valve FC1
on A13 and remove knob. Also, remove the two bolts holding the mud
flow control manifold A13 to the front shield of the engine bay.
6. Support top shield of the engine bay and unbolt front shield of the engine
bay. Move it about 4″ (10 cm) forward. This may require disconnecting
wires to engine bay controller and/or the fuse panel. If so, carefully label
Stakedown

all connectors to simplify reassembly.

7. Disconnect inlet hose from the fitting on PFC pump PMP3. Also,
disconnect pressure hose from fitting in port B and disconnect load sense
line from the fitting in port LS. Plug or cap all open hose ends and ports.
8. Support PFC pump PMP3 as you loosen and remove the two bolts
holding PMP3 to PMP1. Remove PFC pump. Also, locate and remove
O-ring between PMP3 and PMP1. Plug or cap all open hose ends and
ports.
Continued on next page...

8-22
D20x22 Navigator HDD Service Component Repair

9. Transfer hose fittings from the old pump to the new pump. Torque
fittings into the new pump as follows:
• inlet port fitting to 107.5 ft-lb (145.7 Nm)
• pressure port fitting to 117.5 ft-lb (159.3 Nm)
• T-fitting (into pressure port fitting) to 31.5 ft-lb (42.7 Nm)
• reducer fitting (from tee into smaller tee) to 38 ft-lb (52 Nm)
• load sense port fitting to 38 ft-lb (52 Nm)
10. Replace O-ring removed in step 8. Coat new O-ring with clean oil or
petroleum jelly and install it.
11. Carefully support PFC pump PMP3, align splines and slide it into PMP2.
Be careful when bringing the mating surfaces together to avoid pinching
the O-ring.
12. Reconnect hoses to PMP3. Do not overtighten.
13. Install rear shield.
14. Install manifold A13 on rear shield and install the handle on the flow
control valve.
15. Install remaining shields.

Stakedown

8-23
 Component Repair D20x22 Navigator HDD Service

Stakedown Control Valve A10

Valves DV11, DV12, These valves are located in manifold A10, mounted near the front of the
DV13, and DV14 machine.

A10

3
Stakedown

1. Carefully label all hoses to aid reassembly.

2. Disconnect hoses. Cap all open hose ends and manifold ports.
3. Remove three bolts holding the manifold to the mounting plate. Move
manifold to a clean area of the workbench.
4. Remove nuts (3) from the 3 bolts (1) that hold the sections together.
Remove bolts. They will not be re-used.
5. Pry apart sections only where needed to remove the faulty valve. Remove
and discard the O-rings (2) on either side of the faulty valve section.
6. Remove hose fittings from the old valve section. Install them in the new
section. Torque fittings to the A and B ports to 28.5 ft-lb (38.6 Nm).
Continued on next page...

8-24
D20x22 Navigator HDD Service Component Repair

7. Two O-ring kits are needed, one for either side of the new valve section.
Do not lubricate O-rings before installing them on either side of the new
valve section.
8. Remove handle from the old valve section and install it on the new
section.
9. Hold new section in place and assemble sections by inserting new bolts
(1). Install and torque nuts to 32 ft-lb (43 Nm).
10. Install manifold under the mounting plate. Install bolts and torque the
nuts to 20 ft-lb (27 Nm).
11. Reconnect hoses. Torque them as follows:
• hoses to ports A and B to 28 ft-lb (38 Nm)
• hoses to In and Out ports to 38 ft-lb (52 Nm)
• hose to load sense port to 9.5 ft-lb (12.9 Nm)

Counterbalance Valves CV26 and CV27

To replace valve:

Stakedown
1. Label hoses.
2. Disconnect hoses and
disconnect fittings.
3. Install fittings in new valve
body.
• Torque straight fittings in
the top of the valve body to
19 ft-lb (26 Nm).
• Torque the elbow fittings
to 12.5 ft-lb (17 Nm).
4. Remove mounting bolt and
old valve body. Bolt new
valve onto machine. Torque
the bolt to 20 ft-lb (27 Nm).
5. Connect hoses to the fittings
on the valve body and torque to 19 ft-lb (26 Nm).

8-25
 Component Repair D20x22 Navigator HDD Service

Stakedown Motors MH7 and MH8

1. Label hoses at the motor ends. Disconnect
hoses from ports A and B.
2. Remove fittings from port A and B of old
motor and install in new motor. Torque
them to 38 ft-lb (52 Nm).
3. Remove motor from mounting plate. Install
new motor. Torque mounting bolts to 90 ft-
lb (122 Nm).
4. Connect hoses to the fitting in the ports
and torque them to 19 ft-lb (26 Nm).
Stakedown

8-26
D20x22 Navigator HDD Service Component Repair

Stakedown Cylinders CY1 and CY2

1. If needed, disconnect auger from the
motor by rolling the rubber O-rings out of
the way and removing the two stake
keeper pins.
2. Label hoses and disconnect them from the
cylinder. Cap the open hose ends.
3. Remove the two bolts (1) holding the 1
cylinder to the frame and stakedown slide
tube.
4. Lift cylinder from the frame.
5. If replacing the cylinder, remove hose
fittings from the old cylinder and install
them in the 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 the cylinder, refer to the

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

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

8-27
This page intentionally left blank.
D20x22 Navigator HDD Service Overview

Chapter 9: Stabilizer/Rack Angle

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

Functions/Components
Functions The following functions are included in this chapter:

• Stabilizer
• Rack Angle

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

Stabilizer/Rack Angle
• Implement Pump PMP3
• Rack Angle/Stabilizer Valve Assembly A11
• Stabilizer Cylinder CY13
• Rack Angle Cylinder CY14

9-1
 Overview D20x22 Navigator HDD Service

Component Locations

PMP3
IMPLEMENT
PUMP
Stabilizer/Rack Angle

CY14
RACK ANGLE
CYLINDER CY14

RACK ANGLE/
STABILIZER
VALVE ASSEMBLY

A11

9-2
D20x22 Navigator HDD Service Overview

Hose Connections
OIL
TANK
RES1

RACK ANGLE/
STABILIZER
ASSEMBLY A11

Stabilizer/Rack Angle
IMPLEMENT
PUMP PMP3

STABILIZER
CYLINDER CY13

RACK ANGLE
CYLINDER CY14

Troubleshooting
Troubleshooting procedures are given in this chapter for each functions
operating modes. Each procedure begins by performing a pretest inspection
of the machine (see the following page).

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 "Machine Performance," page 9-6.

9-3
 Overview D20x22 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.

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

Mechanical

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

Electrical

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 wires 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...

9-4
D20x22 Navigator HDD Service Overview

Hydraulic

Check hydraulic components for any obvious problems 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 can cause
erratic behaviors 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

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

Stabilizer/Rack Angle

9-5
 Overview D20x22 Navigator HDD Service

Machine Performance
If there are malfunctioning components in other functions, they may have an
effect on Stabilizer and Stakedown function operation.

Therefore, the preferred way to troubleshoot any problems that occur in

these functions is to operate all machine functions and document the
performance of the working actuators.

Make note of any functions not operating normally based on the normal
operation given in each chapter for that function. Comparing the results
with the normal operation given for each mode of a particular function will
help to isolate the problem.

Check machine performance, and 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 below.

Possible Results 1. If all machine functions are malfunctioning, it would indicate a function
Stabilizer/Rack Angle

or component that is common to all the actuators is most likely

malfunctioning. The following functions and components should be
investigated:
• See Power chapter 3
• Shared hydraulic components (See chapter 4)
2. If problems are noted in the stakedown, and stabilizer functions as well
as the rack, rod loader, water 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:
• Pump PMP3
• Tracking cooler flow valve assembly A18

9-6
D20x22 Navigator HDD Service Overview

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 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.

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

Stabilizer/Rack Angle
Electrical:

• Nominal circuit voltage - 12 volts DC

• Drill/transport valve solenoid coils L4 and L5 - 4.3 ohms @ 68°F (20°C)

Hydraulic:

• Pump PMP3 normal output flow - variable to 20 gpm (76 L/min)

• Pump PMP3 load sense spool PV8 setting - 250 psi (bar)
• Pump PMP3 high pressure compensator PV9 setting - 3200 psi (217 bar)
• Control valve assembly A7 relief valve PV4 pressure setting - 3500 psi
(241 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 4-19, and follow instructions.

9-7
 Stabilizer/Rack Angle Circuit D20x22 Navigator HDD Service

STABILIZER/RACK ANGLE CIRCUIT

CY1 MH8 CY2
MH7

CV26 CV27

A9

DV11 DV12 DV13 DV14

CY13

CV14
Stabilizer/Rack Angle

CY14

PV10

A10
HE1

DV15

DV16
RES1 PV11
SV2

PV8
L21

PV9
PMP3

RES1 RES1

Continued on next page...

9-8
D20x22 Navigator HDD Service Stabilizer/Rack Angle Circuit

Pump PMP3
Refer to "Pump PMP3," page 8-10.

Compensator
Refer to "Compensator," page 8-11.

Rack Angle/Stabilizer Valve Assembly A11

Operation The rack angle/stabilizer valve
assembly A11 consists of two
manually operated directional
valve spools.

The inlet of A11 contains a

pressure relief valve PV11. If

Stabilizer/Rack Angle
pressure in line of any of
functions increases to 3500 psi
(241 bar), it will open to drain
some of fluid to tank. This
protects components in
hydraulic circuits from over-
pressurization.

The individual valve sections control the following functions:

• DV16 - Stabilizer
• DV17 - Rack Angle
For normal operation and troubleshooting on the individual functions, see
information starting on page 9-10.

NOTE: If all functions operate abnormally, see the following

troubleshooting.

Troubleshooting If both functions, rack angle and stabilizer, are operating abnormally and all
other machine functions are OK, it would indicate a component common to
just these two functions is most likely faulty.

1. Inspect rack angle/stabilizer valve assembly A11 including pressure

relief valve PV11 for damage or contamination. Refer to component
repair section for information on control valve and relief valve repair.

9-9
 Stabilizer Function D20x22 Navigator HDD Service

STABILIZER FUNCTION

CY13
RETURN
PRESSURE
LOAD SENSE CV14

CY14

HE1

A11

RES1 DV15

DV16
Stabilizer/Rack Angle

PV11
SV2

L21

PMP3

Stabilizer LOWER Mode

Required Operating • Engine must be running at full throttle.
Conditions. • Control handle must be pushed FORWARD.

Operation When required operating conditions are met:

• CY13 extends to lower stabilizer and raise machine.

• Lock valve CV14 keeps the cylinder from drifting when
non-actuated by locking oil in the cylinder. The valve also ensures the
machine will not drop if a hose or fitting fails.

NOTE: If stabilizer LOWER mode does not operate as expected, see

following troubleshooting.

9-10
D20x22 Navigator HDD Service Stabilizer Function

Troubleshooting/ 1. Before beginning any troubleshooting or testing procedures, perform the

Testing "Pretest Inspection," page 9-4. If nothing obvious is found, continue.
2. In order to ensure the fault is isolated to just the stabilizer LOWER or
RAISE modes, the technician should operate all the machine functions
and observe the actuators as discussed in "Machine Performance," page 9-
6.
3. If any functions other than the stabilizer function are faulty, continue
troubleshooting based on the possible results given. If all other machine
functions are operating normally, continue.
4. If the cylinder is operating abnormally, either the cylinder, lock valve, or
control valve has malfunctioned. See the most common symptoms
associated with these components under "Hydraulic Troubleshooting,"
page 1-12 in the General Information chapter, then proceed with step 5.

NOTE: Hydraulic component testing is based on volumetric efficiency.

Testing 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.

Stabilizer/Rack Angle
5. 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
seal system.
The cylinder is considered worn out if any flow is measured when
deadheading with pump PMP3 high compensator setting of 3200 psi (217
bar). If so, repair or replace cylinder. Refer to component repair
information at the end of this chapter for information. If OK, continue
with step 5.
6. Test lock valve CV14. Excessive leakage across the blocked-flow ports
can be caused by contamination, damage, or wear to internal
components.
The valve is leaking excessively if pressure drops rapidly or if it fails to
pressurize when tested with mini-tester to 3200 psi (217 bar). If so,
replace valve. Refer to component repair information at the end of this
chapter for information. If OK, continue with step 7.

7. Disassemble stabilizer/rack angle control valve assembly A11 and

inspect for contamination or damage to internal seals, O-rings, and
internal components. Refer to component repair information at the end
of this chapter for information.

9-11
 Stabilizer Function D20x22 Navigator HDD Service

CY13

CV14
RETURN
PRESSURE
LOAD SENSE
CY14

HE1

A11

RES1 DV15

DV16
PV11
SV2
Stabilizer/Rack Angle

L21 PMP3

Stabilizer RAISE Mode

Required Operating • Seat must be unoccupied.
Conditions • Engine must be running at full throttle.
• Control handle must be pulled back.

Operation When required operating conditions are met:

• CY13 retracts to raise stabilizer.

• Lock valve assembly A20 keeps the cylinder from drifting when
non-actuated by locking oil in the cylinder. The valve also ensures the
machine will not drop if a hose or fitting fails.

NOTE: If stabilizer RAISE mode does not operate as expected, see

"Troubleshooting/Testing," page 9-11.
\

9-12
D20x22 Navigator HDD Service Rack Angle Function

RACK ANGLE FUNCTION

The rack angle circuit is the only other function that will operate when
machine is in Transport mode. All other circuits that receive flow from the
PFC pump are disabled in Transport mode because the track drive cooling
circuit drains all flow from PMP3.

Switch S21 opens when rack control valve handle is moved away from
center. This de-energizes solenoid L21 on track drive cooling valve DV30.
When solenoid L21 is not energized, flow from PMP3 is available to operate
the rack angle circuit.
CY13

CV14
RETURN
PRESSURE
LOAD SENSE
CY14

CV15
HE1

Stabilizer/Rack Angle
A11

RES1 DV15

DV16
PV11
SV2

L21

PMP3

Rack LOWER Mode

Required Operating • Seat must be unoccupied.
Conditions • Engine must be running at full throttle.
• Control handle must be pushed forward.

9-13
 Rack Angle Function D20x22 Navigator HDD Service

Operation When required operating conditions are met:

• CY14 retracts to lower front end of rack.

• Check valve CV15 keeps the cylinder from drifting when non-actuated by
locking oil in the cylinder. The valve also ensures the machine will not
drop if a hose or fitting fails.

Troubleshooting/ If rack angle circuit fails to operate normally in both Transport and Drill
Testing mode:

1. Inspect rack angle/stabilizer valve assembly A11 for leaks. Refer to "Rack
Angle/Stabilizer Valve Assembly A11," page 9-16.
If rack angle circuit functions normally during Drill mode, but does not
operate in Transport mode:

1. Check continuity across switch S31 that is built into rack angle control
valve. When control handle for rack angle is centered, switch S31 should
Stabilizer/Rack Angle

be closed. If not, replace switch S31.

If cylinder creeps down while supporting a load:

1. Inspect cylinder CY14 for signs of leakage at gland. If OK, continue.

2. Replace counterbalance valve CV15 for cylinder CY14. If problem
persists, continue.
3. Disassemble cylinder and install new seals.

9-14
D20x22 Navigator HDD Service Rack Angle Function

CY13

CV14
RETURN
PRESSURE
LOAD SENSE
CY14

CV15
HE1

A11

RES1 DV15

DV16
PV11

Stabilizer/Rack Angle
PMP3

Rack RAISE Mode

Required Operating • Seat must be unoccupied.
Conditions • Engine must be running at full throttle.
• Control handle must be pulled BACK.

Operation When required operating conditions are met:

• CY14 extends to raise front end of rack.

• Check valve CV15 keeps the cylinder from drifting when non-actuated by
locking oil in the cylinder. The valve also ensures the machine will not
drop if a hose or fitting fails.
NOTE: If rack RAISE mode does not operate like expected, refer to
"Troubleshooting/Testing," page 9-14.

9-15
 Component Repair D20x22 Navigator HDD Service

COMPONENT REPAIR
Rack Angle/Stabilizer Valve Assembly A11
Valves DV15, DV16 These valves are located in manifold A9, mounted to the transport control
and PV11 panel.

DV16
DV15
1

A11
PV11
Stabilizer/Rack Angle

1. Disconnect harness from the tracking cooler interrupt switch S38.

2. Carefully label all hoses to aid reassembly.
3. Disconnect hoses. Cap all open hose ends and manifold ports.
4. Remove the four bolts (1) holding the manifold to the mounting plate.
Move manifold to a clean area of the workbench.
If replacing PV11, continue at step 5. If replacing DV15 or DV16, continue at
step 7.

5. Unscrew valve PV11 from the manifold. Note position of the two O-ring
seals and O-rings on the valve. Also note backup ring next to the smaller
O-ring.
6. Using the repair kit, install O-rings and backup ring on the new valve
PV11 and install it in the manifold. Torque the valve to 20 ft-lb (27 Nm).
Continue at step 14.
7. Remove nuts (3) from the three bolts (1) that hold the sections together.
Remove bolts. They will not be re-used.
Continued on next page...

9-16
D20x22 Navigator HDD Service Component Repair

8. Pry apart the sections only where needed to remove the faulty valve
DV15 or DV16. Remove and discard O-rings (2) on either side of the
faulty valve section.
9. Remove hose fittings from the old valve section. Install them in the new
section. Torque fittings to the A and B ports to 28 ft-lb (38 Nm).
10. Two O-ring kits are needed, one for either side of the new valve section.
Do not lubricate O-rings before installing them on either side of the new
valve section.
11. Remove handle from the old valve section and install it on the new
section.
12. Hold new section in place and assemble sections by inserting new bolts
(1). Install nuts and torque nuts to 32 ft-lb (43 Nm).
13. Install manifold under the mounting plate. Install bolts and torque nuts
to 20 ft-lb (27 Nm).
14. Reconnect hoses. Torque them as follows:
• hoses to ports A and B to 28 ft-lb (38 Nm)

Stabilizer/Rack Angle
• hoses to In and Out ports to 38 ft-lb (52 Nm)
• hose to load sense port to 9.5 ft-lb (12.9 Nm)

9-17
 Component Repair D20x22 Navigator HDD Service

Rack Angle Cylinder CY14

1. Use an overhead hoist to
support the weight of the
rack.
2. Remove pin and pivot pin
holding the rod end to the
rack.
3. Label hoses and
disconnect them from the
cylinder. Cap open hose
ends.
4. Remove pin and the pivot
pin that holds the base of
the cylinder to the frame.
5. Lift cylinder from the
frame.
Stabilizer/Rack Angle

6. If replacing the cylinder, CY14

remove hose fittings from
the old cylinder and
install them in the new
cylinder. Torque the
fittings to 19 ft-lb (26 Nm).

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

9-18
D20x22 Navigator HDD Service Component Repair

Stabilizer Cylinder CY13

1. Use a jack or other
suitable device to
support the weight of
the water pump and
other attached
hardware as you work
on this cylinder.
2. Remove retaining bolt
and washer and remove
pin that holds the
stabilizer pad to the
lower sliding sleeve.
3. Use a roll pin punch to
knock out the roll pin
from the lower sleeve.
4. Remove pin holding the
end of the rod to the

Stabilizer/Rack Angle
sleeve.
5. Label and disconnect hoses from the upper end of the cylinder. Cap the
hoses.
6. Use a roll pin punch to knock out the roll pin from the upper sleeve. Lift
cylinder out of the sleeve.
7. If replacing the cylinder, remove the hose fittings from the old cylinder
and install them in the new cylinder. Torque fittings to 19 ft-lb (26 Nm).

If rebuilding the cylinder, refer to the parts books for rebuild/repair kit
and use generic cylinder repair instructions found in the Vermeer
Technicians Shop Manual.
8. Reverse steps 1–6 above to install cylinder and stabilizer pad. Torque
hoses to cylinder to 19 ft-lb (26 Nm).

9-19
This page intentionally left blank.
D20x22 Navigator HDD Service Overview

Chapter 10: 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; CY3, CY4, and CY5.

All the solenoids in A13 are controlled by inputs from controllers A1 and A2.
Controllers respond to inputs from operator controlled switches.

Functions/Components
Functions The following functions are included in this chapter:

• Rear Vise Clamp

• Front Vise Clamp

Vises
• Rear Vise Rotate

10-1
 Overview D20x22 Navigator HDD Service

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

• Hydraulic Fluid Distribution Components

• Implement Pump PMP3
• Vise Valve Assembly A13 including:
• Front Vise Clamp Valve DV17
• Front Vise Clamp Solenoid L6
• Rear Vise Clamp Valve DV18
• Rear Vise Clamp Solenoid L8
• Rear Vise Rotate Valve DV19
• Rear Vise Rotate Solenoid L2
• Front Vise Clamp Hold Valve DV25
• Front Vise Clamp Hold Solenoid L1
• Rear Vise Clamp Hold Valve DV26
• Rear Vise Clamp Hold Solenoid L23
• Shift Pressure Valve PV13
• Front Vise Cylinder CY3
• Rear Vise Cylinder CY4
• Rear Vise Rotation Cylinder CY5
Vises

• Right Joystick Assembly A22 including:

• Front Vise Engage/Joint Break Sequence Button S13
• Rod Loader Arm Extend/Rear Vise Engage Button S17
• Rear Vise Disengage/Rod Loader Arm Retract Button S14
• Front Vise Disengage Button S18

10-2
D20x22 Navigator HDD Service Overview

Component Locations

VISE VALVE
MANIFOLD A13

SHIFT VALVE
PV13

Vises
FRONT VISE REAR VISE
CONTROL ROTATE
VALVE DV17, VALVE DV19,
SOLENOID L6 SOLENOID L2
PFC PUMP PMP3

REAR VISE
CONTROL
VALVE DV18,
SOLENOID L8
FRONT VISE
CLAMP HOLD
VALVE DV25, SOLENOID L1

REAR VISE CLAMP

HOLD VALVE DV26, SOLENOID L23

10-3
 Overview D20x22 Navigator HDD Service

JOUNT BREAK SEQUENCE REAR VISE CLAMP SWITCH S17

SWITCH S13
REAR VISE UNCLAMP SWITCH S14

FRONT VISE UNCLAMP

SWITCH S18

DRILLOUT/
PULLBACK
MODE
SWITCH
S16
Vises

CONTROLLER A2

10-4
D20x22 Navigator HDD Service Overview

Hose Connections

Vise Valve
Assembly A13

Oil Tank
RES1

Rod Loader
Valve
Assembly A14

Vises
Stakedown Valve
Assembly A10 Implement Pump
PMP3

Rear Vise
Cylinder CY4

Front Vise
Cylinder CY3

Rear Vise
Rotation
Cylinder CY5

10-5
 Overview D20x22 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.

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
"Machine Performance," page 10-8.

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 wires 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...

10-6
D20x22 Navigator HDD Service Overview

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.

Vises
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.

10-7
 Overview D20x22 Navigator HDD Service

Machine Performance
Possible faults may occur in the vise functions 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.

Therefore the preferred way to troubleshoot any problems that occur in the
vise circuits is to operate all the functions of the machine and document the
performance of the working actuators.

Make note of any functions not operating normally based on the theory
given in each chapter for that function. Comparing the results with the
normal operation given for each mode of a particular function will help to
isolate the problem.

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
Vises

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:
• Refer to "Engine," page 3-8.
• Refer to "Overview," page 4-1.

2. If faults are noted in the Vise functions, as well as the Rack Angle/
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 PMP3," page 4-16.
3. If faults are noted in only the Vise function and all other functions are
OK, the hydraulic components common to just the vises should be
investigated:
• "Vise Valve Assembly A13," page 10-12.

10-8
D20x22 Navigator HDD Service Overview

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.

Specifications
Listed below are the electrical and hydraulic specifications for the Vise
functions.

Electrical:

Vises
• Nominal circuit voltage - 12 volts DC
• Vise valve solenoid coils L1, L2, L6, and L8 resistance - 4.3 ohms @ 68°F
(20°C)
Hydraulic:

• Pump PMP3 normal output flow - variable to 20 gpm (76 L/min)

• Pump PMP3 load sense spool DV1 setting - 250 psi (17 bar)
• Pump PMP3 high pressure compensator PV9 setting - 3200 psi (217 bar)
• Vise valve assembly A13 relief valve PV13 pressure setting - 2500 psi
(172 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 4-19 and follow instructions.

10-9
 Hydraulic Schematic D20x22 Navigator HDD Service

HYDRAULIC SCHEMATIC

CY3 CY4 CY5

L23
Pin C3 of A2
L1 A13
Pin C4 of A2 DV25
DV26

Pin A3 of A2
L6
DV17 L8 L2
Pin A4 of A2 DV18 DV19

PV13
Vises

PUMP PMP3

10-10
D20x22 Navigator HDD Service Electrical Schematic

ELECTRICAL SCHEMATIC

REAR VISE CLAMP

ENABLE SOLENOID L23

12 VOLTS
FROM BATTERY VISE SUPPLY
ON SOLENOID L1

CAN CONNECTION REAR VISE

TO REMOTE LOCKOUT ROTATE SOLENOID L2
AND CONTROLLER A1
REAR VISE
ENGAGE SWITCH
S17
A2

FROM FUSE F3

Vises
FRONT VISE
UNCLAMP SWITCH
REAR VISE S18
UNCLAMP
SWITCH
S14

LOWER VISE
CLAMP SOLENOID L6

ROTATION TORQUE
LIMITER SOLENOID L7

REAR VISE
CLAMP SOLENOID
L8

10-11
 Pump PMP3 D20x22 Navigator HDD Service

PUMP PMP3
Refer to "Pump PMP3," page 8-10.

COMPENSATOR
Refer to "Compensator," page 8-11.

VISE VALVE ASSEMBLY A13

Operation Flow from the implement pump PMP3 enters the vise valve assembly A13,
where it is directed to vises based on operator inputs. Directing this flow is
accomplished by three directional valves, DV17, DV18, and DV19. Valves
DV25 and DV26 to 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. DV17 is controlled by L6, DV18 is controlled by L8, and
DV19 is controlled by solenoid L2. DV25 is controlled by solenoid L1, and
Vises

DV26 is controlled by solenoid L23. As the operator provides inputs into the
switches on the right joystick, a signal is sent to the console controller A2,
which then relays the signal to the vise valve assembly.

REAR VISE
REAR VISE ROTATE CYLINDER
CYLINDER CY4 CY5
FRONT VISE
CYLINDER CY3

Pin C3 of A2 L23
L1 A13
Pin C4 of A2 DV25 DV26
To Load Sensing
Pin A3 of A2 L6 L8 L2
Pin A4 of A2 DV17 DV18 DV19
To RES1

From PMP3
PV13

When solenoids are not energized, oil from PMP3 flows to the rod end of
cylinders CY3, and CY4, holding them in the retracted position.

10-12
D20x22 Navigator HDD Service DRILL OUT Mode

DRILL OUT MODE

Front Vise CLAMP Operation
REAR VISE ROTATE CYLINDER
CYLINDER CY4 CY5
FRONT VISE
CYLINDER CY3

L23
A13
L1
To Load Sense
Port on Pump DV25 DV26
+12v from
Pin A3 of
Controller A2 L6 L8 L2
DV17 DV18 DV19
To RES1

PV13

Vises
From PMP3

To operate front vise CLAMPING mode:

• Remote Lockout system must be in

normal RUN mode.
• Engine must be running.
• Switch S16 must be in DRILL OUT
mode.
• Operator must activate front vise
switch S13 (1) on right joystick.

10-13
 DRILL OUT Mode D20x22 Navigator HDD Service

When required operating conditions are met:

• Switch S13 sends signal to console controller A2.

• Coil L6 is energized and shifts DV17, allowing oil to reach base end of
CY3.
• CY3 extends and clamps onto end of drill string.
• Controller A2 de-energizes L6 and DV25 holds pressure to CY3.
• CY12 extends to shut off and disable the drill fluid pump function.
• Cylinders CY4 and CY5 remain retracted.

Coil L6 is energized, allowing oil to pass through DV17 to the base end of
CY3. Once L6 is de-energized, the check feature of DV25 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 the
following troubleshooting.
Vises

10-14
D20x22 Navigator HDD Service DRILL OUT Mode

Troubleshooting/Testing
Before beginning any troubleshooting or testing procedures, perform the
"Pretest Inspection," page 10-6. 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 "Machine Performance," page 10-8.
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. Test for acceptable voltage starting at coil L6 of DV17. If voltage is

acceptable, continue with step 4. If not, continue with step 5.
4. Test resistance of solenoid coil L6.
Expected result: Resistance should measure 4.3 ohms @ 68°F (20°C). If
OK, continue with step 6. If not, replace coil.

5. Continue testing for acceptable voltage in the rest of the circuit at pins/

Vises
terminals of components and wire harness connector inputs and outputs
back to controller. If voltage is not within specification (10.5 volts min.),
repair or replace faulty component(s) or wire harness segment(s).
6. Test cylinder CY2 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.
7. Remove and inspect the cartridge valves in vise valve assembly A13.
Refer to component repair information in this chapter. Repair or replace
any faulty components.

10-15
 DRILL OUT Mode D20x22 Navigator HDD Service

Front Vise UNCLAMP

FRONT VISE
CYLINDER CY3

REAR VISE ROTATE CYLINDER

CYLINDER CY4 CY5

L1
L23
To Load DV25 DV26
Sense Port
on Pump

L6 L8 L2

DV17 DV18 DV19

To RES1
Vises

From PMP3
PV13

Required Operating • Remote Lockout system must be in

Conditions normal Run mode or Override
mode.
• Engine must be running.
• Switch S16 must be in Drill Out
mode.
• Operator must activate front vise
disengage switch S18 (1) on right
joystick.

10-16
D20x22 Navigator HDD Service DRILL OUT Mode

Operation When required operating conditions are met:

• Coil L1 of DV25 receives 12 volts DC from pin C4 of console controller

A2.
• Coil L6 of DV17 is NOT energized, allowing flow to enter at rod end of
cylinder CY3 and to leave the base end of the cylinder CY3.
• CY3 retracts fully.
When coil L1 is energized, the check feature of DV25 is shifted and flow is
allowed to leave the base end of the cylinder. This causes the cylinder to
retract, unclamping from the drill rod.

If problems occur during unclamping, see the following troubleshooting

section.

Vises

10-17
 DRILL OUT Mode D20x22 Navigator HDD Service

Troubleshooting/ Before beginning any troubleshooting or testing procedures, perform the

Testing "Pretest Inspection," page 10-6. If nothing obvious is found, continue.

1. In order to ensure the fault is isolated to just the front vise unclamping
mode, the technician should operate all machine functions and observe
the actuators as discussed in "Machine Performance," page 10-8.
2. If any functions other than the front vise unclamping 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. Test for voltage at coil L6 of DV17. If voltage is present, coil L6 is

wrongly receiving voltage. Problem is either in a stuck closed switch S13,
or a controller issue.
4. Test for acceptable voltage at coil L1 of DV25. If voltage is acceptable,
continue with step 4. If not, continue with step 5.
5. Test resistance of solenoid coil L1.
Expected result: Resistance should measure 4.3 ohms @ 68°F (20°C). If
OK, continue with step 6. If not, replace coil.
Vises

6. 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 min.), repair or replace faulty component(s) or wire harness
segment(s).
7. Test cylinder CY2 for internal leakage. Refer to the Vermeer Industrial
Dealership 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.
8. Remove and inspect the cartridge valves in vise valve assembly A13.
Refer to component repair information in this chapter. Repair or replace
any faulty components.

10-18
D20x22 Navigator HDD Service PULLBACK Mode

Torque Limiter Function

The torque limiter function utilizes switch S13. When the front vise is
clamped, coil L7 of SV1 becomes energized. The switch works in conjunction
with both Thrust/Pullback and Drill Rotation functions.

The torque limiter function keeps the rod joints from being over-tightened
when adding to the drill string.

NOTE: Refer to Drill Rotation Chapter 7 for information on torque limiter

function as well as the drill rotation hydrostatic closed-loop circuit.

PULLBACK MODE
Front Vise Clamp
Refer to "Front Vise CLAMP Operation," page 10-13.

Front Vise Unclamp

Vises
Refer to "Front Vise UNCLAMP," page 10-16.

10-19
 PULLBACK Mode D20x22 Navigator HDD Service

Rear Vise CLAMP

REAR VISE CYLINDER CY4 ROTATE CYLINDER
FRONT VISE CY5
CYLINDER CY3

DV25 L23 A13

L1
To Load Sensing DV26

L6
+12 v from L8 L2
DV17 DV18 DV19
Pin A4 of
Controller A2 To RES1

PV13

From PMP3
Vises

Required Operating To operate rear vise Clamp mode:

Conditions
• Operator must be seated at drill controls.
• Remote Lockout system must be in normal Run mode.
• Engine must be running.
• Switch S16 must be in Pullback mode.
• Front vise CY3 must be clamped.

10-20
D20x22 Navigator HDD Service PULLBACK Mode

Normal Operation The rear vise cylinder CY4 is responsible for loosening rods from drill string
while machine is in Pullback mode. CY4 also assists rod loading function by
clamping onto rods while rod loader arm extends to staging area. Once rod
loader arm has rod in position, operator disengages rear vise allowing rod to
be placed back onto rack.

Once required operating conditions have been met, there are two ways in
which the rear vise is used:

[Link] Break Sequence:

2
•Operator presses and holds front
vise engage switch S13 (1).
Controller energizes L6 of DV17 and
L8 of DV18. DV17 and DV18 shift
and front vise CY3 and rear vise CY4
cylinders extend. Rear vise cylinder
CY5 extends to turn rod and thus
break joint. Refer to "Rear Vise
1 Rotate (Extend)," page 10-25.
•Once switch S13 is released, the
rear vise releases drill rod and vise rotate cylinder CY5 retracts. Refer
to "Rear Vise Rotate (Retract)," page 10-27.
2. Unloading Sequence:

Vises
• Once drill rod is unscrewed from drill string in Pullback process,
operator presses rod loader arm extend/rear vise engage switch S17 (2)
which does two things. First, rear vise clamps front of rod. Second, rod
loader arm extends to staging area to retrieve rod. Refer to rod loader
chapter 11.

10-21
 PULLBACK Mode D20x22 Navigator HDD Service

Troubleshooting/ Before beginning any troubleshooting or testing procedures, perform the

Testing "Pretest Inspection," page 10-6. 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 "Machine Performance," page 10-8.
2. If any functions other than the front vise Unclamping 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. Test for acceptable voltage at coil L8 of DV18. If voltage is acceptable,

continue with step 4.

Expected result: 12 volts DC, ± 1.2V. If not, continue with step 5.

4. Test resistance of solenoid coil L8.
Expected result: Resistance should measure 4.3 ohms @ 68°F (20°C). If
OK, continue with step 5. If not, replace coil.

5. Continue testing for acceptable voltage in the rest of the circuit at pins/
Vises

terminals of components and wire harness connector inputs and outputs

back to controller. If voltage is not within specification (10.5 volts min.),
repair or replace faulty component(s) or wire harness segment(s).
6. Test cylinder CY4 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.
7. Remove and inspect the cartridge valve DV18 in vise valve assembly
A13. Refer to component repair information in this chapter. Repair or
replace if necessary.

10-22
D20x22 Navigator HDD Service PULLBACK Mode

REAR VISE ROTATE CYLINDER

Rear Vise Unclamp CYLINDER CY4 CY5

FRONT VISE
CYLINDER CY3

L1 A13
L23
DV25 DV26
To Load Sensing

L6 L8 L2
DV17 DV18 DV19
To RES1

PV13

Vises
From PMP3
Required Operating To operate rear vise Unclamp mode:
Conditions
• Operator must be seated at drill controls.
• Remote Lockout system must be in normal Run mode.
• Engine must be running.
• Switch S16 must be in Pullback mode.
• Front vise CY3 must be clamped.

10-23
 PULLBACK Mode D20x22 Navigator HDD Service

Operation 1. Joint Break Sequence:

2
• Once S13 is released by operator,
coils L8 of DV18 and L2 of DV19
become de-energized. This causes
rear vise cylinder CY4 to release
drill rod and vise rotate cylinder
CY5 retract to NEUTRAL position.
Refer to "Rear Vise Rotate
(Retract)," page 10-27.
2. Unloading Sequence: 1

• Operator presses rear vise

disengage/rod loader arm retract
switch S14. This allows rear vise to
release rod and rod loader arm to return rod to rod box. Refer to rod
loader chapter 11.

Troubleshooting/ If problems are noticed with the rear vise in Pullback mode, refer to
Testing "Troubleshooting/Testing," page 10-24.
Vises

10-24
D20x22 Navigator HDD Service PULLBACK Mode

Rear Vise Rotate (Extend)

ROTATE CYLINDER
FRONT VISE CY5
CYLINDER CY3

REAR VISE
CYLINDER CY4

L23 A13
L1
DV25 DV26
To Load Sensing

L6
L8 L2
DV17
DV18 DV19
+12v from
Pin A3 of To RES1
Controller A2

From PMP3
PV13

Vises
Required Operating • Operator must be seated at drill controls.
Conditions • Remote Lockout system must be in normal Run mode.
• Engine must be running.
• Switch S16 must be in Pullback mode.
• Front vise CY3 must be clamped.
• Rear vise CY4 must be clamped.

10-25
 PULLBACK Mode D20x22 Navigator HDD Service

Operation The rear vise rotation cylinder CY5 is used during the joint-break sequence
when pulling drill rod back. After a rod is pulled back and has engaged the
front vise cylinder CY3, then presses and holds the front vise engage switch
S13. This causes oil to flow to the base end of the rear vise cylinder CY4 and
allows it to clamp onto the male end of the rod which has just been pulled
back. Once the rear vise cylinder CY4 has clamped completely, oil flows to
the base end of the rotation cylinder CY5, rotating the rear vise cylinder
CY4 as well as the rod that it is clamped to. This loosens the rod from the
drill string and allows the operator to use the reverse rotation function to
completely unscrew the rod.

NOTE: If at any time during the joint-break sequence the operator releases
the front vise engage switch S13, the rear vise cylinder will retract, thus
releasing the rod. Similarly, the rear vise cylinder CY5 will retract and
return to its NEUTRAL position.
Vises

10-26
D20x22 Navigator HDD Service PULLBACK Mode

Rear Vise Rotate (Retract)

FRONT VISE
CYLINDER CY3

REAR VISE ROTATE

CYLINDER CY4 CYLINDER CY5

L1
L23 A13
DV25 DV26
To Load Sensing

L6 L8 L2
DV17 DV18 DV19
To RES1

PV13

Vises
+12v from
Pin A3 of
Controller A2 From PMP3

Required Operating • Operator must be seated at drill controls.

Conditions • Remote Lockout system must be in normal Run mode.
• Engine must be running.
• Switch S16 must be in Pullback mode.
• Front vise CY3 must be clamped.
• Rear vise CY4 must be clamped.

Operation Refer to "Rear Vise Rotate (Extend)," page 10-25.

10-27
 Component Repair D20x22 Navigator HDD Service

COMPONENT REPAIR
Pump PMP3
Refer to "PFC Pump PMP3 High and Low Pressure Compensator Adjustment,"
page 4-24.

If PMP must be replaced, refer to "PMP3 Replacement," page 4-37.

Vise Valve Assembly A13

Solenoids L1, L2, These coils and valves are located on vise valve assembly A13. A13 is located
L6, L8 below the stakedown valve assembly A10 near the front of the machine.

Valves DV26, DV25, 1. Remove nut which secures coil to valve.

DV17, DV18, DV19
2. Remove coil from valve and replace if necessary.
3. Remove valve from manifold and check for damage or contamination. If
necessary, replace.
4. Use the following torque specifications.
Vises

• All solenoid retaining nuts – 5 ft-lb (7 Nm)

• DV26, DV25 – 20 ft-lb (27 Nm)
• DV17, DV18, DV19 – 23 ft-lb (31 Nm)
• PV13 – 25 ft-lb (34 Nm)
DV19 DV26 DV25
A13 L23
L2
DV18 L1
DV17
L8
L6

PV13

Continued on next page...

10-28
D20x22 Navigator HDD Service Component Repair

Check Valve CV19 This check valve is

located on the bottom of
vise valve assembly A13.
CV19
1. Remove hex plug and
observe location of O-
rings and backup
ring.
2. Install new O-rings
and backup ring on
new check valve and
install plug.
3. Torque hex plug to 20
ft-lb (27 Nm).

Vises

10-29
 Component Repair D20x22 Navigator HDD Service

Vise Clamp Cylinders CY3 and CY4

NOTE: The rod joint greaser is
clamped to the front vise
cylinder CY3. To replace front
vise cylinder, first loosen two
bolts clamping greaser assembly
to cylinder CY3.

1. Extend cylinder fully to

expose pin that holds vise
jaw to cylinder rod. A spring-
loaded ball secures pin in
rod. Work a screwdriver
under edge of head of pin
and pry up. Use a pliers or
vise grip to pull pin out.
Remove vise jaw.
2. Retract cylinder. Label and
remove hoses.
3. Remove four bolts holding
cylinder to frame. Lift
cylinder from frame.
Vises

4. Clean any residue from

threads of bolts and holes in
frame.
5. If replacing cylinder, remove
hose fittings from old
cylinder and install in new cylinder. For rear vise cylinder CY4, 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.
6. Apply Loctite 277 to threads of four mounting bolts. Install cylinder and
use a crisscross pattern to torque mounting bolts to 570 ft-lb (773 (Nm).
7. Attach hoses. Torque hoses to fittings to 9.5 ft-lb (13 Nm).
8. Extend cylinder and install vise jaw and retaining pin.
If needed, reinstall rod joint grease assembly and tighten clamps.

10-30
D20x22 Navigator HDD Service Component Repair

Vise Rotation Cylinder CY5

See drawing on previous page.

1. Label hoses and remove them.

2. Remove cotter pins and remove larger pins holding cylinder ends to
frame.
3. If replacing cylinder, remove hose fittings from old cylinder and install in
new cylinder. Torque fittings to 9.5 ft-lb (13 Nm).

If rebuilding cylinder, refer to parts books for rebuild/repair kit and

cylinder repair procedures found in the Technician’s Shop Manual.
4. Attach cylinder to frame with pins. Install cotter pins.
5. Attach hoses. Torque hoses to fittings to 9.5 ft-lb (13 Nm).

Vises

10-31
 Component Repair D20x22 Navigator HDD Service
Vises

10-32
D20x22 Navigator HDD Service Overview

Chapter 11: Rod Loader

OVERVIEW
This chapter is comprised of information about circuits and components
necessary for rod loading and unloading.

The operator uses the rod loader along with the rear vise to add or remove
rods from drill string. The rod loader valve assembly A14 is connected to six
cylinders which control the rod loader function.

All the solenoids in A14 are controlled by inputs from controllers A1 and A2.
Controllers respond to inputs from operator controlled switches.

Functions/Components
Functions The following functions are included in this chapter:

• Rod loading in Drill Out mode.

Rod Loader
• Rod-unloading in Pullback mode.

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

• Hydraulic Fluid Distribution Components

• Pump PMP3
• Rod Loader Valve Assembly A14
• Rear Selector Cylinder CY6
• Front Selector Cylinder CY7
• Rear Arm Cylinder CY8
• Front arm Cylinder CY9
• Rear Rod Lift Cylinder CY10
• Front Rod Lift Cylinder CY11
• Right Joystick Assembly A22 including:
• Front Vise Engage/Joint Break Sequence Button S13
• Rod Loader Arm Extend/Rear Vise Engage Button S17
• Rear Vise Disengage/Rod Loader Arm Retract Button S14
• Front Vise Disengage Button S18

11-1
 Overview D20x22 Navigator HDD Service

Component Locations
Rod Loader

Implement Pump
PMP3

11-2
D20x22 Navigator HDD Service Overview

CY8 CY6

CY9

CY7
CY11 CY10

Rod Loader
S13 S17 S14 S18

S16

A2

11-3
 Overview D20x22 Navigator HDD Service

Hose Connections
Rear Arm
Cylinder CY8
Vise Valve
Assembly A13
Rear Rod Selector
Cylinder CY6

Oil Tank Rear Rod

RES1 Lift Cylinder
CY10

Front
Selector
Cylinder CY7
Rod Loader
Valve
Assembly A14
Implement Pump
PMP3 Front Arm
Cylinder CY9
Front Rod Lift
Rod Loader

Cylinder CY11

Stakedown Valve
Assembly A10

11-4
D20x22 Navigator HDD Service Overview

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.

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
"Machine Performance," page 11-6.

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

Rod Loader
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 wires 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...

11-5
 Overview D20x22 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 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.
Rod Loader

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.

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.

Therefore the preferred way to troubleshoot any problems that occur in the
hydraulic circuits is to operate all the functions of the machine and
document the performance of the working actuators.

Make note of any functions not operating normally based on the theory
given in each chapter for that function. Comparing the results with the
normal operation given for each mode of a particular function will help to
isolate the problem.

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 on the following page.

11-6
D20x22 Navigator HDD Service Overview

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:
• Refer to "Engine," page 3-8.
• Refer to "Overview," page 4-1.

2. If faults are noted in the vise functions, as well as the rack angle/
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 PMP3," page 4-16.
3. If faults are noted in only the rod loading function and all other functions
are OK, the hydraulic components common to just the rod loader should
be investigated:

Rod Loader
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 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.

11-7
 Overview D20x22 Navigator HDD Service

Specifications
Listed below are the electrical and hydraulic specifications for the rod loader
functions.

Electrical:

• Nominal circuit voltage - 12 volts DC.

• Rod loader valve solenoid coils L13, L16, L11, and L15 resistance - 7.3
ohms @ 68°F (20°C).
Hydraulic:

• Pump PMP3 normal output flow - variable to 20 gpm (76 L/min).

• Pump PMP3 load sense spool DV1 setting - 250 psi (17 bar).
• Pump PMP3 high pressure compensator PV9 setting - 3200 psi (217 bar).
• Vise valve assembly A13 relief valve PV13 pressure setting - 2500 psi
(172 bar).

Component Repair/Replace
Rod Loader

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 4-19 and follow instructions.

11-8
D20x22 Navigator HDD Service Rod Loader Circuit

ROD LOADER CIRCUIT

REAR
SELECTOR
CYLINDER
CY6

FRONT
SELECTOR
CYLINDER
CY7

PMP3 REAR
ARM
CYLINDER
CY8

Rod Loader
FRONT
ARM
CYLINDER
CY9

A14 DV21
PV14

L11 REAR
ROD LIFT
L15 CYLINDER
DV22 CY10
DV20
L13
PV15
L16

FRONT
ROD LIFT
CYLINDER
CY11

11-9
 Rod Loader Circuit D20x22 Navigator HDD Service

Pump PMP3
Refer to "Pump PMP3," page 8-10.

Compensator
Refer to "Compensator," page 8-11.

Rod Loader Valve Assembly A14

Operation Flow from the implement pump PMP3 enters the rod loader valve assembly
A14 where it is directed to rod loading cylinders based on a series of operator
inputs. Directing this flow during semi-automatic rod loading/unloading is
accomplished by a dual coil operated directional valve DV20, as well as pilot-
operated sequence valves PV14 and PV15. Additionally, coil operated valves
DV21 and DV22 can be used to direct flow when in manual mode.

DV20 has two coils, L11 for retracting rod loader arms, and L13 for
extending them. DV21 and DV22 are controlled by L15 and L16,
Rod Loader

respectively.

Coils L11 and L13 receive power from engine bay controller A1 based on
operator inputs to switches S14 and S17. How these coils respond to
operator inputs depends on whether the machine is in Drill Out or Pullback
mode, which is controlled by S16.

DV21
To Tank
RES1
L11

PV14 L15
From PMP3
DV22

DV20

L13

L16
PV15

11-10
D20x22 Navigator HDD Service Drill Out Mode

DRILL OUT MODE

Extend Rod Loader Arm
REAR
SELECTOR
CYLINDER
CY6

FRONT
SELECTOR
CYLINDER
CY7

REAR
ARM
CYLINDER
CY8

Rod Loader
FRONT
ARM
To Tank To Pin 6C of CYLINDER
Controller A1 CY9
RES1

REAR
PV14 ROD LIFT
DV21
CYLINDER
CY10

L15
DV22
FRONT
PV15 ROD LIFT
CYLINDER
L16 CY11

From PMP3
To Pin 6D of
Controller A1

+12v from Pin D4

of Controller A1

NOTE: Notice that rod loading cylinders CY6–CY9 and CY10–CY11 are
connected in parallel. If a cylinder fails or a leak occurs, all cylinders may be
affected.

Continued on next page...

11-11
 Drill Out Mode D20x22 Navigator HDD Service

Operation • Remote Lockout system must be in

normal Run mode. 2

• Engine must be running at full

throttle.
• Switch S16 must be in Drill Out
mode.
• Front vise engage button (1) must be
pushed to engage front vise.
• Operator must activate rod loader 1
arm extend button (2).

Once the rod loader arm extend button is pushed:

• Coil L13 of DV20 is energized by controller A1, allowing oil to flow to

PV14 and to flow through DV21 to the base end of rod lift cylinders
CY10 and CY11. Flow from the rod end of CY10 and CY11 flows
through DV22.
• Once cylinders CY10 and CY11 are fully extended, pressure at PV14
Rod Loader

exceeds 1200 psi (83 bar). Pilot-operated sequence valve PV14 shifts to
allow oil to reach the base end of the selector cylinders CY6 and CY7 as
well as the arm cylinders CY8 and CY9.
• Arm cylinders CY8 and CY9 extend, placing a rod into position to be
added to drill string. Operator rotates drive chuck into female end of
rod and then rotates rod onto drill string. At the same time, selector
cylinders CY7 and CY7 position next rod in rack to be picked up by rod
loader arms.

11-12
D20x22 Navigator HDD Service Drill Out Mode

Troubleshooting/ Before beginning any troubleshooting or testing procedures, perform the

Testing "Pretest Inspection," page 11-5. If nothing obvious is found, continue.

1. In order to ensure the fault is isolated to just the rod loading function,
the technician should operate all machine functions and observe the
actuators as discussed in "Machine Performance," page 11-6.
2. If any functions other than rod loading function are faulty, continue
troubleshooting based on the possible results given. If all other machine
functions are operating normally, continue.
NOTE: Refer to the Technician’s Shop Manual (Vermeer P/N 105400V80) for
helpful information on testing electrical circuits for shorts, opens, and high
resistance.

3. Test for acceptable voltage starting at coil L13 of DV20. If voltage is

acceptable, continue with step 4. If not, continue with step 5.
4. Test resistance of solenoid coil L13.
Expected result: Resistance should measure 7.3 ohms @ 68°F (20°C). If
OK, continue with step 6. If not, replace coil.

5. Continue testing for acceptable voltage in the rest of the circuit at pins/

Rod Loader
terminals of components and wire harness connector inputs and outputs
back to controller. If voltage is not within specification (10.5 volts min.),
repair or replace faulty component or wire harness segment.
NOTE: Selector cylinders and rod arm cylinders operate in parallel.
Problems in a single cylinder may affect the other cylinders.

6. If all cylinders within rod loader function are operating abnormally,

remove and inspect the cartridge valves in rod loader valve assembly
A14. Refer to component repair information in this chapter. Repair or
replace any faulty components. If problem can be traced to a single
cylinder, continue.
7. Test cylinder(s) for internal leakage. Refer to the 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.

11-13
 Drill Out Mode D20x22 Navigator HDD Service

Retract Rod Loader Arm

REAR
SELECTOR
CYLINDER
CY6

FRONT
SELECTOR
CYLINDER
CY7

REAR
ARM
CYLINDER
CY8

FRONT
Rod Loader

To Tank +12v from Pin 6C ARM

RES1 of Controller A1 CYLINDER
CY9
REAR
PV14 ROD LIFT
DV21
CYLINDER
CY10

L15
DV22
FRONT
PV15 ROD LIFT
CYLINDER
L16 CY11

From PMP3
To Pin 6D of
Controller A1

To Pin D4
of Controller A1

Continued on next page...

11-14
D20x22 Navigator HDD Service Drill Out Mode

Operation • Remote Lockout system must be in

normal Run mode. 2 3

• Engine must be running at full

throttle.
• Switch S16 must be in Drill Out
mode.
• Front vise engage button (1) must be
pushed to engage front vise.
• Operator must activate rod loader 1
arm retract button (2).

1. Once rod is screwed into drill string, operator presses Rod Loader Arm
Retract Button (3). This does several things in sequence.
• Coil L11 of DV20 is energized by controller A1, allowing oil to flow to
PV15 and through DV22, to the rod end of rod lift cylinders CY10 and
CY11. Flow from the base end of CY10 and CY11 flows through DV21.
• Once rod lift cylinders CY10 and CY11 are fully retracted, pressure at

Rod Loader
PV15 exceeds 1200 psi (83 bar) and the pilot-operated sequence valve
PV15 shifts to allow oil to reach the rod end of the selector cylinders
CY6 and CY7 as well as the arm cylinders CY8 and CY9.
2. Arm cylinders CY8 and CY9 and selector cylinders CY6 and CY7 retract.

Troubleshooting/ Refer to "Troubleshooting/Testing," page 11-13.

Testing

11-15
 Pullback Mode D20x22 Navigator HDD Service

PULLBACK MODE
Extend Rod Loader Arm
REAR
SELECTOR
CYLINDER
CY6

FRONT
SELECTOR
CYLINDER
CY7

REAR
ARM
CYLINDER
CY8
Rod Loader

FRONT
To Tank To Pin 6C of ARM
Controller A1 CYLINDER
RES1
CY9

REAR
PV14 ROD LIFT
DV21
CYLINDER
CY10

L15
DV22
FRONT
PV15 ROD LIFT
CYLINDER
L16 CY11

From PMP3
To Pin 6D of
Controller A1

+12v from Pin D4

of Controller A1

NOTE: Notice that rod loading cylinders CY6–CY9 and CY10–CY11 are
connected in parallel. If a cylinder fails or a leak occurs, other cylinders may
be affected.

Continued on next page...

11-16
D20x22 Navigator HDD Service Pullback Mode

Operation • Remote Lockout system must be in

normal Run mode. 2

• Engine must be running at full

throttle.
• Switch S16 must be in Pullback
mode.

1
Once all required operating conditions
have been met and drill rod has been
completely pulled out of bore hole:

1. Engage front vise by activating the front vise engage button (1). This
causes the front vise to clamp onto female end of drill rod.
2. Operator then presses and holds this button in to allow the rear vise to
clamp and rotate drill rod to loosen it from drill string. Once operator
releases button, rear vise will return to NEUTRAL.
3. Once rod is unscrewed from drill string, operator selects rear vise engage
button/rod loader arm extend button (2). This sends an input to the

Rod Loader
console controller A2, which in turn does a number of things
simultaneously.
• Rear vise is activated, thus allowing operator to unscrew drive chuck
from rod.
• Coil L13 of DV20 is energized by controller A1, allowing oil to flow to
PV14 and to flow through DV21 to the base end of rod lift cylinders
CY10 and CY11. Flow from the rod end of CY10 and CY11 flows
through DV22.
• Once cylinders CY10 and CY11 are fully extended, pressure at PV14
exceeds 1200 psi (83 bar). Pilot-operated sequence valve PV14 shifts to
allow oil to reach the base end of the selector cylinders CY6 and CY7 as
well as the arm cylinders CY8 and CY9.
• Arm cylinders CY8 and CY9 extend into position to retrieve rod from
drill string.

Troubleshooting/ Refer to "Troubleshooting/Testing," page 11-13.

Testing

11-17
 Pullback Mode D20x22 Navigator HDD Service

Retract Rod Loader Arm

REAR
SELECTOR
CYLINDER
CY6

FRONT
SELECTOR
CYLINDER
CY7

REAR
ARM
CYLINDER
CY8

FRONT
Rod Loader

To Tank +12v from Pin 6C ARM

RES1 of Controller A1 CYLINDER
CY9
REAR
PV14 ROD LIFT
DV21 CYLINDER
CY10

L15
DV22
FRONT
PV15 ROD LIFT
CYLINDER
L16
CY11

From PMP3
To Pin 6D of
Controller A1

To Pin D4
of Controller A1

Continued on next page...

11-18
D20x22 Navigator HDD Service Component Repair

Operation • Remote Lockout system must be in normal Run mode.

• Engine must be running at full throttle.
• Switch S16 must be in Pullback mode.
1. Once rod is removed from drill
string, the operator presses rod 1
loader arm retract button (1). This
also does several things in sequence.
• Rear vise clamp is released.
• Coil L11 of DV20 is energized by
controller A1, allowing oil to flow to
PV15 and through DV22, to the rod
end of rod lift cylinders CY10 and
CY11. Flow from the base end of
CY10 and CY11 flows through
DV21.
• Once rod lift cylinders CY10 and
CY11 are fully retracted, pressure at PV15 exceeds 1200 psi (83 bar)
and the pilot-operated sequence valve PV15 shifts to allow oil to reach
the rod end of the selector cylinders CY6 and CY7 as well as the arm
cylinders CY8 and CY9.

Rod Loader
2. Arm cylinders CY8 and CY9 and selector cylinders CY6 and CY7 retract,
bringing rod to rack.

Troubleshooting/ Refer to "Troubleshooting/Testing," page 11-13.

Testing

COMPONENT REPAIR
Pump PMP3
Refer to "PFC Pump PMP3 High and Low Pressure Compensator Adjustment,"
page 4-24.

If PMP must be replaced, refer to "PMP3 Replacement," page 4-37.

11-19
 Component Repair D20x22 Navigator HDD Service

Rod Loader Valve Assembly A14

PV14
L15
DV21 L11
L13
DV20

DV22
L16 PV15
Solenoids L11, L13, These coils and valves are located on rod loader valve assembly A14. A14 is
L15, L16 located below the rack about halfway up the machine.

Valves DV20, PV14, 1. Remove nut which secures coil to valve.

PV15, DV21, DV22
Rod Loader

2. Remove coil from valve and replace if necessary.

3. Remove valve from manifold and check for damage or contamination. If
necessary, replace.
4. Use the following torque specifications.
• All solenoid retaining nuts – 5 ft-lb (7 Nm).
• DV20 – 25 ft-lb (35 Nm)
• DV21, DV22 – 23 ft-lb (32 Nm)
• PV14, PV15 – 20 ft-lb (27 Nm)

11-20
D20x22 Navigator HDD Service Component Repair

Rod Lift Cylinders CY10 and CY11

Remove rod box to gain access to these cylinders.

1 CY8
2 3

CY6
5

7
6
lift plate retaining
bolt goes here

CY10

Rod Loader
1. Label and disconnect hoses. Cap all open hoses and fittings.
2. Remove bolt (4) holding the rod lift plate (7) to the cylinder rod.
3. Remove four bolts (8) holding the cylinder to the frame.
4. If replacing the cylinder, remove hose fittings from the old cylinder and
install them in the new cylinder. Torque fittings to 9.5 ft-lb (12.9 Nm).

If rebuilding the cylinder, refer to parts book for rebuild/repair kit and
cylinder repair procedures can be found in the Technician’s Shop Manual.
5. Reattach cylinder to the frame. Torque the four mounting bolts evenly to
90 ft-lb (122 Nm).
6. Install bolt (4) holding rod lifter plate to cylinder rod.
7. Connect hoses to fittings and torque them to 90 ft-lb (122 Nm).

11-21
 Component Repair D20x22 Navigator HDD Service

Rod Loader Shift Cylinders CY8 and CY9

1. Label and disconnect hoses. Cap all open hoses and fittings.
2. Remove bolts holding ends of cylinder to frame and sliding arm. Note
number and placement of washes on each bolt.
3. If replacing the cylinder, note orientation of fittings. Remove hose
fittings from the old cylinder and install them in the new cylinder.
Torque fittings to 9.5 ft-lb (12.9 Nm).

If rebuilding the cylinder, refer to parts book for rebuild/repair kit and
cylinder repair procedures can be found in the Technician’s Shop
Manual.
4. Reverse steps 1–3 to install the cylinder. Torque mounting bolts to 35 ft-
lb (47 Nm). Torque hoses to the fittings to 9.5 ft-lb (12.9 Nm).

Rod Loader Selector Cylinders CY6 and CY7

1. Remove top nut from lift plate restraint bolt (not shown in drawing).
2. Remove bolt (4) holding lift cylinder rod to lift plate (7) selector plate.
Rod Loader

3. Remove bolt (5) holding rear pin (3) in rod selector plate (6).
4. Drive out roll pin (2) holding front pin (1) in rod selector plate (6).
5. Raise the rod lift plate assembly high enough to remove the front and
rear pin from the selector plate.
6. Lift selector plate and selector plate cylinder high enough to label and
disconnect hoses to selector plate cylinder. Cap all open hoses and
fittings.
7. Move selector plate and selector plate cylinder to bench.
8. Remove long hose fittings from cylinder. Remove cylinder from selector
plate.
9. If replacing the cylinder, remove hose fittings from the old cylinder and
install them in the new cylinder. Torque fittings to 9.5 ft-lb (12.9 Nm).

If rebuilding the cylinder, refer to parts book for rebuild/repair kit and
cylinder repair procedures can be found in the Technician’s Shop Manual.
10. Reverse steps 1–8 to install cylinder and selector plate. Torque fittings to
CY9 or CY10 to 9.5 ft-lb (12.9 Nm). Torque hoses to fittings to 9.5 ft-lb
(12.9 Nm).

11-22
D20x22 HDD Navigator Service Overview

Chapter 12: Drilling Fluid

OVERVIEW
This chapter consists of the functions and components necessary to supply
the drill string with drilling fluid while drilling. The Drilling Fluid function
is supplied by the implement pump PMP3.

Functions/Components
Functions The following functions are included in this chapter:

• Drill Fluid

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

Drilling Fluid
• Water Pump Drive Motor MH9
• PFC Pump PMP3
• Valve Assembly A12 Including
• Full Flow Valve DV31
• Full Flow Solenoid L12
• Pressure Relief PV12
• Water On/Off Valve DV32
• Water On/Off Solenoid L18
• Flow Control Valve FV1
• Ball Valve Control Valve DV23
• Ball Valve Control Solenoid L17
• Ball Valve Cylinder CY12
• Water Flow Meter DS7
• Water ON Light DS8
• Water Control Switch S10
• Water Motor Speed Pickup B3

12-1
 Overview D20x22 HDD Navigator Service

Specifications
Listed below are the electrical and hydraulic specifications for the drill fluid
functions.

Electrical:

• Nominal circuit voltage - 12 volts DC.

• Drill valve assembly A12 solenoid coils L12, L18, and L17, resistance -
4.3 ohms @ 68°F (20°C).
Hydraulic:

• Water pump PMP4 rotation speed at full flow - 400 rpm.

• Pump PMP3 normal output flow - variable to 20 gpm (76 L/min).
• Pump PMP3 load sense spool setting - 250 psi (bar).
• Pump PMP3 high pressure compensator setting - 3200 psi (217 bar).
• Drill fluid valve assembly A12 relief valve PV12 pressure setting - 2350
psi (172 bar).
Drilling Fluid

12-2
D20x22 HDD Navigator Service Overview

Component Locations

Drilling Fluid
PFC Pump
PMP3

12-3
 Overview D20x22 HDD Navigator Service

WATER PUMP DRIVE MOTOR MH9

WATER FLOW
CONTROL VALVE
DV32

PRESSURE
RELIEF VALVE
PV12

WATER FULL FLOW

VALVE DV31
Drilling Fluid

WATER FLOW
METER DS7

WATER ON
LIGHT DS8

12-4
D20x22 HDD Navigator Service Overview

WATER FLOW
Hose Connections SWITCH S5 METER DS7

VALVE ASSEMBLY A12

TANK RES1

Drilling Fluid
MOTOR MH9

PUMP PMP3

CYLINDER
CY12

VALVE
ASSEMBLY
A24

12-5
 Overview D20x22 HDD Navigator Service

Electrical Schematic
FUSE F5

WATER MOTOR
SPEED PICKUP B3

BAT 1 GROUND DISCONNECT

SWITCH S1
FUSE F3 RELAY K2
CIRCUIT A2
BREAKER
WATER CB2
CONTROL
SWITCH S10

FRONT VISE
SWITCH S13
Drilling Fluid

WATER ON
LIGHT DS8

A1

FULL FLOW
SOLENOID L12

TO GROUND

BALL VALVE
CONTROL SOLENOID L17

WATER ON/OFF SOLENOID L18

12-6
D20x22 HDD Navigator Service Overview

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.

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
"Machine Performance," page 12-9.

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

Drilling Fluid
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 wires 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...

12-7
 Overview D20x22 HDD Navigator 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 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.
Drilling Fluid

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.

12-8
D20x22 HDD Navigator Service Overview

Machine Performance
Possible faults may occur in the drilling fluid functions 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.

Therefore the preferred way to troubleshoot any problems that occur in the
drilling fluid circuits is to operate all the functions of the machine and
document the performance of the working actuators.

Make note of any functions not operating normally based on the theory
given in each chapter for that function. Comparing the results with the
normal operation given for each mode of a particular function will help to
isolate the problem.

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.

Drilling Fluid
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:
• Refer to "Engine," page 3-8.
• Refer to "Overview," page 4-1.

2. If faults are noted in the Drilling Fluid function, as well as the Vise,
Rack Angle/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 PMP3," page 4-16.
3. If faults are noted in only the Drilling Fluid function and all other
functions are OK, the hydraulic components common to just the Drilling
Fluid function should be investigated:
• "Drill Fluid Valve Assembly A12," page 12-12.
• "Water Pump PMP4," page 12-14.
• "Water Pump Motor MH9," page 12-15.

12-9
 Overview D20x22 HDD Navigator Service

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 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.

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
Drilling Fluid

or other chapters where instructed. After repairs have been made, refer
to"Hydraulic Fluid Sampling," page 4-19 and follow instructions.

12-10
D20x22 HDD Navigator Service Drilling Fluid Hydraulic Circuit

DRILLING FLUID HYDRAULIC CIRCUIT

SOLENOID L17
CYLINDER CY12
VALVE
DV23

FULL FLOW PRESSURE

SOLENOID L12, RELIEF PV12
VALVE DV31

PMP4

MOTOR MH9
A12

Drilling Fluid
FLOW VALVE
FV1

WATER ON/OFF
SOLENOID L18,
VALVE DV32

PUMP
PMP3

12-11
 Drilling Fluid Hydraulic Circuit D20x22 HDD Navigator Service

Pump PMP3
Refer to "Pump PMP3," page 8-10.

Compensator
Refer to "Compensator," page 8-11.

Drill Fluid Valve Assembly A12

Operation Flow from pump PMP3 enters the drill fluid valve assembly A12 where it is
directed to the water ball valve and to the motor which operates the water
pump PMP4. Directing this flow is accomplished by two coil-operated valves
DV31 and DV32.

When solenoid L18 is energized by controller A1, the spool in valve DV32 is
shifted which allows oil to flow to water pump motor MH9. When solenoid
L12 is energized by controller A1, the spool in valve DV31 shifts and
increases the flow already provided by DV32. Pressure relief PV12 opens to
Drilling Fluid

tank when pump drive circuit pressure exceeds 2350. This protects water
pump motor MH9.

TO LOAD SENSE PORT ON PUMP

L12
PV12

To Tank RES1
DV31

L18

To PMP4
DV32

FV1

From PMP3

12-12
D20x22 HDD Navigator Service Drilling Fluid Hydraulic Circuit

Troubleshooting/ Before beginning any troubleshooting or testing procedures, perform the

Testing "Pretest Inspection," page 12-7. If nothing obvious is found, continue.

1. In order to ensure the fault is isolated to just the drilling fluid function,
the technician should operate all machine functions and observe the
actuators as discussed in "Machine Performance," page 12-9.
2. If any functions other than drilling fluid 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. Test for acceptable voltage starting at coil L18 of DV32. If voltage is

acceptable, continue with step 4. If not, continue with step 7.
4. Test resistance of solenoid coil L18.
Expected result: Resistance should measure 4.3 ohms @ 68°F (20°C). If
OK, continue. If not, replace coil.

5. Test for acceptable voltage at coil L17 of DV23. If voltage is acceptable,

Drilling Fluid
continue with step 11. If not, continue with step 10.
6. Test resistance of solenoid coil L17.

Expected result: Resistance should measure 4.3 ohms @ 68°F (20°C). If

OK, continue with step 7. If not, replace coil.
7. 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 min.), repair or replace faulty component(s) or wire harness
segment(s).
8. Remove and inspect cartridge valves in drilling fluid valve assembly
A12. Refer to component repair section for cartridge torque settings.
Repair or replace any faulty components. If valve assembly is OK,
continue.

12-13
 Drilling Fluid Hydraulic Circuit D20x22 HDD Navigator Service

Water Pump PMP4

Operation Water pump
PMP4 is PMP4
responsible for
supplying drilling
fluid to the drill
head. This pump
is hydraulically
driven by a
hydraulic motor
MH9. MH9 drives
the pump at
variable speeds,
depending on the
amount of flow
MH9 receives
from the drill
fluid valve
assembly A12. MH9
Drilling Fluid

12-14
D20x22 HDD Navigator Service Drilling Fluid Hydraulic Circuit

Water Pump Motor MH9

Operation Motor MH9 is a
5.0 cid (82 cc)
displacement
MH9
motor responsible
for powering
water pump
PMP4.

The pump
receives hydraulic
fluid from
implement pump
PMP3, which first
must be allocated
by drill fluid valve
assembly A12. In
variable flow
mode, the
operator controls
the amount of
fluid reaching

Drilling Fluid
MH9 by adjusting
flow valve FV1.

In full flow mode,

MH9 operates at
400 rpm and flow control valve FV1 is bypassed. Pressure relief valve PV1
limits pressure in the circuit to 2350 psi (162 bar).

12-15
 Drill Fluid OFF D20x22 HDD Navigator Service

DRILL FLUID OFF

SOLENOID L17

CYLINDER CY12
VALVE
DV23
FULL FLOW
SOLENOID L12,
VALVE DV31 PRESSURE
RELIEF PV12
A12

PMP4

MOTOR MH9
Drilling Fluid

FLOW VALVE
FV1

WATER ON/OFF
SOLENOID L18,
VALVE DV32

From PMP3

Operation To turn drill fluid OFF:

• Push Fluid ON/OFF/Full Flow button S10 a second time.

• Drilling fluid pump PMP4 will stop.
• Fluid ON indicator DS8 will turn OFF.
• Motor MH9 will stop.

Troubleshooting/ If drilling fluid OFF mode does not operate as expected, refer to
Testing "Troubleshooting/Testing," page 12-19.

12-16
D20x22 HDD Navigator Service Drill Fluid ON

DRILL FLUID ON
Variable Flow Mode
When operator turns drilling fluid ON, by pressing the Water Control switch
S10 once (momentary switch), controller A1 energizes coils L18 and L17.

Solenoid L14 shifts DV23 to send flow to extend cylinder CY12, which turns
on ball valve.

Solenoid L18 shifts DV32 to passing position, and flow passes through FV1
to the motor. FV1 is manually adjusted to provide desired flow. A pulse
pickup reads rotation speed of motor to pump driveshaft and translates that
into flow, displayed on digital readout panel.

+12v from Pin D7

of Controller A1 SOLENOID L17

CYLINDER CY12 VALVE

DV23

FULL FLOW

Drilling Fluid
SOLENOID L12, PRESSURE
VALVE DV31 RELIEF PV12

PMP4

MOTOR MH9

FLOW VALVE
FV1

WATER ON/OFF
SOLENOID L18,
VALVE DV32

RES1
From PMP3

Continued on next page...

12-17
 Drill Fluid ON D20x22 HDD Navigator Service

Required Operating To operate drill fluid ON mode:

Conditions
• Operator must be seated at
drill controls. 1
2
• Remote Lockout system
must be in normal RUN
mode.
• Engine must be running at
full throttle.
• Drill Fluid ON/OFF/Full
Flow switch S10 on left
joystick (1) must be pressed
once.
• Flow amount is controlled by
FV1 (2).

Operation Variable drilling fluid flow is enacted when the drill operator presses the
Drill Fluid ON/OFF/Full Flow button S10, located on the left joystick. By
pressing this button once, a signal is sent to the console controller A2.
Drilling Fluid

Controller A2 sends this signal through the controller-area-network (CAN)

so that it reaches the engine bay controller A1.

The engine bay controller then energizes coil L18 of DV32 and coil L17 of
DV23, which are located in the drilling fluid valve A14. When coil L18 shifts
DV32, hydraulic fluid from the implement pump PMP3 is allowed to pass
through flow control valve FV1 where the operator controls flow amount.
From FV1, oil reaches the water pump motor MH9. The amount of oil to
reach MH9 determines how much drilling fluid the water pump PMP4 can
send to the drill head.

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D20x22 HDD Navigator Service Drill Fluid ON

Troubleshooting/ Before beginning any troubleshooting or testing procedures, perform the

Testing "Pretest Inspection," page 12-7. If nothing obvious is found, continue.

1. In order to ensure the fault is isolated to just the drilling fluid function,
the technician should operate all machine functions and observe the
actuators as discussed in "Machine Performance," page 12-9.
2. If any functions other than drilling fluid function are faulty, continue
troubleshooting based on the possible results given. If all other machine
functions are operating normally, continue.
NOTE: Refer to the Technician’s Shop Manual (Vermeer P/N 105400V80) for
helpful information on testing electrical circuits for shorts, opens, and high
resistance.

3. With engine at full throttle, slowly rotate flow control valve FV1 knob to
full flow and observe flow meter DS7 and pressure gauge GA1.

Expected result: Water flow meter DS7 should show an increasing flow in
GPMs in proportion to the position of the control valve knob of FV1.
Pressure gauge GA1 should indicate a somewhat low pressure.

Pressure can vary based on flow rates and nozzle sizes used in tooling. A

Drilling Fluid
maximum indication of 2000 psi (138 bar) on drilling fluid pressure
gauge could be an indicator that flow has become restricted (drill head
clogged). If maximum pressure is indicated, continue with step 4.
4. If plugged drill rod is suspected, shut down machine. Ensure drill rod
joint has been broken to relieve drilling fluid pressure in drill string
before unclogging or removing nozzle.

WARNING: Relieve drilling fluid pressure in the drill string before cleaning out
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.

5. Clean drill head nozzle with tip cleaner.

6. Ensure front vise is unclamped. When front vise is clamped, controller
A1 automatically turns water function OFF.
Continued on next page...

12-19
 Drill Fluid ON D20x22 HDD Navigator Service

7. Refer to "Troubleshooting," page 12-23 for information on troubleshooting

drill fluid valve assembly A12.
8. Disconnect rod of water ball cylinder CY12 from ball valve. Attempt to
rotate ball valve by hand.

Expected result: The valve turns on and off. If so, continue. If not, replace
ball valve.
9. With ball valve still disconnected from cylinder, start machine and watch
cylinder CY12 as you turn water switch S10 ON and OFF. If cylinder
does not function, or appears to be operating erratically, replace cylinder
CY12. If OK, continue
10. Test hydraulic circuit starting with drive motor MH9 for excessive
internal leakage. Refer to the Industrial Dealerships Technician’s Shop
Manual (Vermeer P/N 105400V80) for helpful information on testing
hydraulic motors. If motor tests OK, continue.
11. Remove and inspect cartridge valves in drilling fluid valve assembly
A12. Refer to component repair section for cartridge torque settings.
Repair or replace any faulty components. If valve assembly is OK,
continue.
12. Test pump PMP3 for excessive internal leakage. Refer to Industrial
Drilling Fluid

Dealerships Technician’s Shop Manual (Vermeer P/N 105400V80) for

helpful information on testing hydraulic pumps. If pump tests OK,
continue.
13. Disassembly and inspect drilling fluid pump PMP4 for damage or
contamination. Refer to component repair section for information. Repair
or replace if necessary.

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D20x22 HDD Navigator Service Drill Fluid ON

Full Flow Mode

+12v from Pin D7

of Controller A1 SOLENOID L17
CYLINDER CY12
VALVE
+12v from Pin C7 DV23
FULL FLOW of Controller A1
SOLENOID L12,
VALVE DV31
PRESSURE
RELIEF PV12

PUMP PMP4

MOTOR MH9

Drilling Fluid
FLOW VALVE
FV1
WATER ON/OFF
SOLENOID L18,
VALVE DV32

From PMP3

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 Drill Fluid ON D20x22 HDD Navigator Service

Operation To operate drill fluid ON mode:

• Operator must be seated at drill

controls. 1

• Remote Lockout system must be in

normal RUN mode.
• Engine is running at full throttle.
• Drill Fluid ON/OFF/Full Flow
switch S10 on left joystick (1) must
be pressed and held for two seconds
to enable Full Flow mode.
Variable drilling fluid flow is enacted when the drill operator presses the
Drill Fluid ON/OFF/Full Flow button S10, located on the left joystick. By
pressing this button once, a signal is sent to the console controller A2.
Controller A2 sends this signal through the controller-area-network (CAN)
so that it reaches the engine bay controller A1.

The engine bay controller then energizes coil L18 of DV32 and coil L17 of
DV23, which are located in the drilling fluid valve A14. When coil L18 shifts
DV32, hydraulic fluid from the implement pump PMP3 is allowed to pass
through flow control valve FV1 where the operator controls flow amount.
Drilling Fluid

From FV1, oil reaches the water pump motor MH9.

When S10 is pressed and held down, coil L12 of DV31 shifts allowing oil
under 2350 psi (162 bar) to bypass FV1 and go straight to motor MH9. This
allows maximum flow to reach the water pump drive motor which sends the
maximum amount of drilling fluid to the drill head. Full flow light on
controller lights up.

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D20x22 HDD Navigator Service Drill Fluid ON

TROUBLESHOOTING
If Remote Lockout system is in LOCKOUT mode, the controllers will not
allow the water pump motor to run or the water control ball valve to open.
Put the system in RUN mode before troubleshooting problems with the
water pump circuits.

When the controller sends an output to clamp the front vise, it turns off the
water flow by de-energizing solenoids L18, L12 and L17 if they happen to be
energized. Press the button farthest right on the right joystick to ensure the
front vise is disengaged.

Check Controllers First

The controllers each have LEDs on the faceplate that assist in
troubleshooting.

View the controller faceplates and LEDs, see "Controllers A1 and A2," page 2-
13. A1 is the engine bay controller. A2 is the console controller. The LEDs in
the rear area of the faceplate indicate the control is sending an output. The

Drilling Fluid
LEDs in the front area indicate the control is receiving an input.

The Water & B.V. LED (output) on engine bay controller A1 indicates the
controller is sending voltage to solenoids L18 and L17. These solenoids shift
valves that operate the water pump and the water on/off ball valve.

The Water LED (output) on A2 indicates the controller is sending voltage to

drilling fluid indicator light DS4 on the console.

The Water On/Off LED (input) on A2 indicates the controller is receiving

voltage from switch S10 at pin A10.

A “D.” in the fault window of engine bay controller A1 indicates a fault for
the water full flow solenoid L12.

An “H.” in the fault window of engine bay controller A1 indicates a fault for
the water flow and ball valve solenoids L18 and L17.

12-23
 Drill Fluid ON D20x22 HDD Navigator Service

Ball Valve Not Turning On/Off

1. With ignition switch S4
turned ON, observe Water
On/Off LED on the console
controller A2 while
repeatedly pressing and
releasing water on/off switch
S10 on the left joystick.
Expected result: Water
On/Off LED will turn on and
off. Pressing and releasing S10
the button once turns it on,
pressing it again turns it off.

If so, continue below.

If not, look at the fault code window. An “H.” indicates a problem with the
solenoids L18 or L17 or the wiring leading to and from these solenoids. If
there is no “H.”, troubleshoot the switch. See "Troubleshooting the Water
On/Off Switch," page 12-36.
Drilling Fluid

2. Disconnect solenoid L17. Measure voltage to the solenoid L17 when the
Water & B.V. LED on engine bay controller is glowing.
Expected result: 12 volts DC, ± 12.v DC. If so, continue below.

If not, test continuity from solenoid to controller and from solenoid to

ground. If open, repair or replace faulty segment.

Continued on next page...

12-24
D20x22 HDD Navigator Service Drill Fluid ON

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.

3. Measure resistance across solenoid terminals.

Expected result: 9.8 Ω, ± 1.0 Ω. If so, continue below. If not, replace
solenoid. See "Fluid Shutoff Valve Assembly A24," page 12-39.

4. Disconnect rod of the cylinder CY12 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.

Drilling Fluid
5. With the ball valve still disconnected from the cylinder, start machine
and watch cylinder CY12 as you turn water switch S10 ON and OFF.
Expected result: The cylinder will smoothly extend when water is turned
on, and smoothly retract when water 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 CY12. 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.

Continued on next page...

12-25
 Drill Fluid ON D20x22 HDD Navigator Service

6. Shut down machine, disconnect hoses to the cylinder CY12, and connect
them reversed. Restart machine and watch the cylinder. Also watch
Water On indicator on the console so you can tell when switch is turned
on and off.
Expected result: The water 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 water switch ON. If cylinder
does not retract, replace valve DV23 ("Fluid Shutoff Valve Assembly A24,"
page 12-39).

If the cylinder was retracted and did not extend, shut down and remove
and inspect all lines to and from the valve DC23 and the cylinder CY12
for obstructions. Replace lines if needed.

If the cylinder was extended at startup, turn the water switch ON, then
OFF again a few seconds later. If cylinder CY12 retracts then extends
again, valve DV23 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 DV23.
Drilling Fluid

12-26
D20x22 HDD Navigator Service Drill Fluid ON

Water 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 the farthest right
button on the right joystick.
• Ensure Remote Lockout system is in RUN mode.
• Ensure flow control valve FV1 is turned open. If not, open it. If FV1 is
partially open, but flow volume does not change when adjusting the
handle of FV1, replace flow control valve FV1.
• Observe ball valve cylinder CY12 as water is turned on to ensure ball
valve is being opened. If not, troubleshoot that circuit. See
"Ball Valve Not Turning On/Off," page 12-24.
• If water is mixed with additives to create drilling mud, there may be a
clog in the water line at the ball valve between the ball valve and the
outlet at the gearbox. Also, if antifreeze is not used during cold weather,
water in the line can freeze. The blockage may cause resistance in excess
of the pressure relief setting of PV12 (2350 psi or 162 bar). Disconnect
water line at the inlet side ball valve and try pumping water again. If it
flows, clean out the water line on the outlet side of the ball valve.

Drilling Fluid
After checking those things, continue below.
Continued on next page...

12-27
 Drill Fluid ON D20x22 HDD Navigator Service

1. Start machine, run engine at

2400 rpm and watch 1
pressure gauge (1) as you
turn on the water using
switch S10. Indicator DS8
will glow when water is
turned ON. DS4
Expected result: After start-
up, the indicated pressure S10
will indicate standby setting
of the compensator on the
pump PMP3, about 250 psi
(17 bar). When the switch
S10 is turned ON, the
pressure will dip, then rise as the pump comes on stroke.

If the pressure reaches 2350 psi, ± 50 psi (162 bar, ± 3.5 bar) and stays
there, pump flow is going over the relief valve PV12, probably due to
resistance in the water pump. Clean or rebuild water pump PMP4.

If the pressure rises to some value below 2300 psi (158 bar) and stays
there, flow is going over relief, but the relief is opening too soon. Replace
Drilling Fluid

relief valve PRL3.

If the pressure remains at its original setting, the valve DV32 is not
shifting or FV1 has failed in the closed position. Continue below.

2. With the water turned ON (check DS8), press and hold S10 to turn on
FULL FLOW. Observe pressure gauge and output from the water pump.
Expected result: The water pump PMP4 will turn at full speed. If so, the
PFC pump PMP3 is working normally. Continue at the next step.

If not, check fault code window on the engine bay controller. If it shows
“D.”, troubleshoot solenoid L12 for the full flow circuit. See page "Full
Flow Switch Does Not Increase Speed of Water Pump," page 12-31.

If there is no fault code, check the pressure gauge PG3. If it reads 2350
psi, ± 50 psi (162 bar, ± 3.5 bar), clean or rebuild the water pump PMP4.
If it indicates less than 2300 psi (158 bar), the PFC pump PMP3 may be
worn beyond requirements.

Continued on next page...

12-28
D20x22 HDD Navigator Service Drill Fluid ON

3. Shut down machine, then turn key switch S4 to ON. Observe Water &
B.V. LED on the engine bay controller A1 while repeatedly pressing and
releasing the water on/off switch (1) on the left joystick.
Expected result: Water & B.V. LED will turn on and off. Pressing and
releasing the button once turns it ON, pressing it again turns it OFF.

If so, switch S10 is good, and the wiring to the controllers is good.
Continue below.

If not, troubleshoot switch S10. See "Troubleshooting the Water On/Off

Switch," page 12-36.

4. Disconnect solenoid L18. Measure voltage to the solenoid L18 when the
Water & B.V. LED on engine bay controller is glowing.
Expected result: 12 volts DC, ± [Link]. If so, wiring from the controller
to the solenoid L18 and from L18 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.

Drilling Fluid
Expected result: 9.8 Ω, ± 1.0 Ω. If so, solenoid is apparently good.
Continue below. If not, replace solenoid L18.

The last two candidates for the

faulty item are the valve DV32, DV31
L12 DV32
and the flow control valve FV1.
PV12
NOTE: Due to clearances
between the top of the manifold
A12 and top of the engine bay, to
L18
perform the next two steps you
need to remove the two screws
holding A12 to the wall of
A12
engine bay.
FV1
6. Label or mark solenoid L18.
Remove the retaining nut on
DV32 and slide solenoid L18
off the valve. Do the same for solenoid L12 on DV31.
Continued on next page...

12-29
 Drill Fluid ON D20x22 HDD Navigator Service

7. Valves DV32 and DV31 are

identical. Remove them and DC22
DV31
L12
L9 DC21
DV32
swap them (see"Valve
PRL3
PV12
Assembly A12," page 12-38
for remove and install
instructions). Replace
solenoids, start machine and
L18
L8
test to see if regulated water
flow now works.
Expected result: Water turns A13
A12
on and flow (water pump
motor speed) can be FC1
FV1
controlled by adjusting FV1.

If so, replace the faulty valve

(which is now installed in the cavity for DV31).

If not, replace the flow control valve FV1 ("Drill Fluid Valve Assembly
A12," page 12-12).
Drilling Fluid

12-30
D20x22 HDD Navigator Service Drill Fluid ON

Full Flow Switch Does Not Increase Speed of Water Pump

If regulated water flow also does not work, troubleshoot it first—see
"Water Pump Motor Does Not Turn at Regulated Speed," page 12-27. If
regulated water flow is working, continue below.

1. Press S10 once to turn on the regulated water flow. The water flow
indicator DS7 on the control console will glow when regulated flow is
turned on. Watch the “Full Flow” LED on the engine bay controller while
pressing and holding S10.
Expected result: The Full Flow LED will glow. If so, continue below.

If not, troubleshoot the Water On/Off switch S10. See "Troubleshooting

the Water On/Off Switch," page 12-36.

2. Disconnect solenoid L12. Measure voltage to the solenoid L12 when the
Full Flow LED on engine bay controller is glowing.
Expected result: 12 volts DC, ± [Link]. 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 D4 of the controller to solenoid connector

Drilling Fluid
and from solenoid connector to ground. If open, repair or replace the
faulty segment.

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 L12. See "Valve Assembly
A12," page 12-38.

NOTE: Due to clearances

between the top of the manifold DC22
DV31
L12
L9 DC21
DV32
A13 and top of the engine bay, to
PRL3
PV12
perform the next two steps you
need to remove the two screws
holding A12 to the wall of
engine bay.
L18
L8
4. Label or mark solenoid L12.
Remove the retaining nut on
A13
A12
DV31 and slide solenoid L12
off the valve. Do the same for
FC1
FV1
solenoid L18 on DV32.

Continued on next page...

12-31
 Drill Fluid ON D20x22 HDD Navigator Service

5. Valves DV31 and DV32 are

identical. Swap them, start DC22
DV31
L12
L9 DC21
DV32
machine and test to see if
PRL3
PV12
full flow works.
Expected result: Full flow
works. If so, replace valve
that is now installed in the L18
L8
cavity for DV32.

If not, perform a flow test for A13

A12
the PFC pump test
procedure. FC1
FV1

If the pump is worn beyond

limits, replace pump (see
"Pump PMP3," page 12-36).

If the pump appears to be in good condition, the water pump drive motor
may need to be replaced. Test motor MH9 that is driving the water
pump. See test procedure on the following page.
Drilling Fluid

Water 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 PV12 in A12 is opening at a lower setting. Install pressure gauge at
port G on manifold A12. If pressure indicated on gauge indicates 2350 psi, ±
50 psi (162 bar, ± 3.5 bar) while pumping water at full flow (or regulated
flow), examine the water pump PMP4 to determine why it is producing so
much resistance. If the indicated pressure on PG3 is comfortably below 2350
psi (162 bar), continue with the flow test on the following page.

12-32
D20x22 HDD Navigator Service Drill Fluid ON

Flow Test of Motor 1. The results of this test depend on the water flow meter DS13 being
MH9 properly calibrated. The “rate dsp” must be 60 and the “rate inp” must be
833.3 for the meter to give accurate measurements.
2. Attach a 15 gpm flow meter to the outlet of motor MH9. Ensure flow
arrow on the meter points away from the motor and towards the hose
connected to the tank RES1.

from A12
MH9

flow meter 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.

3. Start machine, and run engine at 2400 rpm. Record engine RPM on the
worksheet.
4. Press water flow switch S10 once to turn on the water flow. Press and
hold it to turn on full flow. Observe water flow meter DS7 on the control

Drilling Fluid
console and note the flow indicated. Record it on the worksheet next to
“Water flow indicated on DS7”.
5. While still pumping water at full flow, note the flow on the flow meter
from MH9 to tank. Record it on the worksheet next to “Hydraulic flow
indicated on flow meter”.
6. Shut down machine.
7. Complete the calculations described on the following worksheet. A
simple pocket calculator will be useful.

12-33
 Drill Fluid ON D20x22 HDD Navigator Service

Worksheet for Flow Test of Motor MH9

A. Water flow indicated on DS7_______________gpm

B. Hydraulic flow indicated on flow meter____________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 5.0. This is the theoretical speed
of the output shaft of motor MH9. 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 water pump produces approximately 0.036 gallons of water flow
for every revolution, the water flow meter divides the RPM recorded by the
Drilling Fluid

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
Results item F (new and worn rpm). If the actual rpm falls between these two
values, the motor wear appears to be within limits. Search for another cause
for slow water pump speed.

If the actual speed (item G) is at or below the worn speed (item F), replace
the motor MH9. See "Drill Fluid Motor MH9," page 12-37.

12-34
D20x22 HDD Navigator Service Drill Fluid ON

Water Flow Meter Not Working

1. With the key switch S4 turned ON, disconnect
the connector from the water pump motor pulse 112
pickup B3. Measure voltage from the pin for 724
wire 112 to wire 300.
Expected result: 12 volts DC, ± 1.2 vDC. If so,
continue below.
300
J418
If not, test continuity of wire 112 to fuse F3 and
wire 300 to the ground disconnect switch S1.
Repair or replace faulty segment.

2. Remove rear shield from the control console to access the back of the
water flow meter DS7.
3. Measure voltage on the terminals attached to wires 112-OR and 300-BK.
Expected result: 12 volts DC, ± 1.2 vDC. If so, continue below.

If not, test continuity of wire 112 to fuse F3 and wire 300 to the ground
disconnect switch S1. Repair or replace the faulty segment.

Drilling Fluid
4. Test continuity of wire 724-PK from speed pickup B3 to the terminal on
water flow meter DS7.
Expected result: Continuity. If so, replace water meter. If problem
persists, replace motor MH9 ("Drill Fluid Motor MH9," page 12-37). Sensor
B3 is built into the motor.

If not, repair or replace faulty harness segment.

Water Flow Meter If the flow meter is working, but is dark, test continuity of the wire 600-PU
Not Illuminated to the work lights switch S5 from the water meter. If continuity is good, the
LED inside the meter is faulty. It is integral to the meter, so the meter must
be replaced.

12-35
 Component Repair D20x22 HDD Navigator Service

Troubleshooting the Water On/Off Switch

1. Watch “Water On/Off ” LED on the faceplate of controller A2 while
repeatedly pressing the water switch S10.
Expected result: Starting with the LED dark, pressing and releasing the
switch once will turn water ON (LED glowing), pressing and releasing it
again will turn the water OFF (LED dark). When the water is ON,
pressing and holding switch S10 turns on full flow until switch is
released.

If so, switch S10 and wiring to and from the switch is working normally.

If not, continue below.

2. Disconnect left joystick at connector.

3. With the key switch S4 turned ON, test voltage at wire 112-OR from fuse
F3 to switch S10.
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

COMPONENT REPAIR
Pump PMP3
Refer to "PFC Pump PMP3 High and Low Pressure Compensator Adjustment,"
page 4-24.

If PMP must be replaced, refer to "PMP3 Replacement," page 4-37.

12-36
D20x22 HDD Navigator Service Component Repair

Drill Fluid Motor MH9

Drilling Fluid

12-37
 Component Repair D20x22 HDD Navigator Service

Valve Assembly A12

Disassembly 1. Disconnect electrical harness from solenoid.
2. Remove nut solenoid coil and
DV31 PV12
cartridge valve.
L12
3. Inspect seals and valve body
for contamination or wear.
Replace seals, if necessary.
Clean valve body. DV32
L18

FV1
Drilling Fluid

Assembly Install O-rings and backup rings on cartridge valves if needed.

Before installing components, apply a light coat of petroleum jelly to O-rings.

Torque cartridge valves DV31 and DV32 to 25 ft-lb (34 Nm).

Torque solenoid retaining nuts (1) on to 5 ft-lb 7 Nm).

Torque flow control valve FV1 to 25 ft-lb (34 Nm).

Torque pressure relief valve PV12 to 20 ft-lb (27 Nm).

12-38
D20x22 HDD Navigator Service Component Repair

Fluid Shutoff Valve Assembly A24

Removal 1. Label, disconnect and cap all hoses and
1
fittings.
2. Disconnect electrical wiring harnesses from 2
coil.
3. Remove bolts, washers, and nuts holding
valve to mounting plate. 3

Disassembly 1. Remove nut (1) solenoid coil (2) and cartridge valve (3).
2. Inspect O-rings and replace if necesary.

Drilling Fluid
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 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).

12-39
 Component Repair D20x22 HDD Navigator Service

Fluid Shutoff Cylinder CY12

4
3

1
Drilling Fluid

Remove 1. Label, disconnect 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) holding base end of cylinder to pin.
4. Remove nuts on studs holding ball valve to mounting flange.
Reverse steps to install. Torque bolt (6) to 90 ft-lb (120 Nm). Torque nuts on
ball valve studs to 30 in-lb (3.3 Nm).

12-40
D20x22 HDD Navigator Service Component Repair

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 the rod. Scarring the
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 Parts Manual for seal kit components. Apply a light coat
of petroleum jelly to seals before installation.
Reverse steps for assembly.

12-41
 Component Repair D20x22 HDD Navigator Service

Ball Valve
3

16

14

13
15

7 8 12
6 11
5
4
1
2 10
4 9
1

14
16
Drilling Fluid

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 2. Loosen four body studs, but remove only 3 studs (17). Swing out body
handle before center (9), using a stud as pivot. Remove support rings (13) and ball
disassembly. Also, ball (12), saving them for assembly. Remove and discard O-rings (15) and
must be rotated to the seat subassemblies (14).
closed position to
remove it. 3. Remove stem nut (1) and stem spring (4) holding lever arm on center
valve body (9). Discard the spring.
4. Remove grounding spring (2), nut (1), stem spring (4), and gland (5).
Discard the springs, gland and stem bearings.
5. Remove packing support (6). Carefully pry top and bottom packings (7)
and (8) out of the bore. Discard the packing support and packings.
Continued on next page...

12-42
D20x22 HDD Navigator Service Component Repair

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 the stem
threads.

2. Slide new stem bearings (10) on the stem and install the stem. Insert
ball (12) in the body center until the stem tang is engaged, rotating the
stem to the open position. The ball is now secure.
Keep the packings and 3. Push new bottom and top packings (8) and (7), followed by new packing
packing support straight support (6), into the packing bore.
during installation.
4. Place new gland (5) and two new springs (4) (convex sides facing each
other) on the stem.
5. Thread nut (1) on the stem; hold the stem with handle; and torque the
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).
handle must be Torque nut to 100 in-lb (11.3 Nm).
positioned as it was
before disassembly to IMPORTANT: Lubricate new O-rings (15) and new seat sub-assemblies
indicate the proper (14), using a silicone or Teflon based lubricant. Do not use a petroleum base
direction of valve flow. lubricant.

7. Place support rings (13) (chamfered sides toward the ball), seat
sub-assemblies (metal springs away from the ball) and O-rings in body
center (9).
8. Swing body center back into position. Install
body studs (17) and nuts. With valve in the 4 1
fully open position, torque studs in five stages,
using the 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

12-43
 Component Repair D20x22 HDD Navigator Service
Drilling Fluid

12-44
This page intentionally left blank.
 Component Repair D20x22 HDD Navigator Service
Drilling Fluid

12-46
D20x22 Navigator HDD Service Overview

Chapter 13: Rod Greaser

OVERVIEW
This chapter is comprised of information about circuits and components
necessary for operation of the optional auto rod greaser.

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

• PFC Pump PMP3

• Hydraulic Fluid Distribution Components
• Valve Manifold Assembly A21 Including:
• Grease Cylinder Control Valve DV27
• Grease Cylinder Control Solenoid L9
• Joystick Control Including:

Rod Greaser
• Auto Greaser Switch S15
• Greaser Cylinder CY15

13-1
 Overview D20x22 Navigator HDD Service

Component Locations
CYLINDER CY15
GREASER
A21
MANIFOLD
GREASER
VALVE DV19

Solenoid Coil
PMP3 SOLENOID
L9
Rod Greaser

Auto Grease Switch

S15
S2

Front Vise
Switch

13-2
D20x22 Navigator HDD Service Overview

Hose Connections

HYDRAULIC
TANK RES1

Rod Greaser
GREASER MANIFOLD A21

PUMP PMP3
GREASER
CYLINDER CY15

13-3
 Overview D20x22 Navigator HDD Service

The machine may be equipped with an optional auto greaser for lubricating
drill rod threads.
Greasing Mode

VALVE SOLENOID
ASSEMBLY L9
A21

CYLINDER
CY15
VALVE
DV27
Rod Greaser

PUMP PMP3

13-4
D20x22 Navigator HDD Service Overview

Required Operating To operate optional auto greaser:

Conditions
• There must be grease available to
greaser cylinder CY15
• Operator must seated at drill
controls. S15
• Remote Lockout system must be in
normal RUN mode.
• Greaser switch S15 must be pushed
and held.

CY15 L9

Rod Greaser
A21

Normal Operation When required operating conditions are met:

• Grease cylinder CY15 will extend.

• Grease will be applied to the threads of drill rod.

NOTE: If the auto greaser function does not operate as expected, see the
following troubleshooting.

13-5
 Overview D20x22 Navigator HDD Service

Troubleshooting/ Before beginning any troubleshooting or testing procedures, perform the

Testing pretest inspection. 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. Also review information in the General chapter
"Troubleshooting Guidelines," page 1-8.
2. If any functions other than the auto greaser 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.

See schematic on previous pages for testing reference.

3. Test for acceptable voltage starting at test point (1), solenoid coil L9 of
valve DV27. If voltage is acceptable, continue with step 4. If not,
continue with step 5.
4. Test resistance of coil L9.
Rod Greaser

Expected result: Resistance should measure 8.8 ohms @ 68°F (20°C). If

OK, continue with step 6. If not, replace coil.

5. 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 test point (4). If voltage is not within specification,
repair or replace faulty component(s) or wire harness segment(s).
6. Remove and inspect the cartridge valves in greaser assembly A21. Refer
to component repair section to repair or replace faulty components.

13-6
D20x22 Navigator HDD Service Component Repair

COMPONENT REPAIR
Rod Thread Greaser Cylinder CY8
NOTE: The rod thread greaser assembly is mounted to a plate that is
clamped to the front vise cylinder.

1. Label hoses. Disconnect

hoses from cylinder and cap
the open ends of hoses.
2. Pull up grease tube follower
to relieve grease pressure in
the grease housing.
3. Remove two bolts holding
the cylinder to the grease
housing. 2

4. Remove cylinder and O-ring 1

(1).
L9, DV27
5. Note orientation and remove
hose fittings from cylinder.

Rod Greaser
6. Install fittings in new
cylinder. Torque fittings to
9.5 ft-lb (12.9 Nm).
CY15
7. Install O-ring and insert end
of cylinder ram into the
sleeve (2) inside grease
housing. 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).

13-7
 Component Repair D20x22 Navigator HDD Service

Grease Cylinder

1
HEAD
PISTON 5 8

4 6 2
3 ROD ASSEMBLY
7

IMPORTANT: Protect rod assembly when extended to avoid damage to

chrome surfaces.
Rod Greaser

IMPORTANT: Use vise with soft jaws to grip rod assembly without clevis.

Cylinder Disassembly
1. Place cylinder on a clean surface.
2. Clamp cylinder body (1) into a vise. Do not apply excessive clamping
force to the cylinder body.
3. Remove gland (2) with spanner wrench.
4. Pull rod assembly from cylinder tube.
5. Remove nut (3).
6. Refer to the 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)

13-8
D20x22 Navigator HDD Service Component Repair

Auto Greaser Valve DV27

Rod Greaser
1. Disconnect electrical supply to solenoid (1).
2. Remove nut (2) and solenoid (3).
3. Remove valve (4).
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.

13-9
This page intentionally left blank.
D20x22 Navigator HDD Service Overview

Chapter 14: 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 behind the control panel to the right of the seat.

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,

Remote Lockout
engine will shut down. The engine cannot be restarted 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.

14-1
 Theory D20x22 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 Transmitter A23

• Remote Lockout Base A4
• CAN Controlled
• Battery Charger A22
Remote Lockout

• Antenna E1
• Indicator Lights DS9–DS11
• Horn AD2
• Alarm Cancel Switch S19

14-2
D20x22 Navigator HDD Service Theory

Component Locations
LOSS
COMMUNICATION
LIGHT
DS10
REMOTE
BATTERY

REMOTE
CHARGER A22 LOCKOUT RUN LIGHT
LIGHT DS9 DS11

ANTENNEA
HORN CANCEL
SWITCH S19

Remote Lockout

2 PIN JUMPER

REMOTE
TRANSMITTER A23 REMOTE LOCKOUT BASE A4

14-3
 Theory D20x22 Navigator HDD Service

Hydraulic Schematic

MH2

MH3
MH5 MH6
MH1
MH4

A6

DRILL/TRANSPORT VALVE A7
Remote Lockout

VALVE ASSEMBLY
A8

A9

FL3

GA3 GA4

B5
PMP2 PRESSURE
PMP1
TRANSDUCER

B4 HE1
PRESSURE FL1
TRANSDUCER ROTATION PUMP

THRUST PUMP
FL4

14-4
D20x22 Navigator HDD Service Theory

Electrical Schematic
BATTERY DISCONNECT SWITCH
S1
BT1

ALT1
IGNITION
SWITCH
S3 S4
S2

FUSE F1
FUSE F2

FUSE F3
FUSE F5
FUSE F6 REMOTE LOCKOUT
STOP DS9

REMOTE LOCKOUT
POWER RELAY
TEST/FAULT DS10
A2
CIRCUIT BREAKER
CB2
RUN DS11

WATER CONTROL
S10

SEAT SWITCH
S11

Remote Lockout
REMOTE
LOCKOUT
A4

J1
HORN CANCEL HORN AD2
SWITCH S19 J2

A1
ENGINE FUEL L10 A22

THRUST/PULLBACK
TRANSDUCER B5 RL MOVE OUT L13

DRILL/TRANSPORT L14

BALL VALVE L17

ROTATION
TRANSDUCER B4
WATER ON/OFF L18

14-5
 Theory D20x22 Navigator HDD Service

Hydraulic Lockout Function

NOTE: See "Electrical Schematic," page 14-5, and "Hydraulic Schematic,"
page 14-4, 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 normal 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 S4.
• 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 A23 sends a lockout command, the remote
unit will signal base module A4.
Remote Lockout

• Base module A4 communicates through CAN to de-energize thrust and

rotation EDCs. Ball valve coil L17 and Water ON/OFF coil L18 will also
be de-energized.
NOTE: Pressure transducers B4 and B5 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 is
between 0.25–1.0 V. Voltage outputs between 1.0–4.5 V is considered high
pressure and will not confirm a lockout. When in a confirmed lockout if high
pressure is encountered, power is removed from fuel coil L10, causing engine
shutdown.

NOTE: If the hydraulic LOCKOUT function does not operate as expected,

see "Troubleshooting/Testing the Remote Lockout Function," page 14-17.

Continued on next page...

14-6
D20x22 Navigator HDD Service Theory

Hydraulic Lockout Pressure transducer B4 is installed in the rotation pump PMP1 to monitor
with Backup Engine rotation hydraulic pressure to ensure that the drill remains locked out
Shutdown Function 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 the thrust/pullback pump PMP2 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 falls in the 0.25–1.0 V range.

If the seat is occupied and hydraulic pressure increases above 750 psi (51
bar) while the machine is in confirmed hydraulic lockout, base module A4
will disable the fuel enable circuit and the engine will be shut down.

The engine cannot be restarted until the run button is pushed or the
operator is out of the seat. See "Power On," page 14-12.

Remote Lockout

14-7
 Theory D20x22 Navigator HDD Service

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, grey jumper plug (1) must be
moved from hydraulic connector (power
applied to circuit 707-TN) to engine
shutdown connector (ground connected
1
to circuit 707-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 normal Run mode.
Remote Lockout

The following theory of operation explains how the electrical and hydraulic
functions react when the engine shutdown lockout is activated under normal
conditions:

• At start-up, voltage is present at base module A4 through ignition switch

S4.
• 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 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 L10.
NOTE: If the engine shutdown lockout function does not operate as
expected, see "Troubleshooting/Testing the Remote Lockout Function," page 14-
17.

NOTE: Engine shutdown lockout confirmation is defined as a CAN message

sent to the base module A4 indicates the engine has been shutdown.
Continued on next page...

14-8
D20x22 Navigator HDD Service Troubleshooting

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 14-6. For theory
of operation on engine shutdown lockout, refer to "Engine Shutdown Lockout
Function," page 14-8.

The remote unit user can select either Run or Lockout mode. System status
is indicated by indicator lights DS9–DS11 and horn AD2.

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
AD2 at the control panel when in Drill mode (operator in the seat). The horn
can be silenced by pressing the alarm horn cancel button.

If the machine is not in Lockout mode, yellow indicator light DS10 will flash.
If the machine is in Lockout mode, red lockout indicator light DS9 will be on.

Remote Lockout

14-9
 Troubleshooting D20x22 Navigator HDD Service

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)
Remote Lockout

Light B indicates status of radio connection.

• Base module is in “Registering” mode (red).

• Base module is initializing internal radio (green).

• No communications with remote unit (green).

• Remote unit is in range (green).

Light C, on this machine, allows user to verify software (green)

(LK2 CAN - P/N 296272506 & 296272510).

• CAN NOT OK if lights are (red).

Continued on next page...

14-10
D20x22 Navigator HDD Service Troubleshooting

Light D indicates lockout state.

• Run (green)

• Engine Lockout requested (green)

• Engine locked (red)

• Hydraulic Lockout requested (green)

• Hydraulic locked (red)

Remote Lockout

14-11
 Troubleshooting D20x22 Navigator HDD Service

Power On
Remote Unit On Turn on remote unit by either pressing
Power ON/OFF Button (1) and holding 1 2
for 2 seconds or pressing the 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 machine.
Remote Lockout

• 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 DS10 (1) begins to
1
flash. If the machine was unlocked prior to
shutdown, the green RUN light (2) turns on.
Engine can be started, and machine can be
operated. If there is no communication with
remote for 10 seconds after turning power on, 2
the base module sounds a continuous alarm
until alarm cancel button S19 (3) is pressed
and held for a second.
3

Continued on next page...

14-12
D20x22 Navigator HDD Service Troubleshooting

If the Remote Lockout system is in hydraulic

mode, and the base module was locked out prior
to shutdown, then the red lockout light DS9 (1)
1
turns on. In this state, the engine can be
started, but thrust and rotation will be
disabled.

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.

Remote Lockout
Lockout Mode
When pressed, the red Lockout button sends a lockout command via CAN for
drill string rotation, thrust and pullback, and fluid flow to be stopped. See
"Hydraulic Lockout Function," page 14-6. 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 S4 to OFF to shut off base module power.

14-13
 Troubleshooting D20x22 Navigator HDD Service

Remote Registration
In the event that the base module A4 or remote unit 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 DS10 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
Remote Lockout

to a double flashing red.

The Remote Lockout signal light

DS10 on control panel will be
double blinking.
Base is now in registration mode.

4. Turn remote unit ON.

Continued on next page...

14-14
D20x22 Navigator HDD Service Troubleshooting

5. Press and hold red and black

buttons on remote unit until yellow 1
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 remote unit.

Remote Lockout

14-15
 Troubleshooting D20x22 Navigator HDD Service

Battery Condition
Low Battery NOTE: Low battery indication is only
displayed on the remote transmitter. 1

When there is approximately 10% of

battery life left, blue light (1) on remote
transmitter 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 compartment in the event of transmitter battery failure.
Remote Lockout

NOTE: The Remote Lockout battery will not charge if the machine battery
disconnect switch S4 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.

14-16
D20x22 Navigator HDD Service Troubleshooting

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 "Flow Chart for Determining Machine Problem (Without
Remote)," page 14-22, and "Flow Chart for Determining Machine Problem (With
Remote)," page 14-23.

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...

14-17
 Troubleshooting D20x22 Navigator HDD Service

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
Remote Lockout

(initializing 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...

14-18
D20x22 Navigator HDD Service Troubleshooting

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.

Remote Lockout
Hydraulic or Engine To determine shutdown mode:
Shutdown Lockout
Mode 1. Turn machine and remote ON.
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...

14-19
 Troubleshooting D20x22 Navigator HDD Service

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: Two versions of the battery

charger have been produced. Check the
label (1) for the revision number to verify
which revision is on the machine. Rev. A is
2.253.1001; Rev. B/C is 2.250.1452. Rev. A
has an orange light (2) and a green light
(3). Rev. B/C has one light (2) that flashes
orange and green.
1 2 3
The charger lights indicate as follows:
Remote Lockout

NOTE: The indications listed below apply to all versions, unless otherwise
stated.

• Power test to unit: Green light is ON (input voltage is between 9–36

Volts DC).
• Battery is not detected:
Rev. A. Orange light is OFF.
Rev. B/C. 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...

14-20
D20x22 Navigator HDD Service Troubleshooting

• 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

14-21
 Troubleshooting D20x22 Navigator HDD Service

Flow Chart for Determining Machine Problem (Without Remote)

Machine and Turn Machine ON. All three remote lockout lights on the
Radio are OFF. Leave Radio OFF. machine turn on for 2 seconds as a system
check. Set machine into DRILL mode.
Check:
1. If horn is connected to
ground.
2. If wiring between pin 6
on receiver and horn has Wait 10
seconds, No communication
continuity. NO light (yellow) DRILL
horn will Last state of
sound. flashes, other (UNLOCKED)
3. Connection to ground for lights are OFF. the drill.
the horn. LOCKED
4. If pin 6 on receiver
produces 12V when horn
should sound. Lock light (RED)
is ON, all other
YES lights are OFF.

Check:
Check:
[Link] horn is connected to
1. If switch contacts close ground.
on press.
Press 2. That wiring between pin 6
2. Wiring between pin 6 on HORN Horn will
Warning on receiver and horn has
receiver and switch has ON continuity. sound
continuity. OFF Button. NO
3. The connection to ground lockout
3. If one side of switch is for the horn. pattern.
attached to ground.
4. That pin 6 on receiver
produces 12 volts when
Remote Lockout

HORN OFF horn should sound.

YES

Check:
1. Wiring between pin 2 on
receiver and hydraulic
control circuit. Do machine
YES Will Engine YES functions
START? 2. That pin 9 is producing 0
Volts and light D is on solid operate?
RED.
NO Otherwise retest.

NO
Will thrust
and rotation
operate? Check:
1. Wiring between pin 2 on receiver
and hydraulic control circuit.
Will engine ENGINE Determine
2. That pin 9 is producing 12 volts, start or run?
and light D is on solid green. SHUTDOWN Mode
YES NO
Otherwise retest.

YES
No Problem Found HYDRAULIC
NO

Check:
Check:
1. Wiring between pin 9 on
1. Wiring between pin 2 on receiver and starter and fuel No problem found
receiver and hydraulic control control circuit.
circuit. To start engine, Will engine
2. That pin 9 is producing 0 place into Unlock start or run?
2. That pin 9 is producing 12 volts, and light D is on flashing mode.
volts, and light D is on solid RED.
green. YES
Otherwise retest.
Otherwise retest.
NO

Continued on next page...

14-22
D20x22 Navigator HDD Service Troubleshooting

Flow Chart for Determining Machine Problem (With Remote)

Machine and Turn Machine ON. Turn All three remote lockout lights on the machine
Radio are OFF. radio ON with black button. turn on for 2 seconds as a system check.

Remote not married to Remote

machine or flashes
YELLOW LIGHT yellow then
RF module has a problem. goes to solid
See functional chart. red or green.

Set machine in Drill

mode, lock light (red) is
GREEN LIGHT RED LIGHT ON all other lights are
OFF.

Check:
1. That horn is connected to ground.
Will engine
start? NO 2. Wiring between pin 6 on receiver
and horn has continuity. Horn will
NO sound
3. Connection to ground for the lockout
horn. pattern.
Check:
4. That pin 6 on the receiver
YES 1. Wiring between pin 9 on produces 12 volts when horn should
receiver and starter and sound.
fuel control circuit. YES

Remote Lockout
2. That pin 9 is producing
12 volts, and light D is on
solid green. Check:
Will thrust Otherwise retest. 1. Wiring between pin 2 on receiver
and rotation and hydraulic control circuit.
operate? Do machine
2. That pin 9 is producing 0 volts, YES functions
and light D is on red. operate?
Otherwise retest.
YES NO

NO
No problem found,
change state and
re-test.

Will engine ENGINE Determine

start or run? SHUTDOWN mode

Check:
1. Wiring between pin 2 on YES
receiver and hydraulic NO
control circuit. HYDRAULIC
2. That pin 9 is producing
12 volts, and light D is on
solid green. Check: No problem
1. Wiring between pin 9 on found.
receiver and starter and fuel
To start YES Will engine
control circuit. engine, place start or run?
2. That pin 9 is producing 0 into Unlock
volts, and light D is on mode.
flashing RED.
Otherwise retest.
NO

14-23
 Component Repair D20x22 Navigator HDD Service

COMPONENT REPAIR
Shuttle Valve

4 2

1
TO
ROTATION PRESSURE
GAUGE
3

TO
THRUST/PULLBACK
PRESSURE GAUGE
Remote Lockout

THRUST PUMP
PMP2

ROTATION PUMP
PMP1

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...

14-24
D20x22 Navigator HDD Service Component Repair

Disassembly 1. Disconnect wiring harness from transducer.

2. Disconnect Thrust/Pullback transducer B5 (1) or Rotation transducer B4
(2) as required.
3. Remove fittings (3) from transducers.
Reverse steps for installation. Torque fittings (3) to 19 ft-lb (26 Nm). All
other connections torque to 9.5 ft-lb (13 Nm).

Remote Lockout

14-25
This page intentionally left blank.
D20x22 Navigator HDD Service Overview

Chapter 15: 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:

• Acceptable Voltage
• Voltage Strike
• Current Strike
• Voltage Test
• Current Test

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

• Strike Alert Module A3

• Alarm Horn AD1
• Strike Alert Sensing Coil B2
• Voltage Stake E1
• Test Switch S8
• Reset Switch S9
• Indicator Light DS15

15-1
 Theory D20x22 Navigator HDD Service

Component Locations

HORN AD1
Strike Alert

HORN CANCEL SWITCH S9

TEST SWITCH S8

INDICATOR LIGHT DS15

SENSING COIL B2

Continued on next page...

15-2
D20x22 Navigator HDD Service Theory

STRIKE ALERT MODULE A3

Strike Alert System Test

The D20x22 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 E2 inserted in the

Strike Alert
ground. When test switch S8 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 sounding the alarm horn. Release button to silence

alarm.

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 indicated when the green light DS15 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 15-6.

15-3
 Theory D20x22 Navigator HDD Service

Electrical Schematic
BT1

CB2 K2 F6
GROUND DISCONNECT SWITCH S1

SENSING COIL B2

VOLTAGE STAKE E1

STRIKE ALERT MODULE A3 HORN AD1

TEST SWITCH S8

RESET SWITCH S9

INDICATOR LIGHT DS15

Strike Alert

15-4
D20x22 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 E1 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 15-6.

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 B2. Coil B2 is mounted
so it encircles the drill rod.

Strike Alert
• 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/Testing," page 15-6.

15-5
 Troubleshooting/Testing D20x22 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
Strike Alert

• check the integrity of the wiring harness

• 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.

Daily Test Fails The test causes Strike Alert module A3 to sound the horn AD1 until the test
button is released.

If the test works, it proves that:

• The horn AD1 is connected and working.

• Ground stake E1 is connected to A3.
• The module is responding correctly to the voltage at terminal 3.
• Sensing ring B2 is complete (not shorted) and connected to A3.
• The module A3 is sending current through terminal 9 and responding
correctly when it receives current through the coaxial cable.
Focus on the items above if the test fails.

15-6
D20x22 Navigator HDD Service Troubleshooting/Testing

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

• 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

Strike Alert

15-7
 Troubleshooting/Testing D20x22 Navigator HDD Service

Strike Alert Module Lights

Light A indicates power supply.

• Power off

• Power on (green)

Light B indicates status.

• Self-test passed

• Ground stake not in ground (red)

Strike Alert

• Current sensor failed (red)

• Ground stake wiring failed (red)

Light C indicates no CAN bus is present (red) (normal operation)

Light D indicates alarm state.

• No alarm (green)

• Voltage alarm (red)

• Current alarm (red)

15-8
D20x22 Navigator HDD Service Component Repair

COMPONENT REPAIR
Voltage Stake E1

3 2

6
7
9
4
7
5

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. Note the location of the
wires before removing.
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.

15-9
 Component Repair D20x22 Navigator HDD Service

Strike Alert Coil Assembly B2

3
5
7

5
6

1
Strike Alert

1. Remove wiper (2) from mounting bracket (1).

2. Unscrew bolts holding mounting bracket to vise assembly.
3. Remove bolts (7) holding coil (4) in mounting bracket.
4. Remove roller bolt (6) and washers (5). Remove guide roller and bushing
(3) from center of strike alert.
5. Disconnect strike alert harness from coil (4).
Reverse steps for installation.

15-10
D20x22 Navigator HDD Service Index

A D
Adjusting Charge Pressure Relief Valve PV4, 4-29 Daily test, 15-3, 15-6
Adjusting Load Sense Spool and Compensator Diagrams and Schematics, 1-7
Settings, 8-19 Directional Control Valves, 1-14
Adjusting Pump Swashplate NEUTRAL Position, 4-40 Directional Valve DV1, 5-34
Adjusting Relief PV4, 4-22 Directional Valves DV2 & DV3, 5-34
Analysis of Case Flow Test for MH5 and MH6, 5-21 Directional Valves DV4 & DV5, 5-35
Auto Greaser Valve DV27, 13-9 Discharged Battery, 14-16
Avoid Oil Contamination, 1-16 Do Not Modify Machine, 1-3
Avoid Trapped Pressure, 1-15 Drill Fluid Motor MH9, 12-37
Drill Fluid OFF, 12-16
B Drill Fluid ON, 12-17
Ball Valve, 12-40, 12-42 Drill Fluid Valve Assembly A12, 12-12
Ball Valve Not Turning On/Off, 12-24 Drill Joysticks A19 & A20, 6-29
Base Module, 14-18 DRILL OUT Mode, 10-13
Base module, 14-10 Drill Out Mode, 11-11
Base Module Run, 14-12 Drill Rotation, 7-1
Battery, 14-16, 14-20 Drill Rotation Function, 7-17
Battery Charging Circuit, 3-11, 3-15 Drill Transport Valve Assembly A7, 5-33
Battery Condition, 14-16 Drill/Transport Valve Assembly A7, 5-7
Battery Disconnect Switch S1, 3-25 Drilling Fluid, 12-1
Brake Release Circuit, 5-8 Drilling Fluid Hydraulic Circuit, 12-11
Breaker CB1, 3-22 Drilling/Backreaming High Mode, 7-17
Bypass Valve Adjustment, 4-23 Drilling/Backreaming Low Mode, 7-23
C E
Caterpillar Warranty, 1-2 EDCs for PMP1 and PMP2, 4-39, 5-29
Chapter Organization, 1-7 Electrical schematic
Charge Pressure Circuit, 5-5 Strike alert, 15-4
Charge Pressure Measurement, 4-14 Electrical Specifications, 2-10
Charge Pump, 4-12, 5-29 Electrical Troubleshooting, 1-11
Charge Pump Inlet Restriction Measurement, 4-13 Emergency Stop Switches S2 or S3, 3-24
Charge Pump Replacement, 4-23 Engine, 2-11, 3-8
Check Valve CV19, 10-29 Engine LEDs, 2-19
Cold Weather Starting, 2-3 Engine Maintenance, 3-8
Common Electrical Problems, 1-11 Engine Overview, 5-1, 8-1, 9-1
Compensator, 8-11 Engine Protection Interlock, 2-12
Component locations Engine Service, 3-8
Remote Lockout, 14-3 Engine shutdown lockout, 14-2, 14-8
Strike alert, 15-2 Engine Shutdown Lockout Function, 14-8
Connecting a Needle Valve, 1-17 Engine Specifications, 2-10
Connecting Flow Meters, 1-16 Engine Start Circuit, 3-9
Connecting Pressure Gauges, 1-17 Engine Start Interlocks, 2-12
Control Panel Light, 15-7 Excessive Noise/Vibration, 4-7
Controller LEDs Associated with PFC Pump Functions, Extend Rod Loader Arm, 11-11, 11-16
2-22
Controllers A1 and A2, 2-13 F
Counterbalance Valves CV26 and CV27, 8-25 Failure of Both Tracks, 5-24
Current, 15-3 Failure of Single Track, 5-25
Current strike, 15-5 Filter Components, 4-36
Current Strike Circuit, 15-5 Flow chart, 14-22, 14-23
Cylinder Disassembly, 13-8 Flow Chart for Determining Machine Problem (With
Cylinders, 1-14 Remote), 14-23
 Index D20x22 Navigator HDD Service

Flow Chart for Determining Machine Problem (Without Kohler Warrant, 1-2
Remote), 14-22
Flow Test of Motor MH9, 12-33
L
Fluid Sample Collection Points, 4-21 Leakage Path Analysis, 1-12
Fluid Shutoff Cylinder, 12-40 Left Track Function, 5-26
Fluid Shutoff Cylinder CY12, 12-40 Legend for Reference Designators, 2-3
Fluid Shutoff Valve, 12-39 Lights, 14-10
Fluid Shutoff Valve Assembly A24, 12-39 Load Sense, 8-12
Front Vise Clamp, 10-19 Lock Valves, 1-14
Front Vise CLAMP Operation, 10-13 Lockout, 14-13
Front Vise Unclamp, 10-19 Lockout Mode, 14-13
Fuel and Lubricants, 2-11 Low Battery, 14-16
Full Flow Mode, 12-21 M
Full Flow Switch Does Not Increase Speed of Water
Machine Interlocks, 2-12
Pump, 12-31
Machine Reference and Orientation, 2-9
Function Theory, 1-7
Measure Battery Voltage, 3-12
Fuse Panel, 3-21
Measuring Case Drain Flow, 5-20
G Measuring Current, 1-19
General Information, 1-1 Measuring Resistance, 1-18
General Machine Specifications, 2-9 Measuring Voltage, 1-18
Grease Cylinder, 13-8 Motors MH2, MH3, and MH4, 6-27
Greasing Mode, 13-4 N
Ground Drive, 5-1
Nulling the EDC, 4-41
Ground Drive Circuit, 5-13
O
H
Oil Cooler HE1, 4-18
High Pressure Mode, 8-10
Oil Cooling, 4-18
High Speed Carriage Valve Assembly A6, 6-26
Oil Filtering, 4-17
Hydraulic Fluid Distribution, 4-1
Operation - Left Track, 5-7
Hydraulic Fluid Sampling, 4-19
Operation - Right Track, 5-7
Hydraulic Hose Connections - Fluid Supply and Return,
Operation Overview, 2-3
4-4
Operator Presence Interlock, 2-12
Hydraulic lockout, 14-2, 14-6
Hydraulic Lockout Backup Engine Shutdown, 14-1 P
Hydraulic Lockout Function, 14-6 Personnel and Lifting Requirements, 1-20
Hydraulic Lockout or Engine Shutdown Option, 14-1 PFC Pump PMP3, 4-16
Hydraulic Lockout with Backup Engine Shutdown PFC Pump PMP3 High and Low Pressure
Function, 14-7 Compensator Adjustment, 4-24
Hydraulic or Engine Shutdown Lockout Mode, 14-19 Pilot Valve Assembly A8, 5-16, 5-32, 6-13
Hydraulic Specifications, 2-9 Plug, 14-8
Hydraulic Troubleshooting, 1-12 PMP1 & PMP2 Hydrostatic Loop, 4-11
I PMP1/PMP2 Charge Checks and High Pressure Relief
Valves, 4-28
Ignition Switch S4, 3-24
PMP1/PMP2 Tandem Pump Adjustments, 5-29
Interlock, 2-13
PMP1/PMP2 Tandem Pump Replacement, 4-30, 5-29
J PMP3 Replacement, 4-37
Jumper, 14-8 Power Distribution LEDs, 2-18
Power ON, 14-12
K Pressure Compensator Spool, 8-11
Key Switch S4 at OFF, 3-10 PULLBACK Mode, 10-19
Key Switch S4 at RUN or ACC, 3-10 Pullback Mode, 6-22, 11-16
Key to Fault Codes, 2-17 Pump PMP2, 6-12
Key to LEDs, 2-15 Pump PMP3, 8-10
D20x22 Navigator HDD Service Index

Pump PMP3 Replacement, 4-44 Shutdown Procedure, 2-1

Shuttle Valve, 14-24
R Shuttle Valve SV1, 7-27
Rack Angle Cylinder CY14, 9-18 Software, 14-18, 14-19
Rack Angle Function, 9-13 Solenoid Coils L19, L20, and L, 5-32
Rack Angle/Stabilizer Valve Assembly A11, 9-9, 9-16 Solenoid Coils L3, L4, and L5, 6-26
Rack LOWER Mode, 9-13 Solenoids L1, L2, L6, L8, 10-28
Rack RAISE Mode, 9-15 Solenoids L11, L13, L15, L16, 11-20
Rear Vise CLAMP, 10-20 Special Tools & Test Equipment, 1-20
Rear Vise Rotate (Extend), 10-25 Specifications, 2-9
Rear Vise Rotate (Retract), 10-27 Speed Shift Circuit, 7-16
Rear Vise Unclamp, 10-23 Stabilizer Cylinder CY13, 9-19
Recharge Battery, 14-16 Stabilizer Function, 9-10
Reference Designators, 1-7 Stabilizer LOWER Mode, 9-10
Relay K2, 3-23 Stabilizer RAISE Mode, 9-12
Relief Valve PV1, 7-27 Stabilizer/Rack Angle, 9-1
Remote Lockout, 14-1 Stabilizer/Rack Angle Circuit, 9-8
Remote Lockout System - Shut Down, 2-1 Stake In Mode, 8-18
Remote Lockout valve, 14-6, 14-8 Stake Out Mode, 8-15
Remote Registration, 14-14 Stakedown, 8-1
Remote registration, 14-14 Stakedown Control Valve A10, 8-24
Remote Unit, 14-17 Stakedown Cylinders CY1 and CY2, 8-27
Remote Unit On, 14-12 Stakedown Hydraulic Circuit, 8-9
Repair Guidelines, 1-20 Stakedown Motors MH7 and MH8, 8-26
Replace Shields, 1-3 Stakedown Valve Assembly A10, 8-14
Replacing PMP3, 8-22 Starting Procedure, 2-2
Retract Rod Loader Arm, 11-14, 11-18 Starting the Engine, 2-2
Returning System to Service, 4-33 Stopping the Machine, 2-1
Right Track Function, 5-21 Strike Alert, 15-1
Rod Greaser, 13-1 Strike alert, 15-1
Rod Lift Cylinders CY10 and CY11, 11-21 Strike alert circuits, 15-4
Rod Loader, 11-1 Strike Alert Coil Assembly B2, 15-10
Rod Loader Circuit, 11-9 Strike Alert Module Lights, 15-8
Rod Loader Selector Cylinders CY6 and CY7, 11-22 Strike alert test, 15-3, 15-6
Rod Loader Shift Cylinders CY8 and CY9, 11-22
Rod Loader Valve Assembly A14, 11-10, 11-20 T
Rod Thread Greaser Cylinder CY8, 13-7 Test Fuses, 3-16
Rotation Gearbox, 7-29 Testing Components, 3-16
Rotation Loop Cooling Circuit, 7-25 Testing for Continuity, 1-19
Rotation Motor Flush Circuit, 7-16 Testing Pilot Valve Assembly A8 for Cross Port
Rotation Motor MH1, 7-16, 7-28 Leakage, 5-18
Rotation or Right Track LEDs, 2-21 Testing Transducers B4 and B5, 4-42
Run, 14-12 Thrust Mode, 6-20
Thrust/Pullback, 6-1
S Thrust/Pullback Circuit, 6-11
Safety, 1-3 Thrust/Pullback Function, 6-18
Safety Symbol Explanation, 1-3 Thrust/Pullback or Left Track LEDs, 2-20
Schematic Thrust/Pullback Valve Assembly A6, 6-17
Remote Lockout, 14-4, 14-5 Torque Limiter Function, 10-19
Strike alert, 15-4 Torque Limiter Valve Assembly A9, 7-14, 7-26
Seat Switch S11, 5-29 Torque Values, 1-21
Sequence Valves, 1-14 Track Brakes Release, 5-27
Servicing Hydrostatic Circuits, 4-34 Track Drive Circuit Cooling, 5-27
Shop Requirements, 1-20 Track Drive Motors MH5 & MH6, 5-19, 5-30
Index D20x22 Navigator HDD Service

Track Forward Mode, 5-21, 5-26 Variable Flow Mode, 12-17

Track Reverse Mode, 5-25, 5-26 Vendor Publications, 1-2
Tracking Cooler Flow Valve Assembly A18, 4-19 Verify CAN Operation, 14-19
Tracks Operating in Single Direction, 5-25 Verify software, 14-18, 14-19
Transducer, 14-7 Vermeer Publications, 1-1
Transducers B4 & B5 for PMP1/PMP2, 5-29 Vermeer Warranty, 1-2
Transducers B4 and B5, 4-43 Vise Clamp Cylinders CY3 and CY4, 10-30
Transport Joysticks, 5-35 Vise Rotation Cylinder CY5, 10-31
Transport Mode, 5-5 Vise Valve Assembly A13, 10-12, 10-28
Troubleshooting Vises, 10-1
Remote Lockout, 14-9 Voltage Stake E1, 15-9
Strike alert, 15-6 Voltage strike, 15-5
Troubleshooting Guidelines, 1-8 Voltage Strike Circuit, 15-5
Troubleshooting the Water On/Off Switch, 12-36
Troubleshooting/Testing, 1-8, 8-13
W
Troubleshooting/testing Remote Lockout, 14-17 Warranty, 1-2
Troubleshooting/Testing the Remote Lockout Function, Warranty Considerations, 1-2
14-17 Water Flow Meter Not Illuminated, 12-35
Water Flow Meter Not Working, 12-35
U Water Pump Motor Does Not Turn at Regulated Speed,
Using the Manual, 1-1 12-27
Water Pump Motor MH9, 12-15
V Water Pump Motor Will Not Reach Full Speed, 12-32
Valve Assembly A12, 12-38 Water Pump PMP4, 12-14
Valves DV1, DV2, DV3, DV4, and DV5, 5-33 Water Shutoff Cylinder, 12-40
Valves DV11, DV12, DV13, and DV14, 8-24 Water Valve, 12-39
Valves DV15, DV16 and PV11, 9-16 Worksheet for Flow Test of Motor MH9, 12-34
Valves DV20, PV14, PV15, DV21, DV22, 11-20
Valves DV26, DV25, DV17, DV18, DV19, 10-28
D20X22 Navigator HDD Service

Revision History
Revision Date Page(s) Description
S1_00 01/07 All 1st edition manual released.
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