Page 1 of 476

Service

Manual

D24x40 Series II/

D36x50 Series II_S5_03

D24x40 Serial No. 4001 -

D36x50 Serial No. 3001 -

Order No. 105400DA6

D24x40 Series II/D36x50 Series II

NAVIGATOR®

Horizontal Directional Drill

Page 2 of 476

This manual contains information and procedures that are

intended for experienced service technicians. Study and

understand these procedures thoroughly before servicing

or repairing the machine. Do not attempt any service that

you do not fully understand, or cannot be done safely with

tools and equipment available to you. Failure to do so

could result in personal injury or equipment damage.

Vermeer dealer service technicians can access service- related training courses through Vermeer University. Other

service technicians should ensure they are adequately

trained to understand the information and procedures in

this manual.

There are also many components which are not user- serviceable. If you have questions or encounter an issue

that you do not understand or cannot solve, contact your

Vermeer dealer service representative.

The instructions, illustrations and specifications in this

manual are based on the latest information available at

the time of publication. Your machine may have product

improvements and options not yet contained in this

manual.

Vermeer Corporation reserves the right to 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, VERMEER Logo and NAVIGATOR are

trademarks of Vermeer Manufacturing Company in the

U.S. and/or other countries.

This document may contain portions of technical materials

of various suppliers. Such component suppliers shall not

be responsible for the direct results of their technical

materials being presented out of context.

Designations used by component suppliers to distinguish

their products which appear in this manual are the

property of the respective trademark owner(s). Vermeer

Corporation is aware of the following component suppliers

trademarks.

LOCTITE and VIBRA-SEAL are trademarks of Henkel

Corporation.

FLUKE is a trademark of Fluke Corporation.

TEFLON is a trademark of E.I. DuPont de Nemours and

Company.

SAUER-DANFOSS is a trademark of Danfoss Power

Solutions Inc.

JOHN DEERE is a trademark of John Deere Corporation.

TRIHAWK is a trademark of Earth Tool Co. LLC.

No part of this manual may be reproduced in any form or by any means, electronic or

mechanical, including photocopying, recording, or by any information storage and retrieval

systems, without the express written consent of Vermeer Corporation.

Copyright 2015, 2016 Vermeer Corporation

All rights reserved.

1210 Vermeer Road East, P.O. Box 200

Pella, Iowa 50219-0200, USA

Page 3 of 476

D24x40/D36x50 Series II Navigator HDD Service Table of Contents

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

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

Reference Publications ............................................................................................................................................ 1-2

Vermeer Publications ......................................................................................................................................... 1-2

Vendor Publications ........................................................................................................................................... 1-2

Warranty Considerations ..............................................................................................................................1-3

Vermeer Warranty ..................................................................................................................................................... 1-3

John Deere Warranty................................................................................................................................................ 1-3

Safety ..............................................................................................................................................................1-3

Do Not Modify Machine ............................................................................................................................................ 1-4

Replace Shields ........................................................................................................................................................ 1-4

Safety Symbol Explanation...................................................................................................................................... 1-5

Terminology ...................................................................................................................................................1-7

Function............................................................................................................................................................... 1-7

Circuit .................................................................................................................................................................. 1-7

Inputs and Outputs............................................................................................................................................. 1-7

Reference Designators....................................................................................................................................... 1-7

Diagrams and Schematics ....................................................................................................................................... 1-8

Troubleshooting Guidelines .........................................................................................................................1-8

Troubleshooting Analysis........................................................................................................................................ 1-9

Operator Error..................................................................................................................................................... 1-9

Analysis ............................................................................................................................................................... 1-9

Research the System ....................................................................................................................................... 1-10

Electrical Troubleshooting .........................................................................................................................1-10

Hydraulic Troubleshooting .........................................................................................................................1-10

Recommended Diagnostic Tools .......................................................................................................................... 1-11

Computer System ............................................................................................................................................. 1-11

Electrical Support Items................................................................................................................................... 1-11

Hydraulic Support Items .................................................................................................................................. 1-12

Pretest Inspection................................................................................................................................................... 1-13

Mechanical ........................................................................................................................................................ 1-13

Electrical............................................................................................................................................................ 1-13

Hydraulic ........................................................................................................................................................... 1-13

Hydraulic Connections........................................................................................................................................... 1-14

Trapped Pressure ............................................................................................................................................. 1-14

Avoid Oil Contamination.................................................................................................................................. 1-15

Repair Guidelines ........................................................................................................................................1-15

Safety Equipment.................................................................................................................................................... 1-15

Shop Requirements ................................................................................................................................................ 1-15

Special Tools & Test Equipment ..................................................................................................................... 1-15

Personnel and Lifting Requirements .................................................................................................................... 1-16

Replacement Parts.................................................................................................................................................. 1-16

Part Numbers/Hose Lengths/Fitting Orientation ........................................................................................... 1-16

Parts Ordering................................................................................................................................................... 1-16

Recommended Torque Values............................................................................................................................... 1-16

Valve Service........................................................................................................................................................... 1-17

Disassembly...................................................................................................................................................... 1-17

Assembly........................................................................................................................................................... 1-17

Page 4 of 476

Table of Contents D24x40/D36x50 Series II Navigator HDD Service

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

Start & Stop Procedures ............................................................................................................................... 2-1

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

Start the Engine......................................................................................................................................................... 2-2

Start in Cold Weather................................................................................................................................................ 2-3

Engine ..................................................................................................................................................................2-3

Hydraulic Fluid ....................................................................................................................................................2-3

Specifications ................................................................................................................................................ 2-4

Machine Reference and Orientation ........................................................................................................................ 2-4

Machine Specifications............................................................................................................................................. 2-5

Engine Specifications.........................................................................................................................................2-5

Close Loop Systems Specifications..................................................................................................................2-5

PFC & Drilling Fluid Specifications ......................................................................................................................... 2-5

Fuel and Lubricants .................................................................................................................................................. 2-6

Machine Performance ................................................................................................................................... 2-6

Tools Needed.......................................................................................................................................................2-6

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

Overview......................................................................................................................................................... 3-1

Theory............................................................................................................................................................. 3-1

Functions ................................................................................................................................................................... 3-1

Components .............................................................................................................................................................. 3-2

Component Locations............................................................................................................................................... 3-3

Engine Component Locations.................................................................................................................................. 3-4

Power Distribution Module A18 ............................................................................................................................... 3-5

Ignition Start (Optional Cab)..................................................................................................................................... 3-5

Ignition Start (Non-Cab)............................................................................................................................................ 3-6

Ignition Run Circuit ................................................................................................................................................... 3-7

Battery BT1 ................................................................................................................................................................ 3-8

Battery Ground Disconnect Switch S1.................................................................................................................... 3-8

Starting Interlocks..................................................................................................................................................... 3-8

Fuses .......................................................................................................................................................................... 3-9

Engine............................................................................................................................................................. 3-9

Engine Service........................................................................................................................................................... 3-9

Engine Maintenance.................................................................................................................................................. 3-9

Engine Coolant Temperature ................................................................................................................................. 3-10

Air Intake & Exhaust ............................................................................................................................................... 3-10

Tier 3/Stage IIIA .................................................................................................................................................3-10

Tier 4i/Stage IIIB ................................................................................................................................................3-10

Engine Emissions Aftertreatment.......................................................................................................................... 3-12

Regeneration .....................................................................................................................................................3-12

Engine Fuel Supply ................................................................................................................................................. 3-14

Troubleshooting................................................................................................................................................3-14

Throttle Circuit......................................................................................................................................................... 3-15

Page 5 of 476

D24x40/D36x50 Series II Navigator HDD Service Table of Contents

Troubleshooting ..........................................................................................................................................3-15

Specifications.......................................................................................................................................................... 3-16

Electrical System .............................................................................................................................................. 3-16

Battery ............................................................................................................................................................... 3-16

Fuses ................................................................................................................................................................. 3-16

Engine................................................................................................................................................................ 3-16

Troubleshooting the Engine .................................................................................................................................. 3-17

SPN/FMI Codes ....................................................................................................................................................... 3-19

Engine Error Codes ................................................................................................................................................ 3-19

Ground Disconnect Switch Continuity Test......................................................................................................... 3-26

Battery Voltage Test ............................................................................................................................................... 3-27

No-Load Test..................................................................................................................................................... 3-27

Under Load Test ............................................................................................................................................... 3-27

Troubleshooting the Battery Charging Circuit..................................................................................................... 3-28

Troubleshooting/Testing the Engine Coolant ...................................................................................................... 3-28

Testing Air Cleaner (Tier 3/Stage IIIA)................................................................................................................... 3-30

Troubleshooting Fuel Tanks, Lines, Filters, and Strainers................................................................................. 3-31

Troubleshooting/Testing the Fuel Level Sensor.................................................................................................. 3-31

Fuel Sender (B5) Resistance Test................................................................................................................... 3-31

Troubleshooting the Ignition START Circuit........................................................................................................ 3-32

Testing the Ignition Switch .................................................................................................................................... 3-33

Testing the Alternator............................................................................................................................................. 3-34

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

Overview.........................................................................................................................................................4-1

Theory.............................................................................................................................................................4-1

Functions................................................................................................................................................................... 4-1

Components .............................................................................................................................................................. 4-2

Component Locations .............................................................................................................................................. 4-3

Hose Connections — Fluid Supply and Return ..................................................................................................... 4-4

Hydraulic Fluid Supply Function............................................................................................................................. 4-5

PFC Pump PMP3 ....................................................................................................................................................... 4-5

Low Pressure Standby ....................................................................................................................................... 4-5

Rotation Closed-Loop Pump PMP1......................................................................................................................... 4-7

Charge Pressure Mode....................................................................................................................................... 4-7

High Pressure Mode ........................................................................................................................................... 4-8

Thrust Closed-Loop Pump PMP2 .......................................................................................................................... 4-10

Charge Pressure Mode..................................................................................................................................... 4-10

High Pressure Mode ......................................................................................................................................... 4-11

Electric Displacement Control (EDC).................................................................................................................... 4-13

Hydraulic Fluid Filtering Function......................................................................................................................... 4-14

With Functions Operating or At Rest.............................................................................................................. 4-14

Hydraulic Fluid Cooling Function.......................................................................................................................... 4-15

Operation........................................................................................................................................................... 4-15

Combination Valve AH3.......................................................................................................................................... 4-16

Hydraulic Enable Valve AH6 .................................................................................................................................. 4-17

Return Manifold AH1............................................................................................................................................... 4-18

Specifications.......................................................................................................................................................... 4-19

Electrical............................................................................................................................................................ 4-19

Hydraulic ........................................................................................................................................................... 4-19

Page 6 of 476

Table of Contents D24x40/D36x50 Series II Navigator HDD Service

Troubleshooting .......................................................................................................................................... 4-20

Excessive Noise/Vibration ...............................................................................................................................4-21

Troubleshooting/Testing Pump PMP1................................................................................................................... 4-22

Troubleshooting/Testing Pump PMP2................................................................................................................... 4-22

Troubleshooting/Testing PFC Pump ..................................................................................................................... 4-23

Efficiency Test for PFC Pump ................................................................................................................................ 4-24

Set Up.................................................................................................................................................................4-24

Conducting the Test..........................................................................................................................................4-25

Understanding the Results...............................................................................................................................4-26

Calculating Theoretical Flow and Acceptable Flow.......................................................................................4-26

Troubleshooting/Testing the Hydraulic Fluid Cooling Function ........................................................................ 4-27

Excessive Heat/Leakage...................................................................................................................................4-27

Hydraulic Fluid Sampling ........................................................................................................................... 4-27

Preventive Maintenance ......................................................................................................................................... 4-27

Hydraulic Fluid Condition After Repair ................................................................................................................. 4-28

Fluid Sampling Criteria.....................................................................................................................................4-28

Fluid Sample Collection Points........................................................................................................................4-29

Cleanliness Approval Criteria ..........................................................................................................................4-29

Returning System to Service.................................................................................................................................. 4-30

Component Repair ...................................................................................................................................... 4-30

Return Manifold AH1............................................................................................................................................... 4-31

Remove ..............................................................................................................................................................4-31

Disassembly ......................................................................................................................................................4-32

Combination Valve AH3.......................................................................................................................................... 4-33

Hydraulic Enable Valve AH6................................................................................................................................... 4-34

PFC Pump PMP3 ..................................................................................................................................................... 4-35

Remove ..............................................................................................................................................................4-35

Install..................................................................................................................................................................4-36

Thrust/Pullback Pump PMP2.................................................................................................................................. 4-37

Removal .............................................................................................................................................................4-37

Installation .........................................................................................................................................................4-38

Rotation Pump PMP1 .............................................................................................................................................. 4-39

Removal .............................................................................................................................................................4-39

Installation .........................................................................................................................................................4-40

Multifunction Valve for Rotation Pump or Thrust Pump ..................................................................................... 4-41

Cartridge Repair ................................................................................................................................................4-41

Shaft Seal and Shaft Replacement ........................................................................................................................ 4-43

Return Filters FL1 & FL2 & Manifold ..................................................................................................................... 4-46

Oil Cooler HE1 ......................................................................................................................................................... 4-47

Page 7 of 476

D24x40/D36x50 Series II Navigator HDD Service Table of Contents

Controls & Controllers .................................................................................................................... 5-1

Overview.........................................................................................................................................................5-1

Components...................................................................................................................................................5-1

Component Locations .............................................................................................................................................. 5-2

Displays A8 and A12................................................................................................................................................. 5-4

AutoDrill..................................................................................................................................................................... 5-5

Front Vise/AutoDrill Interlock .................................................................................................................................. 5-6

Operator Presence Interlock.................................................................................................................................... 5-6

Transducer Manifold................................................................................................................................................. 5-7

Joystick Troubleshooting ........................................................................................................................................ 5-8

Rear Transport Station Joysticks............................................................................................................................ 5-9

Remote Control ....................................................................................................................................................... 5-10

Troubleshooting the Controllers ........................................................................................................................... 5-10

Check for Power at Controllers ............................................................................................................................. 5-11

Fault Codes ............................................................................................................................................................. 5-12

Rotation ............................................................................................................................................ 6-1

Overview.........................................................................................................................................................6-1

Components .............................................................................................................................................................. 6-1

Component Locations .............................................................................................................................................. 6-2

Electrical Schematic ................................................................................................................................................. 6-3

Hydraulic Schematic................................................................................................................................................. 6-5

Hose Connections..................................................................................................................................................... 6-6

Rotation Function ..................................................................................................................................................... 6-7

Specifications............................................................................................................................................................ 6-8

Electrical.............................................................................................................................................................. 6-8

Hydraulic ............................................................................................................................................................. 6-8

Charge Pump............................................................................................................................................................. 6-9

Multifunction Valves ............................................................................................................................................... 6-10

Electric Displacement Control (EDC).................................................................................................................... 6-11

Rotation Pressure Limiting .................................................................................................................................... 6-12

Forward.............................................................................................................................................................. 6-12

Reverse.............................................................................................................................................................. 6-12

3-Speed Loop Flush Valve ..................................................................................................................................... 6-12

Rotation Motors....................................................................................................................................................... 6-13

Rotation Speed........................................................................................................................................................ 6-14

D24x40 Series II ................................................................................................................................................ 6-14

D36x50 Series II ................................................................................................................................................ 6-14

Troubleshooting ..........................................................................................................................................6-15

Testing Rotation Speed.......................................................................................................................................... 6-15

Testing Rotation Pressure ..................................................................................................................................... 6-16

Pump and Motor Leakage ...................................................................................................................................... 6-17

Pump Port Locations.............................................................................................................................................. 6-18

Troubleshooting the Rotation Function................................................................................................................ 6-19

Basic Rotation Troubleshooting............................................................................................................................ 6-20

Pump Test Procedure............................................................................................................................................. 6-23

Analyzing Test Results........................................................................................................................................... 6-27

Diagnostic Observations Full Load................................................................................................................. 6-27

Possible Result #1 ............................................................................................................................................ 6-27

Page 8 of 476

Table of Contents D24x40/D36x50 Series II Navigator HDD Service

Possible Result #2 ............................................................................................................................................6-27

Possible Result #3 ............................................................................................................................................6-27

Inspect System Relief Valves................................................................................................................................. 6-28

Check Charge Pressure.......................................................................................................................................... 6-28

Pump Case Pressure Test ...................................................................................................................................... 6-30

Test Objective....................................................................................................................................................6-30

Conditions .........................................................................................................................................................6-30

Procedure ..........................................................................................................................................................6-30

Pump Multifunction Valve Inspection.................................................................................................................... 6-31

Charge Pump Relief Valve Inspection................................................................................................................... 6-32

Charge Pressure - Adjust ....................................................................................................................................... 6-33

Rotation Motors Case Drain Flow Test.................................................................................................................. 6-34

Analyzing Motor Test Results ................................................................................................................................ 6-36

Hydraulic Fluid Sampling ....................................................................................................................................... 6-36

Filter Kit Parts.......................................................................................................................................................... 6-37

Flushing the Rotation System................................................................................................................................ 6-38

Procedure ..........................................................................................................................................................6-38

Component Repair ...................................................................................................................................... 6-40

Rotation Pump PMP1 .............................................................................................................................................. 6-40

Drive Chuck ............................................................................................................................................................. 6-41

Drive Chuck Sub-Saver........................................................................................................................................... 6-42

Special Tools and Materials .............................................................................................................................6-42

Thread Locking Compound Considerations ..................................................................................................6-42

Install Sub-Saver ...............................................................................................................................................6-42

Remove Sub-Saver ...........................................................................................................................................6-43

Gearbox Rear Seal .................................................................................................................................................. 6-44

Special Tools and Materials .............................................................................................................................6-44

Remove Seal......................................................................................................................................................6-44

Install Seal .........................................................................................................................................................6-45

Gearbox.................................................................................................................................................................... 6-45

Special Tools and Materials .............................................................................................................................6-45

Remove Gearbox...............................................................................................................................................6-46

Install Gearbox ..................................................................................................................................................6-48

Motor Replacement ................................................................................................................................................. 6-49

Special Tools and Materials .............................................................................................................................6-49

Removal .............................................................................................................................................................6-49

Install Motors.....................................................................................................................................................6-49

Rotation Shaft and Front Seal Removal/Installation............................................................................................ 6-50

Special Tools and Materials .............................................................................................................................6-50

Remove Rotation Shaft and Front Seal...........................................................................................................6-51

Install Rotation Shaft and Front Seal ..............................................................................................................6-52

3-Speed Loop Flush Valve (D24x40 Series II)....................................................................................................... 6-55

3-Speed Loop Flush Valve (D36x50 Series II)....................................................................................................... 6-56

Torque Limiter Valve............................................................................................................................................... 6-57

R.A.T.T. Component (D24x40 Series II) ................................................................................................................. 6-58

Disassembly/Assembly ....................................................................................................................................6-58

Breakout Bench.................................................................................................................................................6-59

Bent Sub Assembly ..........................................................................................................................................6-60

Bent Sub Removal ............................................................................................................................................6-61

Oil Gauge Assembly ............................................................................................................................................... 6-75

Page 9 of 476

D24x40/D36x50 Series II Navigator HDD Service Table of Contents

Thrust/Pullback................................................................................................................................ 7-1

Overview.........................................................................................................................................................7-1

Components .............................................................................................................................................................. 7-1

Component Locations .............................................................................................................................................. 7-2

Electrical Schematic ................................................................................................................................................. 7-4

Hydraulic Schematic................................................................................................................................................. 7-6

Thrust/Pullback Function......................................................................................................................................... 7-7

Hose Connections..................................................................................................................................................... 7-8

Thrust/Pullback Hydrostatic Pump PMP2............................................................................................................... 7-9

Thrust/Pullback Pump Port Locations.................................................................................................................. 7-10

Charge Pump........................................................................................................................................................... 7-11

Multifunction Valves ............................................................................................................................................... 7-11

Operation........................................................................................................................................................... 7-11

Slowdown, Stop and Anti-Crash Sensors ............................................................................................................ 7-12

Slowdown .......................................................................................................................................................... 7-12

Stop.................................................................................................................................................................... 7-12

Anti-Crash ......................................................................................................................................................... 7-12

Thrust Pressure Limiting........................................................................................................................................ 7-12

Specifications.......................................................................................................................................................... 7-13

Electrical............................................................................................................................................................ 7-13

Hydraulic ........................................................................................................................................................... 7-13

Troubleshooting ..........................................................................................................................................7-14

Troubleshooting Carriage Movement ................................................................................................................... 7-14

Move in One Direction Only............................................................................................................................. 7-14

Move in Neither Direction................................................................................................................................. 7-15

Carriage Creeps in Stop................................................................................................................................... 7-16

Motors Respond Slowly ................................................................................................................................... 7-17

Testing Thrust/Pullback Performance .................................................................................................................. 7-18

Adjusting the Pump Neutral Setting...................................................................................................................... 7-19

Checking Bypass Valves........................................................................................................................................ 7-20

Charge Pump Inlet Restriction Measurement ...................................................................................................... 7-21

Charge Pressure Measurement ............................................................................................................................. 7-22

Function Pressure Measurement .......................................................................................................................... 7-23

Case Pressure Measurement................................................................................................................................. 7-23

Case Drain Flow Measurement.............................................................................................................................. 7-24

Case Drain Flow Analysis ................................................................................................................................ 7-24

Testing Proximity Sensors..................................................................................................................................... 7-25

Multifunction Valves ............................................................................................................................................... 7-26

Charge Pressure Relief Valve PV1 ........................................................................................................................ 7-27

Adjusting Charge Pressure Relief Setting............................................................................................................ 7-28

Flushing the Thrust/Pullback Circuit .................................................................................................................... 7-29

Component Repair.......................................................................................................................................7-31

Charge Pump Replacement ................................................................................................................................... 7-31

Pump PMP2 ............................................................................................................................................................. 7-31

Motors MH5 & MH6 ................................................................................................................................................. 7-32

Special Tools and Materials............................................................................................................................. 7-32

Removal.............................................................................................................................................................7-32

Install Motors .................................................................................................................................................... 7-35

Remove Trapped Air from Thrust/Pullback Hydraulic Circuit ............................................................................ 7-36

Carriage Removal/Installation................................................................................................................................ 7-37

Remove Carriage .............................................................................................................................................. 7-37

Page 10 of 476

Table of Contents D24x40/D36x50 Series II Navigator HDD Service

Install Carriage ..................................................................................................................................................7-39

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

Overview......................................................................................................................................................... 8-1

Components .............................................................................................................................................................. 8-1

Component Locations............................................................................................................................................... 8-2

Hose Connections..................................................................................................................................................... 8-4

Hydraulic Schematic ................................................................................................................................................. 8-5

Electrical Schematic ................................................................................................................................................. 8-6

Selector Shift Valve AH5........................................................................................................................................... 8-7

Selector Valves AH8 & AH9...................................................................................................................................... 8-8

Track FORWARD Function....................................................................................................................................... 8-8

Track REVERSE Function......................................................................................................................................... 8-9

Troubleshooting .......................................................................................................................................... 8-10

Testing Ground Drive Performance....................................................................................................................... 8-11

Troubleshooting/Testing Ground Drive Function ................................................................................................ 8-12

Specifications .......................................................................................................................................................... 8-13

Electrical ............................................................................................................................................................8-13

Hydraulic............................................................................................................................................................8-13

Component Repair ...................................................................................................................................... 8-14

Selector Shift Valve Assembly AH5....................................................................................................................... 8-14

Remove ..............................................................................................................................................................8-14

Install..................................................................................................................................................................8-14

Selector Valves AH8 & AH9.................................................................................................................................... 8-15

Track Motors MH1 and MH2 ................................................................................................................................... 8-16

Remove ..............................................................................................................................................................8-16

Disassembly ......................................................................................................................................................8-17

Install..................................................................................................................................................................8-17

Track Chain.............................................................................................................................................................. 8-18

Remove ..............................................................................................................................................................8-18

Install..................................................................................................................................................................8-18

Track Tension Tightener......................................................................................................................................... 8-19

Remove ..............................................................................................................................................................8-19

Install..................................................................................................................................................................8-19

Track Tension Adjustment ...............................................................................................................................8-20

Towing the Machine ................................................................................................................................................ 8-20

Conditions .........................................................................................................................................................8-20

Disengaging the Planetary Gear......................................................................................................................8-20

Planetary Gears ....................................................................................................................................................... 8-22

Remove ..............................................................................................................................................................8-22

Disassembly ......................................................................................................................................................8-23

Assemble ...........................................................................................................................................................8-25

Install..................................................................................................................................................................8-27

Page 11 of 476

D24x40/D36x50 Series II Navigator HDD Service Table of Contents

Stabilizer, Rack Tilt & Cab Swing ................................................................................................... 9-1

Overview.........................................................................................................................................................9-1

Theory.............................................................................................................................................................9-1

Components .............................................................................................................................................................. 9-1

Component Locations .............................................................................................................................................. 9-2

Hose Connections – Rack Tilt and Stabilizer ......................................................................................................... 9-4

Hydraulic Schematic – Rack Tilt and Stabilizer ..................................................................................................... 9-5

Electrical Schematic – Rack Tilt and Stabilizer...................................................................................................... 9-6

Hydraulic Schematic – Cab Swing .......................................................................................................................... 9-7

Electrical Schematic – Cab Swing........................................................................................................................... 9-8

Stabilizer LOWER Function...................................................................................................................................... 9-9

Stabilizer RAISE Function...................................................................................................................................... 9-10

Rack Tilt Function – Rack RAISE Mode................................................................................................................ 9-11

Rack Tilt Function – Rack LOWER Mode.............................................................................................................. 9-11

Cab Swing Function................................................................................................................................................ 9-12

Operation........................................................................................................................................................... 9-12

Troubleshooting ..........................................................................................................................................9-13

Testing Rack Tilt Performance .............................................................................................................................. 9-14

Troubleshooting/Testing the Rack Tilt Function ................................................................................................. 9-15

Testing Stabilizer Performance ............................................................................................................................. 9-15

Troubleshooting Stabilizer Function..................................................................................................................... 9-16

Troubleshooting the Cab Swing Function............................................................................................................ 9-17

Specifications.......................................................................................................................................................... 9-17

Electrical............................................................................................................................................................ 9-17

Hydraulic ........................................................................................................................................................... 9-17

Component Repair.......................................................................................................................................9-18

Rack Tilt Cylinders CY12 & CY13 .......................................................................................................................... 9-18

Disassembly...................................................................................................................................................... 9-19

Assembly & Install............................................................................................................................................ 9-20

Rack Tilt Cylinder Lock Check Valves .................................................................................................................. 9-21

Cab Swing Valves AH7 and AH23.......................................................................................................................... 9-22

Removal.............................................................................................................................................................9-22

Cab Swing Cylinder CY14 ...................................................................................................................................... 9-23

Stabilizer Valve AH19 ............................................................................................................................................. 9-24

Stabilizer Cylinder CY11......................................................................................................................................... 9-25

Remove.............................................................................................................................................................. 9-25

Disassembly...................................................................................................................................................... 9-26

Assembly & Install............................................................................................................................................ 9-27

Stabilizer Cylinder Check Valves CV17 & CV18................................................................................................... 9-28

Disassembly...................................................................................................................................................... 9-28

Stabilizer .................................................................................................................................................................. 9-29

Page 12 of 476

Table of Contents D24x40/D36x50 Series II Navigator HDD Service

Stakedown..................................................................................................................................... 10-1

Overview....................................................................................................................................................... 10-1

Theory........................................................................................................................................................... 10-1

Functions ................................................................................................................................................................. 10-1

Components ............................................................................................................................................................ 10-1

Component Locations............................................................................................................................................. 10-2

Hydraulic Connections ........................................................................................................................................... 10-3

Hydraulic Schematic ............................................................................................................................................... 10-4

Electrical Schematic ............................................................................................................................................... 10-5

Stakedown Valve AH16........................................................................................................................................... 10-6

Stake Up Function................................................................................................................................................... 10-6

Stake Down Function.............................................................................................................................................. 10-7

Troubleshooting ......................................................................................................................................... 10-8

Troubleshooting the Stakedown Function............................................................................................................ 10-9

Testing Stakedown Performance......................................................................................................................... 10-10

Troubleshooting/Testing Stakedown Function .................................................................................................. 10-11

Specifications ........................................................................................................................................................ 10-13

Electrical ..........................................................................................................................................................10-13

Hydraulic..........................................................................................................................................................10-13

Component Repair .................................................................................................................................... 10-14

Stakedown Valve Assembly AH16....................................................................................................................... 10-14

Remove ............................................................................................................................................................10-14

Disassemble ....................................................................................................................................................10-15

Install................................................................................................................................................................10-15

Stakedown Motors MH9 and MH10...................................................................................................................... 10-16

Remove ............................................................................................................................................................10-16

Motor Breakdown............................................................................................................................................10-17

Install................................................................................................................................................................10-18

Stakedown Cylinders CY7 and CY8..................................................................................................................... 10-19

Remove ............................................................................................................................................................10-19

Disassemble ....................................................................................................................................................10-19

Install................................................................................................................................................................10-20

Vises & Auto Greaser .................................................................................................................... 11-1

Overview....................................................................................................................................................... 11-1

Functions ..................................................................................................................................................... 11-1

Components ............................................................................................................................................................ 11-1

Component Locations............................................................................................................................................. 11-2

Hydraulic Connections ........................................................................................................................................... 11-4

Electrical Schematic ............................................................................................................................................... 11-5

Hydraulic Schematic (D24x40 Series II) ................................................................................................................ 11-6

Hydraulic Schematic (D36x50 Series II) ................................................................................................................ 11-7

Vise Valve AH15 ...................................................................................................................................................... 11-8

Vise Interlocks ......................................................................................................................................................... 11-8

Front Vise Clamp Function..................................................................................................................................... 11-9

Front Vise Unclamp ..........................................................................................................................................11-9

Rear Vise Clamp Function.................................................................................................................................... 11-10

Page 13 of 476

D24x40/D36x50 Series II Navigator HDD Service Table of Contents

Rear Vise Unclamp ......................................................................................................................................... 11-10

Rear Vise Rotation Function................................................................................................................................ 11-11

Auto Greaser Function ......................................................................................................................................... 11-12

Troubleshooting ........................................................................................................................................11-13

Testing Vise Performance.................................................................................................................................... 11-14

Troubleshooting/Testing the Auto Greaser Function........................................................................................ 11-15

Troubleshooting/Testing the Vise Functions..................................................................................................... 11-16

Front Vise Clamp Function ............................................................................................................................ 11-16

Rear Vise Clamp Function ............................................................................................................................. 11-17

Rear Vise Rotate Function ............................................................................................................................. 11-18

Specifications........................................................................................................................................................ 11-18

Electrical.......................................................................................................................................................... 11-18

Hydraulic ......................................................................................................................................................... 11-18

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

Vise Valve AH15 .................................................................................................................................................... 11-19

Removal........................................................................................................................................................... 11-19

Disassembly.................................................................................................................................................... 11-20

Front and Rear Vise Cylinders CY4 and CY5 ..................................................................................................... 11-21

Removal........................................................................................................................................................... 11-21

Disassembly.................................................................................................................................................... 11-22

Vise Rotate Cylinder CY3 ..................................................................................................................................... 11-23

Disassembly.................................................................................................................................................... 11-24

Assembly......................................................................................................................................................... 11-24

Auto Greaser Valve AH20..................................................................................................................................... 11-25

Remove............................................................................................................................................................ 11-25

Disassemble.................................................................................................................................................... 11-25

Auto Greaser Cylinder CY2.................................................................................................................................. 11-26

Remove............................................................................................................................................................ 11-26

Disassemble.................................................................................................................................................... 11-27

Assemble......................................................................................................................................................... 11-27

Rod Loader..................................................................................................................................... 12-1

Overview.......................................................................................................................................................12-1

Components ............................................................................................................................................................ 12-1

Component Locations ............................................................................................................................................ 12-2

Electrical Schematic ............................................................................................................................................... 12-3

Hydraulic Schematic............................................................................................................................................... 12-4

Hose Connections................................................................................................................................................... 12-5

Rod Loader Valve AH17.......................................................................................................................................... 12-6

Rod Loader Lower Mode ........................................................................................................................................ 12-7

Rod Loader Lift Mode ............................................................................................................................................. 12-8

Rod Loader Extend Mode....................................................................................................................................... 12-9

Rod Loader Retract Mode .................................................................................................................................... 12-10

Troubleshooting .......................................................................................................................................12-11

Basic Troubleshooting Questions....................................................................................................................... 12-12

Testing Rod Loader Performance ....................................................................................................................... 12-13

Troubleshooting the Rod Loader Extend/Retract Function.............................................................................. 12-14

Troubleshooting Rod Lift Function..................................................................................................................... 12-16

Specifications........................................................................................................................................................ 12-17

Electrical.......................................................................................................................................................... 12-17

Page 14 of 476

Table of Contents D24x40/D36x50 Series II Navigator HDD Service

Hydraulic..........................................................................................................................................................12-17

Component Repair .................................................................................................................................... 12-17

Rod Loader Valve AH17........................................................................................................................................ 12-18

Remove ............................................................................................................................................................12-18

Directional Valves DV13, DV12, and DV9......................................................................................................12-19

Rod Lift Cylinders CY9 and CY10 ........................................................................................................................ 12-20

Remove ............................................................................................................................................................12-20

Disassembly ....................................................................................................................................................12-21

Assembly .........................................................................................................................................................12-22

Rod Loader Motor MH7 and MH8......................................................................................................................... 12-22

Remove ............................................................................................................................................................12-22

Disassembly ....................................................................................................................................................12-23

Assembly .........................................................................................................................................................12-24

Rod Box.................................................................................................................................................................. 12-24

Drilling Fluid................................................................................................................................... 13-1

Overview....................................................................................................................................................... 13-1

Theory........................................................................................................................................................... 13-1

Components ............................................................................................................................................................ 13-1

Component Locations............................................................................................................................................. 13-2

Hose Connections................................................................................................................................................... 13-4

Hydraulic Schematic (D24x40 Series II) ................................................................................................................ 13-5

Hydraulic Schematic (D36x50 Series II) ................................................................................................................ 13-6

Electrical Schematic ............................................................................................................................................... 13-7

Drilling Fluid Function (with Aplex SC-45 Pump)................................................................................................. 13-8

Drilling Fluid Mode (with FMC or Aplex SC-65L Pump)....................................................................................... 13-9

Drill Fluid Off Function.......................................................................................................................................... 13-10

Wash Wand Function............................................................................................................................................ 13-10

Troubleshooting ........................................................................................................................................ 13-11

Testing Fluid Shutoff Valve Performance ........................................................................................................... 13-12

Troubleshooting/Testing the Drilling Fluid Function......................................................................................... 13-13

Troubleshooting the Drilling Fluid Function....................................................................................................... 13-15

Specifications ........................................................................................................................................................ 13-18

Electrical ..........................................................................................................................................................13-18

Hydraulic..........................................................................................................................................................13-18

Component Repair .................................................................................................................................... 13-19

Combination Valve AH3........................................................................................................................................ 13-19

Fluid Shutoff Valve AH13 & Fluid 2-Speed Shift Valve AH12 (D36x50 Series II) ............................................. 13-20

Remove ............................................................................................................................................................13-20

Disassembly ....................................................................................................................................................13-21

Fluid Shutoff Valve AH22 (D24x40 Series II)....................................................................................................... 13-22

Fluid Shutoff Cylinder CY1 and Ball Valve.......................................................................................................... 13-23

Remove ............................................................................................................................................................13-23

Cylinder Disassembly.....................................................................................................................................13-24

Ball Valve Disassembly ..................................................................................................................................13-25

Ball Valve Assembly .......................................................................................................................................13-26

Fluid Pump PMP4 – Aplex or FMC....................................................................................................................... 13-27

Remove ............................................................................................................................................................13-27

Install................................................................................................................................................................13-28

Fluid Pump PMP4 – Aplex SC-45L....................................................................................................................... 13-29

Page 15 of 476

D24x40/D36x50 Series II Navigator HDD Service Table of Contents

Valve Disassembly ......................................................................................................................................... 13-29

Piston Cup and Piston Rod Disassembly..................................................................................................... 13-31

Piston and Crankcase Disassembly ............................................................................................................. 13-32

Fluid Pump PMP4 – FMC...................................................................................................................................... 13-33

Piston Cup Seal Removal/Installation................................................................................................................. 13-33

Special Tools and Materials........................................................................................................................... 13-33

Remove Piston Cup Seals ............................................................................................................................. 13-34

Install Piston Cup Seals ................................................................................................................................. 13-37

Suction and Discharge Valve Removal/Installation........................................................................................... 13-41

Special Tools and Materials........................................................................................................................... 13-41

Remove Valves ............................................................................................................................................... 13-41

Install Valves ................................................................................................................................................... 13-43

Drilling Fluid Motor MH11 – Aplex SC-45L ......................................................................................................... 13-46

Disassembly.................................................................................................................................................... 13-46

Drilling Fluid Motor MH11 – Aplex SC-65L ......................................................................................................... 13-47

Disassembly.................................................................................................................................................... 13-47

Drilling Fluid Motor MH11 – FMC......................................................................................................................... 13-48

Disassembly.................................................................................................................................................... 13-48

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

Overview.......................................................................................................................................................14-1

Theory...........................................................................................................................................................14-2

Functions................................................................................................................................................................. 14-2

Component Locations ............................................................................................................................................ 14-3

Electrical Schematic ............................................................................................................................................... 14-4

Hydraulic Schematic............................................................................................................................................... 14-5

Base Module Indicators.......................................................................................................................................... 14-6

Hydraulic Lockout Mode ........................................................................................................................................ 14-7

Engine Shutdown Backup................................................................................................................................ 14-8

Engine Shutdown Mode ......................................................................................................................................... 14-8

Run ........................................................................................................................................................................... 14-9

Lockout – Hydraulic Lockout............................................................................................................................... 14-10

Lockout – Engine Shutdown................................................................................................................................ 14-11

Power Off ............................................................................................................................................................... 14-11

Remote Registration............................................................................................................................................. 14-12

Battery Condition.................................................................................................................................................. 14-13

Low Battery ..................................................................................................................................................... 14-13

Discharged Battery......................................................................................................................................... 14-13

Recharge Battery ............................................................................................................................................ 14-13

Troubleshooting ........................................................................................................................................14-13

Loss of Signal ....................................................................................................................................................... 14-14

Troubleshooting/Testing the Remote Lockout Function .................................................................................. 14-15

Remote Unit..................................................................................................................................................... 14-15

Base Module.................................................................................................................................................... 14-16

Software........................................................................................................................................................... 14-16

CAN Operation ................................................................................................................................................ 14-16

Hydraulic or Engine Shutdown Lockout Mode ............................................................................................ 14-17

Battery ............................................................................................................................................................. 14-17

Battery Charger............................................................................................................................................... 14-17

Page 16 of 476

Table of Contents D24x40/D36x50 Series II Navigator HDD Service

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

Overview....................................................................................................................................................... 15-1

Theory........................................................................................................................................................... 15-1

Circuits ..................................................................................................................................................................... 15-1

Components ............................................................................................................................................................ 15-2

Component Locations............................................................................................................................................. 15-3

Electrical Schematic ............................................................................................................................................... 15-4

Strike Alert Module Daily Tests.............................................................................................................................. 15-5

Current Test.......................................................................................................................................................15-5

Voltage Test.......................................................................................................................................................15-5

Voltage Strike Circuit .............................................................................................................................................. 15-5

Current Strike Circuit .............................................................................................................................................. 15-6

Troubleshooting/Testing ............................................................................................................................ 15-7

Determining What to Troubleshoot .................................................................................................................15-7

Daily Test ...........................................................................................................................................................15-7

Strike Alert Module Lights...................................................................................................................................... 15-8

Page 17 of 476

D24x40/D36x50 Series II Navigator HDD Service Using the Manual

1-1

General Information

Chapter 1: General Information

USING THE MANUAL

This manual supplies data and servicing procedures. The manual agrees

with machine knowledge and configuration at the time of publication. The

instructions, illustrations and specifications demonstrate the data available

at the time of publication. Recent improvements to the machine may not be

documented in this manual.

Vermeer Corporation reserves the legal right to make changes at any time

without notice or obligation.

This manual provides one procedure for each task. Alternate procedures

may be available. Contact Vermeer Service Support resources.

Additional copies of this manual are available through the Vermeer Parts

Center. Use the order number on the front cover.

Page 18 of 476

Using the Manual D24x40/D36x50 Series II Navigator HDD Service

1-2

General Information

Reference Publications

Vermeer

Publications

Vermeer Corporation Publication order numbers are available on the

Industrial Vermeer Compass internet site.

Check with your IT department or system administrator. Your computer

must be able to accept PDF files.

To find necessary files:

1. Log into Vermeer Compass.

2. Click on iParts.

3. Select Industrial Manuals to retrieve a complete listing of all industrial

manuals currently available.

4.

5. Select Operator and Maintenance Manuals used with the D24x40/

D36x50 Series II machine.

Other manuals available are as follows:

• Vermeer Industrial Dealerships Technician’s Shop Manual, order number

105400V80.

• Recommended Service Tools Users Guide, order number 105400T69 for

special tools and test equipment.

Contact the Vermeer Parts Center to order these publications.

Vendor Publications Contact a John Deere local dealer for engine manuals. Vermeer Corporation

does not verify the validity of vendor information within the context of the

D24x40/D36x50 Series II Navigator HDD machine configuration.

Page 19 of 476

D24x40/D36x50 Series II Navigator HDD Service Warranty Considerations

1-3

General Information

WARRANTY CONSIDERATIONS

Vermeer Warranty

Vermeer 1 year Limited Warranty is inside the front cover of the

Operator’s Manual. The warranty requires that all service work be

conducted by an authorized Vermeer representative or the warranty shall

become void.

John Deere Warranty

The engine is covered under John Deere Warranty.

Understand that only an authorized John Deere 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 John Deere authorized facility, consult the phone directory

or the John Deere Engine website.

SAFETY

General safety messages are in this Safety section of the manual. Specific

safety messages are in the sections of the manual where a potential hazard

may occur if you do not obey the instructions or procedures.

A signal word "DANGER", "WARNING", or "CAUTION" occurs with the safety

alert symbol.

Safety signs with signal word "DANGER", "WARNING", or "CAUTION" are in

position near specific hazards.

DANGER: Indicates a hazardous situation that, if not avoided, will result

in death or serious personal injury.

WARNING: Indicates a hazardous situation that, if not avoided, could

result in death or serious personal injury.

CAUTION: Indicates a hazardous situation that, if not avoided, could

result in minor or moderate injury.

NOTICE: Indicates information considered important, but not

hazard-related.

Page 20 of 476

Safety D24x40/D36x50 Series II Navigator HDD Service

1-4

General Information

Do Not Modify Machine

Make no modifications to your equipment unless specifically recommended

or requested by Vermeer Corporation.

Replace Shields

Be sure that all safety devices, including shields, are installed and

functioning properly after servicing the machine.

Page 21 of 476

D24x40/D36x50 Series II Navigator HDD Service Safety

1-5

General Information

Safety Symbol Explanation

Continued on next page...

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.

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 a hard hat, safety glasses, hearing

protection, and safety shoes.

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.

WARNING: Use the Stop the Engine procedure before servicing, cleaning,

repairing, or transporting machine. Refer to "Shutdown," page 2-1 for

instructions.

Page 22 of 476

Safety D24x40/D36x50 Series II Navigator HDD Service

1-6

General Information

Continued on next page...

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 hydraulic fluid

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.

WARNING: Fuel and fumes can explode and burn.

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

WARNING: Raised machine or components can fall.

Never work under raised equipment unless it is adequately supported to

prevent it from falling.

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.

Page 23 of 476

D24x40/D36x50 Series II Navigator HDD Service Terminology

1-7

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 A circuit is an identifiable grouping of electrical or hydraulic components

that fill a specific role within a function.

Inputs and Outputs Inputs and outputs have different line styles on the function schematics and

other circuit diagrams. Arrows on the end of the lines show direction of

electrical current flow, hydraulic oil flow, and air flow.

Reference

Designators

Each designator identifies a specific component on the schematics and other

reference diagrams. 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.

WARNING: Battery posts, 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.

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

Stay away from rotating drill rod and drilling tool.

WARNING: Moving parts can crush fingers.

Close all shields before starting.

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.

Page 24 of 476

Troubleshooting Guidelines D24x40/D36x50 Series II Navigator HDD Service

1-8

General Information

Diagrams and Schematics

Functional diagrams, schematics, wire harness connections, and hydraulic

hose connection diagrams are located throughout the manual. The diagrams

show function circuitry and components. Complete electrical and hydraulic

schematics are available on the Vermeer Compass website.

TROUBLESHOOTING GUIDELINES

The troubleshooting procedures in this manual are for the electrical and

hydraulic circuits. Do a check for mechanical issues before reading the

troubleshooting procedures.

Do not skip the troubleshooting. Replacing a component may be the solution,

but it will waste time and money, as well as decrease your credibility with

the customer if it is not the solution. Do the analysis and research to find the

true cause of the issue.

Page 25 of 476

D24x40/D36x50 Series II Navigator HDD Service Troubleshooting Guidelines

1-9

General Information

Troubleshooting Analysis

Do a check of the machine functions and find if there is a technical issue.

Operator Error The operator may not know the correct position of the machine controls for

the operation of a machine function.

Make sure that you and the operator know the correct position of the

machine controls. Do a check of all controls on the machine.

Analysis After doing a check of machine controls, start the analysis as follows:

• Operate all other functions of the machine. Are there any other issues?

Multiple issues can have the same cause or separate causes.

• Do a check for low hydraulic fluid, damaged hoses or damaged wires. If

you are not at the machine, ask the operator to do the check.

• Speak with the operator.

• Is the machine function too slow, too fast or not performing?

• When did the issue start?

• Did the issue start suddenly or slowly?

• Were any changes made to the machine or work procedure before the

issue started?

• Were there any unusual smells, sounds or machine behaviors?

• Is the issue intermittent or continuous?

If intermittent, is the machine cold or fully warmed up?

• Is the weather at the machine cold, hot, dry or humid?

• Compare the issue with other issues you have checked before.

• Record the symptoms and changes.

Page 26 of 476

Electrical Troubleshooting D24x40/D36x50 Series II Navigator HDD Service

1-10

General Information

Research the

System

Read the Machine Information, Power and Hydraulic Fluid Distribution

chapters of this manual. These chapters tell how the machine functions

interact and how some components have effects on more than one machine

function.

If you do not know the machine functions, read the Operator’s Manual for all

or selected functions.

All machine functions with hydraulic circuits share the fluid conditioning

and supply components. If multiple functions fail, troubleshoot these shared

components first. Record which functions appear to behave as expected and

which ones do not.

ELECTRICAL TROUBLESHOOTING

Do a check for ground, high resistance, short circuit, and open circuits when

troubleshooting the electrical circuits. Refer to Part 2 of Vermeer Industrial

Dealerships Technician’s Shop Manual, order number 105400V80 for

procedures and information.

HYDRAULIC TROUBLESHOOTING

In leakage path analysis, you do a test of components under no-load

conditions and then full-load conditions. You compare the test

measurements to the specifications in the troubleshooting section of each

chapter.

The specifications in each chapter frequently give the nominal, minimum,

and maximum operating values.

High leakage will cause system overheating and/or a decrease in actuator

speed. The pressure difference across clearances, oil viscosity, temperature,

and size of clearances increase or decrease the amount of leakage. Loss of

clearance is usually related to viscosity.

For more information on hydraulic component troubleshooting and testing,

refer to Part 3 of Vermeer Industrial Dealerships Technician’s Shop Manual,

order number 105400V80.

Page 27 of 476

D24x40/D36x50 Series II Navigator HDD Service Hydraulic Troubleshooting

1-11

General Information

Recommended Diagnostic Tools

These tools will provide more accurate and timely troubleshooting plus

improved productivity by your technicians and service department. For

information on using flow meters, needle valves, pressure gauges,

thermometers, pyrometers, and multimeters, refer to Vermeer Industrial

Dealerships Technician’s Shop Manual, order number 105400V80.

Computer System Recommended MINIMUM computer system requirements:

• Windows operating system (Windows XP or later).

• At least 512 MB is recommended (optimal 1 GB of RAM or higher).

• At least 1.5 gigabytes of available space on the hard disk.

• 2 USB ports – Need to be 2.0 powered ports. One RS-232 serial port

(could use a USB to Serial converter 296272732).

• CD-ROM or DVD-ROM drive.

• Keyboard and a Mouse or some other compatible pointing device.

• Local Administrator Access

• Access to Email for license registration

• Internet access

• Plus+1 diagnostic tool down-loaded from Compass

• Necessary files for equipment.

• Will need active license (available from Service department.)

• Necessary JSYM files for equipment

• Reflash tool downloaded from Compass (required to re-program ACS

controllers.)

• Necessary VCP files for equipment.

• Support tools for computer:

• 296287412 - Harness CAN Splice 2-pin to 3-pin

• 296287411 - Harness CAN 4 Way Adapter. Allows programming of

blank modules, like strike alert and remote lockout.

Electrical Support

Items

Recommended electrical test tools:

• Multimeter

• 296256528 - Electrical Service Kit: includes sealed Deutsch and Packard

connectors

• 286553001 - Deutsch Crimping Tool (Field)

• 603961001 - Deutsch Crimping Pliers

• 286553003 - Deutsch Tool (Field)

Continued on next page...

Page 28 of 476

Hydraulic Troubleshooting D24x40/D36x50 Series II Navigator HDD Service

1-12

General Information

• 905102001 - Contact Removal Tool

• 276893001 - 20/24 Ga. Extractor Tool (Red)

Hydraulic Support

Items

Recommended hydraulic test tools:

• Pressure gauges

• Hydraulic flow meter

• 152620001 - Proactive Maintenance Kit: 0–50 gpm (0–19 L/min) flow

meter, 0–3000 psi (0–207 bar) pressure gauge, laser pyrometer, 30" Hg

(1.00263 Atm) vacuum gauge, digital tachometer, and miscellaneous

fittings.

• Vacuum gauge – 15" Hg, for measuring inlet pressure

• 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

• Portable hydraulic tester (porta-power)

The following test equipment is necessary for performing electrical and/or

hydraulic troubleshooting.

• Calculator – for doing simple arithmetic quickly and accurately

• Pyrometer or thermometer with a magnetic base – for temperature

readings

Page 29 of 476

D24x40/D36x50 Series II Navigator HDD Service Hydraulic Troubleshooting

1-13

General Information

Pretest Inspection

Do the following visual checks to inspect for obvious signs of failure before

any exhaustive troubleshooting or testing is performed.

Mechanical Inspect mechanical valve control handles and linkages for damage,

misalignment, or improper adjustment.

Electrical Always check the following items before turning on switches or running the

unit.

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

• Look for broken, missing, or corroded wires, or loose connections on the

wires that supply power to 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.

Hydraulic Check hydraulic circuits for any failures.

• Look for broken, kinked, loose, or leaking hoses and fittings on hydraulic

components.

• Check level of hydraulic fluid in hydraulic tank. Low fluid can cause

erratic behavior in hydraulic circuits. Correct level is between the two

lines on sight gauge. Ensure fluid being added has been filtered through

a 5-micron filter.

Also review information in "Hydraulic Troubleshooting," page 1-10. Correct

any issues found during the inspection. Operate machine to verify the fault

is fixed.

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 hydraulic fluid

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.

Page 30 of 476

Hydraulic Troubleshooting D24x40/D36x50 Series II Navigator HDD Service

1-14

General Information

Hydraulic Connections

Trapped Pressure Prevent trapped pressure. Never disconnect hoses or lines unless the engine

is stopped.

Remove all hydraulic pressure from hydraulic system before removing any

hydraulic hoses:

• When you remove components, always remove as much load (weight)

from cylinders and other actuators as possible. Lower any attachment

completely and support it with suitable blocking.

• Relieve pressure in the hydraulic system before you disconnect hoses. If

you lower the attachment to the ground, stop the engine and cycle the

control levers, you may decrease the pressure in many circuits. This will

not relieve all pressure.

• When you loosen fittings in hoses with residual pressure, slowly loosen

the fittings until oil begins to leak. Wait for the leakage to stop before

you disconnect the fittings.

• Do a check that all connections are tight and hoses are in good condition

before you supply pressure to the system.

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.

Page 31 of 476

D24x40/D36x50 Series II Navigator HDD Service Repair Guidelines

1-15

General Information

Avoid Oil

Contamination

Warranty claims may be

denied if contaminated

hydraulic fluid caused

the damage.

Do not let contaminants to go into the hydraulic system. Contaminated oil

will damage a pump in a short period of time.

• Clean dirt from the area near a hose connection before you loosen the

connection.

• Use new, clean caps to plug disconnected hoses. If clean caps are not

available, place clean plastic bags over the ends of the hoses and hold the

bags in position with rubber bands.

• When you add hydraulic fluid, use new fluid filtered through a 5-micron

absolute filter. (New oil contains contaminants and should not be added

directly to the hydraulic tank.)

• Dirt on a cylinder rod can go into the system when the rod retracts.

Wiper seals clean dirt from the rod as it retracts, but scratches in the rod

can let dirt go around the wipers. Examine for scratches on cylinder rods.

Move your fingernail across the surface. If you fingernail can sense a

scratch, polish it out with fine emery cloth or replace the rod.

REPAIR GUIDELINES

Safety Equipment

All technicians must have and use proper safety equipment, including steel- toed shoes, protective eye wear, gloves, and hearing protection. Wear a hard

hat if working around lifted loads shoulder height and above.

Let spectators or bystanders into your shop only when they are wearing

adequate protective gear.

The shop must have proper fire prevention and fire-fighting equipment and

all technicians must know how and when to use it.

Shop Requirements

Special Tools & Test

Equipment

Special tools, available through Vermeer, may be necessary for some tasks.

The procedure will tell which special tools are necessary.

Refer to the Recommended Service Tools Users Guide (Vermeer P/N

105400T69) for special tools and test equipment.

20General Information\

Page 32 of 476

Repair Guidelines D24x40/D36x50 Series II Navigator HDD Service

1-16

General Information

Personnel and Lifting Requirements

Read each procedure to determine the number of personnel necessary for

safe completion.

Do an analysis if you will need suitable lifting devices to safely lift or lower

the component.

Replacement Parts

Part Numbers/Hose

Lengths/Fitting

Orientation

Refer to the most current parts manual for part numbers, hose lengths, and

fitting orientations.

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

replacement components.

Recommended Torque Values

Repair procedures in this manual will show torque values for any part that

must be tightened to a non-standard torque value. For standard torque

values, refer to the torque tables, given in the Vermeer Industrial

Dealerships Technician’s Shop Manual, order number 105400V80.

Page 33 of 476

D24x40/D36x50 Series II Navigator HDD Service Repair Guidelines

1-17

General Information

Valve Service

Always release pressure before you remove a solenoid valve. A cartridge

valve may function as a check valve and may trap and retain pressure in a

system.

If you lower the attachment to the ground, stop the engine and cycle the

control levers, you may decrease the pressure in many circuits. But pilot

pressure from the pump may be necessary to open the valve and relieve

trapped pressure. Never think that there is no pressure in the system

because the engine is stopped or you have cycled a control lever or

button!

Disassembly Inspect the cartridge valve for contamination. O-rings and backup rings

should be intact and in the correct position. The O-ring should always point

towards the higher pressure port or between double backups on bi- directional valves. Inspect the valve body cavity for burrs or defects in the

surface. They can damage O-rings during installation.

Assembly Dip the cartridge valve in clean hydraulic fluid. Turn the cartridge by hand

until the top O-ring makes contact, then use a wrench to tighten it to the

specified torque.

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.

WARNING: Use extreme caution when removing a cartridge valve. The

cartridge may be released with great force if trapped pressure remains in

the circuit. Do not stand in front of the cartridge when removing it.

WARNING: Before performing any maintenance on the machine, follow

the Shutdown procedure unless instructed differently by the manual.

Page 34 of 476

This page intentionally left blank.

Page 35 of 476

D24x40/D36x50 Series II Navigator HDD Service Start & Stop Procedures

2-1

Machine Information

Chapter 2: Machine Information

START & STOP PROCEDURES

Shutdown

For your safety and the safety of others, perform this procedure before you

service, clean, examine or perform other maintenance on the machine.

If you stop the engine while in LOCKOUT mode, the remote transmitter

must be near the operator when you start the engine so that you can cancel

LOCKOUT mode and push the RUN mode button.

1. Push the drilling fluid pump on/off switch to the OFF position.

2. Move joysticks to the NEUTRAL position.

3. Decrease the engine speed to low idle level.

4. Wait 2 minutes to stop the engine after operating at full throttle level.

5. To stop the machine completely, turn the ignition switch to the OFF

position and remove the key.

To stop the engine only, press the emergency stop button on the control

panel. Electrical systems will stay on.

If you do work on the drill string or drill tools at a remote location away from

the machine, perform the procedure in "Run," page 14-9.

In an emergency you may change this procedure. If other procedures in this

manual change steps in this procedure, obey those procedures.

Page 36 of 476

Start & Stop Procedures D24x40/D36x50 Series II Navigator HDD Service

2-2

Machine Information

Start the Engine

1. Make sure the emergency stop buttons are in the Out position.

2. Turn the ignition switch to START position.

If the ignition switch is in the ON position, push the engine start button

(on the control panel or on the remote control).

Never operate starter motor for more than 30 seconds continuously. Let

starter motor cool for 2 minutes before you try again.

3. Push the alarm cancel button to stop the horn during the self-test of the

remote lockout system. The yellow light on the control panel will

continue to flash.

4. Perform the procedures in "Run," page 14-9 to put the remote lockout in

RUN mode.

5. Let the engine warm for 3–5 minutes.

6. Push the Hydraulic Enable button.

7. Monitor the display for faults caused by incorrect switch or joystick

positions during the engine start.

WARNING: Pressing Hydraulic Enable button will result in vise

movement if the vise control switch positions changed while the engine

was turned off. If rod lifter is in lowered position, pressing Hydraulic

Enable button will raise lifter. Crushing injury may result. Keep everyone

clear of machine.

Page 37 of 476

D24x40/D36x50 Series II Navigator HDD Service Start & Stop Procedures

2-3

Machine Information

Start in Cold Weather

Engine Refer to the operation manual from the engine manufacturer for the engine

oil and fuel that they recommend.

Hydraulic Fluid Refer to the “Lubricants” section in the Maintenance Manual 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 the engine.

Gradually increase the engine speed for 30 minutes to allow hydraulic oil to

warm up. To assist in warming up the hydrostatic system, move the

joysticks.

Decrease the throttle if a hydraulic pump makes noise (squeals) because it

does not receive sufficient oil.

To frequently start the machine below 10°F (-12°C), consult your Vermeer

dealer.

Page 38 of 476

Specifications D24x40/D36x50 Series II Navigator HDD Service

2-4

Machine Information

SPECIFICATIONS

Machine Reference and Orientation

This diagram shows the left, right, front, and rear of the machine.

RIGHT

LEFT

REAR

FRONT

Page 39 of 476

D24x40/D36x50 Series II Navigator HDD Service Specifications

2-5

Machine Information

Machine Specifications

Notice: Weights are approximate and rounded.

Engine

Specifications

Refer to "Specifications," page 3-16.

Close Loop Systems

Specifications

Refer to "Specifications," page 6-8 for the rotation circuit and "Specifications,"

page 7-13 for the thrust and pullback circuit.

PFC & Drilling Fluid Specifications

Weights

D24x40 Series II 23,600 lb (10,700 kg)

D36x50 Series II 28,200 lb (12,800 kg)

Dimensions

overall length 23 ft 8 ̋ (7.2 m)

overall width (with cab) 7 ft 9 ̋ (2.4 m)

overall height (at top of rod box with rack raised) 6 ft 3 ̋ (1.9 m)

PFC System

pump make/model Sauer 45 series

high pressure compensator setting 3000 psi (207 bar)

pump nominal flow @ 2400 rpm 32 gpm (121 L/min)

Water System

pump makes/models Aplex SC-45, FMC L0918HD, Aplex SC-65L

pump maximum nominal flow

SC-45 - 50/25 gpm (189/95 L/min)

L0918HD - 53 gpm (201 L/min)

SC-65L - 70 gpm (265 L/min)

pump maximum rated pressure

SC-45 - 492/985 psi (33.9/67.9 bar)

L0918HD - 1300 psi (89.6 bar)

SC-65L - 850 psi (58.6 bar)

Page 40 of 476

Machine Performance D24x40/D36x50 Series II Navigator HDD Service

2-6

Machine Information

Fuel and Lubricants

MACHINE PERFORMANCE

Many chapters have a performance check procedure for that function. Refer

to the information below and "Pretest Inspection," page 1-13 before you

perform those checks.

Tools Needed • Stopwatch

• Pen or Pencil

• Calculator (optional)

• White Marker

• Reflective Tape

• Photo tachometer

• Pyrometer or Magnetic Thermometer

Lubricant Capacity Specifications / Notes

Fuel 45 gal (170 L) An engine operation manual is supplied with each machine. Engine Oil Refer to the manual for engine service requirements. refer to engine

specifications

Hydraulic Fluid

Vermeer HyPower 46 or

Vermeer HyPower 68 or

Vermeer HyPower 100

55 gal (208 L) ISO 46: -13° to 86°F (-25° to 30°C)

ISO 68: -4° to 104°F (-20° to 40 °C)

ISO 100: 14° to 122°F (-10° to 122°C)

Use caution not to get dirt or other contaminants into the

system(s). Filter all fluid through a 5-micron filter before

adding.

Use of any oils other than those recommended, without

written factory approval, will jeopardize the warranty.

All-Purpose Gear Lube

(rotation gearbox)

maintain check plug

level

Oils must conform to API GL5 or MIL-L-2105D

specifications.

-20° to 100°F (-30° to 40°C): 80W-90

20° to 120°F (-10° to 50°C): 85W-140

General Lubricating

Oil

Vermeer Ultra Gold

10W30

as required

SAE10W30

Grease

Vermeer Ultra LC

Grease

as required Lithium complex, extreme pressure NLGI Grade 2

To minimize condensation in bearings, grease machine after

it is shut down for the day.

Fittings and grease applicator nozzle must be clean before

applying grease. Replace all missing fittings.

Page 41 of 476

D24x40/D36x50 Series II Navigator HDD Service Overview

3-1

Power

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 fuses used for the various circuits on the machine.

THEORY

Functions

The following functions and circuits are included in this chapter:

• Ignition Circuits

• Engine Monitoring

• Battery Charging

• Engine

• Engine Fuel Supply and Return

• Engine Intake Air/Exhaust

• Engine Cooling

Page 259 of 476

D24x40/D36x50 Series II Navigator HDD Service Component Repair

7-33

Thrust/Pullback

Because cleanliness is

extremely important,

cap or plug all of the

hoses, tubes and fittings

during disassembly.

4. Label, remove and cap hoses and tube fittings.

Because cleanliness is

extremely important,

cap or plug all of the

hoses, tubes and fittings

during disassembly.

5. Label, cap, and remove hoses attached to the motor and brake assembly.

Continued on next page...

2 3

1

6 5

4

Page 301 of 476

D24x40/D36x50 Series II Navigator HDD Service Theory

9-7

Stabilizer, Rack Tilt & Cab Swing

Hydraulic Schematic – Cab Swing

3000 PSI

B

S

250 PSI

X

M2

L2

L1

1

3 2

4

V1 C1

V2

C2

T

P

C B

3300

PSI

TM LS1

WM

LS2

CAB SWING

CAB SWING

PFC PUMP PMP3

COMBINATION

CYLINDER

VALVE AH3

VALVE AH7

CY14

AH23

DV27

DV28

DV29

PV4 CV5

DV30

DV31

DV33 CV10

CV11

Page 308 of 476

Troubleshooting D24x40/D36x50 Series II Navigator HDD Service

9-14

Stabilizer, Rack Tilt & Cab Swing

Testing Rack Tilt Performance

1. Ensure switches listed in "Rack Tilt Function – Rack RAISE Mode," page 9-

11 or "Rack Tilt Function – Rack LOWER Mode," page 9-11, are in correct

positions.

2. Start the engine.

3. Put Remote Lockout in RUN mode.

4. Press hydraulic enable button to enable rack hydraulic circuits.

5. Push rack raise button to RAISE position until rack tilt cylinders are

fully extended.

6. Ensure rack cylinders are fully extended so that the rack is fully raised.

If necessary, disconnect and remove stakedown augers from motor shafts

before proceeding to help ensure damage does not occur to workplace

floor. Then raise stakedown cylinders to their maximum height.

7. Simultaneously start stopwatch and push rack lower button to the

LOWER position. Stop timing when rack tilt cylinders are fully

retracted. Time required for rack tilt to move from fully raised to fully

lowered position should be 12 ± 2 seconds.

8. Repeat step 7 moving joystick to RAISE position. Time required for rack

tilt to move from fully lowered to fully raised position should be 11 ± 2

seconds.

Page 338 of 476

Component Repair D24x40/D36x50 Series II Navigator HDD Service

10-14

Stakedown

COMPONENT REPAIR

Review all warnings and cautions in "Safety," page 1-3, before performing

any repair procedures.

Stakedown Valve Assembly AH16

Remove 1. Remove screw (4) and washer (2) on console cover.

2. Label, disconnect, and cap all hydraulic hoses to valve.

3. Disconnect wire harnesses going to solenoids.

Continued on next page...

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 hydraulic fluid 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

2

2

2

3

4

5

Page 340 of 476

Component Repair D24x40/D36x50 Series II Navigator HDD Service

10-16

Stakedown

Stakedown Motors MH9 and MH10

Remove

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

2. Remove bolts (1), washers (2), and nuts (3) mounting motor to the

stakedown assembly motor mount (4).

3. Lift motor from motor mount.

4. Remove pin (5) from coupler (6) on motor. Remove motor from coupler.

Motor (dry) weighs approximately 70 lb (40 kg).

1

2

3

4

5

6

Page 341 of 476

D24x40/D36x50 Series II Navigator HDD Service Component Repair

10-17

Stakedown

Motor Breakdown

Refer to the diagram below for motor component locations. Refer to the Parts

Manual for seal kit part numbers.

1. Dust seal 5. Lathe cut seal

2. Metal backup shim 6. Body seal

3. Teflon backup shim 7. Commutator seal

4. Shaft seal 8. O-ring seal

Continued on next page...

1

2

3

4

5

5

6

6

6

7

8

9

10

10

11

12

13

14

14

15

15

16

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

Page 343 of 476

D24x40/D36x50 Series II Navigator HDD Service Component Repair

10-19

Stakedown

Stakedown Cylinders CY7 and CY8

Remove 1. Label, disconnect and cap all

hydraulic hoses and fittings on the

cylinder.

2. Remove bolts (1) and nuts (2)

holding cylinder to motor slide

mount (3) at top of stakedown

assembly.

Cylinder (dry) weighs

approximately 44 lb (20 kg).

Disassemble

1. Remove setscrew (5) securing threaded cap head (7) and threaded gland

(6).

2. With a suitable device (wrench or come-along), pull the rod assembly (4)

out of cylinder body. Ensure ports are open and position to direct oil into

a suitable draining pan.

3. Remove lock nut (1) from rod assembly.

NOTICE: Do not clamp onto unpainted portion of the rod. Scarring rod can

cause premature seal failure.

Continued on next page...

1 2

3

1 8 2 3 4 5 6 7

9 9 10

11 12

13 14

Page 348 of 476

Functions D24x40/D36x50 Series II Navigator HDD Service

11-4

Vises & Auto Greaser

Hydraulic Connections

2

4

3

1

T1 T

P1

P

A3

B3

A2

B2

B1

A1

T

LS2

B

REAR VISE

FRONT VISE

COMBINATION

VISE ROTATION

CYLINDER

AUTO GREASER

CYLINDER CY2

CYLINDER CY3

CYLINDER CY5

CY4

PFC PUMP PMP3

TO TANK

TO TANK

TO TANK

VISE VALVE AH15

GEARBOX LOCK

CYLINDER CY6

VALVE AH3

AUXILIARY DISTRIBUTION

MANIFOLD AH14

AUTO GREASER

VALVE AH20

Page 358 of 476

Troubleshooting D24x40/D36x50 Series II Navigator HDD Service

11-14

Vises & Auto Greaser

Testing Vise Performance

The performance values listed for the vise circuit checks are for reference

purposes only. Operational conditions of these circuits shall not be

determined by the results of these tests alone. If circuit operation is in

question, refer to vise troubleshooting procedures.

1. Conduct inspection before proceeding.

2. Start the engine.

3. Put Remote Lockout in RUN mode.

4. Press hydraulic enable push button to enable hydraulic circuits.

5. Press front vise switch S34 at top to CLAMP position. Front vise cylinder

will fully extend in approximately 2 seconds.

6. Press front vise switch S34 at bottom to RELEASE position. Front vise

cylinder will fully retract in 2 seconds.

7. Move rear vise switch S35 to CLAMP position. Rear vise clamp cylinder

will fully extend in approximately 2 seconds.

8. Move rear vise switch S35 to RELEASE position. Rear vise clamp

cylinder will fully retract in 2 seconds.

9. Press rear vise rotate switch S36 once to ROTATE CCW position. Rear

vise rotate cylinder will fully extend in approximately 2 seconds.

10. Press rear vise rotate switch S36 again. Rear vise rotate cylinder will

fully retract in approximately 2 seconds.

Page 360 of 476

Troubleshooting D24x40/D36x50 Series II Navigator HDD Service

11-16

Vises & Auto Greaser

Troubleshooting/Testing the Vise Functions

Before beginning any troubleshooting or testing procedures, perform the

"Pretest Inspection," page 1-13. If nothing obvious is found, continue.

Front Vise Clamp

Function

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.

2. If any functions other than the front vise clamping function are faulty,

continue troubleshooting based on the possible results given. If all other

machine functions are operating normally, continue.

3. If front vise does not remain clamped, troubleshoot the circuit that

controls solenoid L16 and valve DV22.

Refer to the Vermeer Industrial Dealerships Technician’s Shop Manual

(Vermeer P/N 105400V80), for helpful information on testing electrical

circuits for shorts, opens, and high resistance.

4. Test for acceptable voltage starting at solenoid coil L15 of valve DV21. If

voltage is acceptable, continue with step 6. If not, continue with step 5.

5. Test resistance of solenoid coil L15.

Expected result: Resistance of solenoid coil L15 should measure 7.2 ohms

@ 68°F (20°C). If OK, continue. If not, replace coil.

6. Test cylinder 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. Refer to repair

information in this chapter and repair or replace if necessary. If cylinder

tests OK, continue.

7. Remove and inspect cartridge valve DV21 in vise valve assembly. Refer

to "Vise Valve AH15," page 11-19. Repair or replace faulty components.

Page 363 of 476

D24x40/D36x50 Series II Navigator HDD Service Component Repair

11-19

Vises & Auto Greaser

COMPONENT REPAIR

Review all warnings and cautions in "Safety," page 1-3, before performing

any repair procedures.

Vise Valve AH15

Removal 1. Loosen washers (4) and nuts (5) on vise valve shield (6). Remove shield.

2. Label, disconnect, and cap hydraulic hoses and fittings (3, 8 and 9).

3. Plug valve block ports.

Continued on next page...

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 hydraulic fluid 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

2

3

4

4

5

6

7

9 8

Page 364 of 476

Component Repair D24x40/D36x50 Series II Navigator HDD Service

11-20

Vises & Auto Greaser

4. Disconnect wire harnesses from solenoid coils.

5. Remove bolts (7), washers (4), and nuts (5) mounting valve body to

frame.

6. Remove valve manifold.

Reverse removal procedure to install valve. Torque mounting bolts to 35 ft-lb

(47 Nm).

Disassembly

1. Remove nuts (1) on solenoid coils (2) and solenoid coils (3).

2. Remove cartridge valve.

3. Inspect valves and O-rings for damage and ensure no external

contaminants are present.

4. Inspect valve body cavity for burrs or other irregularities which could

damage seals during installation.

When assembling valve, reverse disassembly procedures.

Torque valves DV19, DV20 and DV21 to 25 ft-lb (33 Nm). Torque valves

DV22 and DV30 to 20 ft-lb (27 Nm). Torque solenoid nuts on coils (1) to 5

ft-lb (6 Nm).

VALVE DV22

SOLENOID L16

1

VALVE DV19

SOLENOID L13

VALVE DV20

SOLENOID L14

VALVE DV21

SOLENOID L15

1

2

3

VALVE DV30

SOLENOID L29

Page 369 of 476

D24x40/D36x50 Series II Navigator HDD Service Component Repair

11-25

Vises & Auto Greaser

Auto Greaser Valve AH20

Remove 1. Disconnect wiring to solenoid (1).

2. Label, disconnect, and cap hoses and remove fittings (2) and (3).

3. Remove bolts (4) and washers (5).

Disassemble 1. Remove nut (6) and solenoid (1).

2. Remove cartridge valve.

3. Inspect valve and seals for damage and ensure no external contaminants

are present.

4. Inspect valve body cavity for burrs or other irregularities.

5. Replace seals if needed.

6. Dip valve in clean, filtered hydraulic fluid.

To install, reverse disassembly and removal steps.

Torque valve to 20 ft-lb (27.1 Nm). Torque solenoid nut to 5 ft-lb (6.8 Nm).

Torque mounting bolts to 10 ft-lb (13 Nm).

1

3

5

2

2

4

6

Page 370 of 476

Component Repair D24x40/D36x50 Series II Navigator HDD Service

11-26

Vises & Auto Greaser

Auto Greaser Cylinder CY2

Remove 1. Stop the engine.

2. Label, disconnect, and cap hoses and remove fittings (1) and quick

connect couplers (2).

3. Remove bolts (4) from cylinder (3).

4. Disengage cylinder (3) from piston (6) on bucket greaser top and remove

O-rings (5).

Continued on next page...

5

3

4

6

1

2

1

Page 374 of 476

Overview D24x40/D36x50 Series II Navigator HDD Service

12-2

Rod Loader

Component Locations

FRONT LIFT REAR LIFT ROD LOADER

FRONT ROD LOADER MOTOR MH8 REAR ROD LOADER MOTOR MH7

ANTI-CRASH

ROD

TRANSFER

RETRACT

SWITCH S39

ROD LOADER LIFT

SWITCH S37

ROD

TRANSFER

EXTEND

SWITCH S38 ROD LOADER LOWER

SWITCH S40

CYLINDER CY9 VALVE AH17 CYLINDER CY10

SENSOR B32

REAR SLOWDOWN

SENSOR B30

FRONT SLOWDOWN

SENSOR B29

REAR STOP

SENSOR B31

FRONT STOP

SENSOR B28

FRONT SLOWDOWN

SENSOR B29

REAR SLOWDOWN

SENSOR B30

REAR STOP

SENSOR B31

10 FT RACK

15 FT RACK

Page 375 of 476

D24x40/D36x50 Series II Navigator HDD Service Overview

12-3

Rod Loader

Electrical Schematic

P457-1 P457-2

P461-1 P461-2

P454-1 P454-2

P458-1 P458-2

(SENSOR GROUND)

C1P12 (DIN)

C1P11

C1P10

(DIN)

(DIN)

C1P07

C1P06

(DIN)

(DIN)

C1P09

(PWMOUT) C1P45

(PWMOUT) C1P44

(DOUT)

(DOUT)

(DOUT)

C1P33

C1P32

C1P31

417-1

417-2

417-3

417-4

419-1

419-2

419-3

419-4

420-1

420-2

420-3

420-4

421-1

421-2

421-3

421-4

422-1

422-2

422-3

422-4

445-TN

785-PU

776-DG

775-DB

341-BK

341-BK

341-BK

341-BK

341-BK

809-PK

810-TN

812-GY

811-PU

442-TN

141-OR

141-OR

141-OR

141-OR

141-OR

141-OR

343-BK

343-BK

343-BK

343-BK

J/P400 J/P400

(POWER+)

(POWER+)

(POWER+)

(POWER+)

(POWER+)

C1P48

C1P50

C1P49

C1P47

C1P02

(CAN1+)

(CAN1-)

(CAN1 SHIELD)

(CAN0 SHIELD)

(CAN0-)

(CAN0+)

(POWER-)

C1P04

C1P20

C1P21

C1P22

C1P05

C1P03

C1P01

MAIN BUSS

RACK BUSS

140-OR

140-OR

140-OR

140-OR

140-OR

340-BK

985-YL

986-GN

994-YL

995-GN

P490-2 P490-1

30A PWM OUT 01

15A DIG OUT 06

CAN

CAN

RR1(1)

RR1(2)

RP1(4)

RP2(5)

RP3(6)

RT2(7)

RT1(8)

+12V P120-2

J/P120-4

J/P120-3

J/P120-1

CAB BUSS

170-OR 376-BK

991-YL

992-GN CAN

A16

A18

A7

RIGHT JOYSTICK

RACK MODULE

PDM

ROD LOADER LIFT S37

ROD LOADER LOWER S40

ROD ARM RETRACT S39

ROD ARM EXTEND S38

FRONT STOP B28

FRONT SLOWDOWN B29

REAR SLOWDOWN B30

REAR STOP B31

ANTI-CRASH B32

ROD LIFT L5

ROD POWER L6

ROD ARM EXTEND L32

ROD ARM RETRACT L33

Page 376 of 476

Overview D24x40/D36x50 Series II Navigator HDD Service

12-4

Rod Loader

Hydraulic Schematic

3000 PSI

B

S

250 PSI

X

M2

L2

L1

19.8

CID

CD

B A 19.8

CID

CD

B A

T

P

C B

3300

PSI

TM LS1 LS2

WM

T

T1

P1 P

C1

C2 C4

C3

T2

M2

M1 M3

M4

PFC PUMP PMP3

TO RETURN MANIFOLD

FRONT

REAR ROD

REAR ROD LIFT

CYLINDER CY9

CYLINDER

COMBINATION VALVE AH3

AUXILIARY

MANIFOLD

STAKEDOWN

VALVE AH16

ROD LOADER

MOTOR MH7

FRONT ROD

MOTOR MH8

ROD LIFT

CY10

DV28

PV4

DV29

DV27

DISTRIBUTION

AH14

VALVE AH17

LOADER

LOADER

CV5

DV30

DV31

DV13

DV12

DV9

FV2

Page 378 of 476

Overview D24x40/D36x50 Series II Navigator HDD Service

12-6

Rod Loader

Rod Loader Valve AH17

Rod loader valve AH17 contains four solenoid valves and orifice FV7 to

control rod loader operation. There is no hydraulic load sense line from the

rod loader valve to PFC pump PMP3.

Pressurized hydraulic fluid flows into the valve at port P and return

hydraulic fluid flows out at port T. Orifice FV2 reduces the flow of incoming

hydraulic fluid to reduce actuator speed.

Relief valve PV4 in combination valve AH3 protects the rod loader circuit

components from damage due to over-pressurization. It is set to relieve at

3300 psi (227 bar). However, the high pressure compensator setting of the

pump is 3000 psi (207 bar).

L6 L5

L32

L33

Page 379 of 476

D24x40/D36x50 Series II Navigator HDD Service Overview

12-7

Rod Loader

Rod Loader Lower Mode

To operate rod lower mode:

• Operator must be seated at drill controls.

• Remote Lockout system must be in RUN mode.

• Carriage must be at rear of rack (beyond rear slowdown sensor).

• Hydraulic enable button on right keypad must be pressed.

• Row selector must be at appropriate row.

• Rod arm must be retracted.

• Rod lower button on right joystick must be pressed.

When required operating conditions are met:

• Rack module A16 sends a signal to solenoid L6 of valve DV9 in rod loader

valve AH17.

• Rack controller A16 receives signals from the RH keypad and rear

slowdown sensor and sends a signal to solenoid L5 on valve DV12 in rod

loader valve AH17.

• Oil flows to the rod end ports of cylinders CY9 and CY10. The cylinders

retract.

If rod lift lower mode does not operate as expected, see "Troubleshooting Rod

Lift Function," page 12-16.

Page 380 of 476

Overview D24x40/D36x50 Series II Navigator HDD Service

12-8

Rod Loader

Rod Loader Lift Mode

To operate rod raise mode:

• Operator must be seated at drill controls.

• Remote Lockout system must be in RUN mode.

• Carriage must be at rear of rack (beyond rear slowdown sensor).

• Hydraulic enable button on right keypad must be pressed.

• Row selector must be at appropriate row.

• Rod arm must be retracted.

• Rod lift raise button on right joystick must be pressed.

When required operating conditions are met:

• Rack module A16 sends a signal to solenoid L6 of valve DV9 in rod loader

valve AH17.

• Rack controller A16 receives signals from the RH keypad and rear

slowdown sensor and sends a signal to solenoid L5 on valve DV12 in rod

loader valve AH17.

• Oil flows to the base end ports of cylinders CY9 and CY10. The cylinders

extend.

If the rod lift raise mode does not operate as expected, see "Troubleshooting

Rod Lift Function," page 12-16.

Page 383 of 476

D24x40/D36x50 Series II Navigator HDD Service Troubleshooting

12-11

Rod Loader

TROUBLESHOOTING

Review all warnings and cautions in "Safety," page 1-3, before performing

any troubleshooting procedures.

Before performing any troubleshooting procedures, refer to "Pretest

Inspection," page 1-13. Often issues can be solved by simply doing a walk- around inspection of the machine looking for the obvious.

If nothing is found during the pretest inspection, continue by operating all

other actuator functions of the machine to help further isolate issues.

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 hydraulic fluid

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.

Page 384 of 476

Troubleshooting D24x40/D36x50 Series II Navigator HDD Service

12-12

Rod Loader

Basic Troubleshooting Questions

1. Is there a mechanical issue? Check for bent, broken, or misadjusted

components.

2. Are the machine common systems operating correctly? The load sense

electrical circuit includes diodes which energize the load sense solenoid

while isolating individual circuits. A shorted or open diode for another

system could cause issues with rod loader operation.

3. Are the related circuits working correctly? PFC pump flow is shared with

other functions as well as the water pump drive circuit. A malfunction in

one circuit could affect the other.

4. Are the controls working correctly?

5. Are the hydraulic components functioning correctly? The four main

solenoid valve manifolds are supplied PFC pump pressure from the

hydraulic enable valve.

The PFC pump and load sense functions must be working correctly, and

the hydraulic enable solenoid valve must allow flow from the ‘B’ port of

the combination valve. Valve FV2 must be functioning properly or loader

lift cylinders CY9 and CY10 might not synchronize at the end of their

cycle.

Page 388 of 476

Troubleshooting D24x40/D36x50 Series II Navigator HDD Service

12-16

Rod Loader

Troubleshooting Rod Lift Function

The rod loader select function contains both electrical and hydraulic

components. If the circuit is not operating properly, begin troubleshooting by

following the general guidelines below.

1. If the rod loader lift cylinders will not extend, and other rod loader

functions are working correctly, remove rod loader valve manifold cover.

2. With the engine running and the operator in seat, ensure Remote

Lockout is functioning properly. Push hydraulic enable button.

3. Ensure rotation gearbox is at the rear of the rack with stop sensor

activated.

4. Use multimeter to check for voltage at

solenoid L6 (1).

Expected result: 12 volts DC. If not,

check components in circuit for voltage.

If OK, continue.

5. Push rod lift switch S37. Disconnect

wire from solenoid L5 (2). Use

multimeter to check for voltage.

Expected result: 12 volts DC. If OK,

check continuity of wire. Replace wire

section if faulty. If so, continue.

6. Test the resistance of coil L5. It should

have a resistance of 7.2 ohms @ 68°F

(20°C). If so, the solenoid is faulty. If

not, troubleshoot the hydraulic system.

7. Inspect rod loader valve AH17. Refer to "Rod Loader Valve AH17," page

12-18. If OK, continue.

8. Test cylinders CY9 and CY10 for cross piston leakage. Refer to the

Vermeer Industrial Dealerships Technician’s Shop Manual.

1

2

Page 389 of 476

D24x40/D36x50 Series II Navigator HDD Service Component Repair

12-17

Rod Loader

Specifications

Listed below are electrical and hydraulic specifications for rod loader

functions.

Electrical • Machine system voltage - 12 volts DC

• Rod loader valve solenoid coils L5, L6, L32, and L33 - 7.2 ohms @ 68°F

(20°C)

Hydraulic • PFC Pump PMP3 normal output flow - variable to 43 gpm (162 L/min)

• PFC Pump PMP3 standby pressure compensator valve setting - 250 psi

(17 bar)

• PFC Pump PMP3 high pressure compensator valve setting - 3000 psi

(207 bar)

• Motor MH7 and MH8 maximum output @ 37 rpm - 562 ft-lb (762 Nm)

COMPONENT REPAIR

Review all warnings and cautions in "Safety," page 1-3, before performing

any repair procedures.

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 hydraulic fluid 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.

Page 391 of 476

D24x40/D36x50 Series II Navigator HDD Service Component Repair

12-19

Rod Loader

Directional Valves

DV13, DV12, and

DV9

1. Disconnect electrical connection

from solenoid coils.

2. Remove nut and solenoid coil L33

and L32 (3), L5 (2), or L6 (1).

3. Unscrew and remove valve from

valve manifold.

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 hydraulic fluid.

8. Screw valve in by hand until O-ring contacts valve body. Torque valve to

25 ft-lb (33.9 Nm).

9. Install solenoid coil. Torque nut to 5 ft-lb (6.8 Nm).

1

2 3

Page 394 of 476

Component Repair D24x40/D36x50 Series II Navigator HDD Service

12-22

Rod Loader

Assembly 1. Slide gland and piston onto rod and tighten nut. Torque nut to 95 ft-lb

(128 Nm).

2. Push rod assembly into cylinder body.

3. Install keystock through groove in side of cylinder. Install gland into

cylinder body and secure.

4. Install cylinder by reversing removal steps. Torque mounting bolts to 35

ft-lb (47 Nm).

Rod Loader Motor MH7 and MH8

Remove 1. Label, disconnect and plug hoses to motor.

2. Remove screws (1) holding motor to underside of rod box.

3. Disengage splined shaft.

1

1

Page 396 of 476

Component Repair D24x40/D36x50 Series II Navigator HDD Service

12-24

Rod Loader

Assembly Use all new O-rings and seals. Coat with petroleum jelly to help position

them during installation.

Follow Assembly procedures from the manufacturer for the Eaton

Corporation Series 4000 motor.

After installing valve housing on the valve plate, check for proper

placement. When pushing down on the valve housing, a slight spring action

should be felt.

1. Install tie bolts (2) in the motor housing (1). If alignment studs were

used, install two bolts opposite the studs.

2. Finger tighten bolts.

3. Remove alignment studs and replace with the two remaining bolts.

4. Gradually torque the bolts to 50 ft-lb (68 Nm), using sequence shown

above.

5. Install case drain plug (3) assembly.

6. Connect sensor connector to wiring harness.

To install motor, reverse removal steps. Torque mounting bolts to 90 ft-lb

(120 Nm).

Rod Box

Refer to the “Rod Box - Remove” procedure in the Operator’s Manual.

1

2

3

Page 397 of 476

D24x40/D36x50 Series II Navigator HDD Service Overview

13-1

Drilling Fluid

Chapter 13:Drilling Fluid

OVERVIEW

This chapter consists of the functions and components necessary to supply

the drill string with drilling fluid while boring and the wash wand with

water for cleanup.

THEORY

Components

The functions covered in this section include the following components:

• Fluid Pump PMP4

• Fluid Pump Motor MH11

• Fluid Shutoff Cylinder CY1

• Combination Valve AH3

• Fluid 2-Speed Shift Valve AH12

• Shutoff Control Valve AH22 (D24x40II only)

• Shutoff Control Valve AH13 (D36x50II only)

• Shutoff Ball Valve AH18

• Fluid Full Flow Selector Switch S16

• Fluid 2-Speed Switch S19

• Fluid On/Off Switch S43

• Fluid Pump Speed PPU B3

Page 399 of 476

D24x40/D36x50 Series II Navigator HDD Service Theory

13-3

Drilling Fluid

VDC A20

RH KEYPAD A19

LEFT JOYSTICK A6

COMBINATION VALVE AH3

Page 402 of 476

Theory D24x40/D36x50 Series II Navigator HDD Service

13-6

Drilling Fluid

Hydraulic Schematic (D36x50 Series II)

WASH WAND

OUT

CD

IN

S

DRILL HEAD

2

3

4

1

2

3

4

1

3000 PSI

B

S

250 PSI

X

M2

L2

L1

C A B

F D E

T2 T1

T

P

C B

3300

PSI

LS1

WM

LS2

FLUID SHUTOFF

VALVE AH13

SHUTOFF

FLUID

COMBINATION VALVE AH3

BALL

RETURN MANIFOLD AH1

PFC PUMP PMP3

FLUID PUMP

MOTOR MH11

DV28

DV24

AUXILIARY DISTRIBUTION MANIFOLD AH14

DV26

MOTOR

VALVE AH12

SHIFT

(SC45 Only)

TO RETURN

MANIFOLD AH2

PUMP PMP4

VALVE AH18

CYLINDER CY1

DV29

PV4 DV30

DV31

CV5

Page 404 of 476

Theory D24x40/D36x50 Series II Navigator HDD Service

13-8

Drilling Fluid

Drilling Fluid Function (with Aplex SC-45 Pump)

To operate drilling fluid function:

• Operator must be in seat.

• Remote Lockout system must be in RUN mode.

• Engine must be running.

• Hydraulic enable button on RH keypad must be pressed.

• Front vise must be open.

• Fluid on/off button S43 must be toggled to ON position.

To adjust flow while in drilling fluid mode, do one or both of the following:

• Flow control button on VDC must be turned to the desired rate.

• High/low pressure/flow button must be pressed.

When required operating conditions are met:

• The left joystick sends a signal to engine bay module A2 which energizes

solenoids L20 and L21 in combination valve AH3.

• Solenoids L20 and L21 shift valve DV30 and DV31 and flow goes to

pump motor MH11.

• Motor MH11 drives water pump PMP4, pushing drilling fluid to the ball

valve.

• For D24x40 Series II, solenoid L17 on valve DV34 in fluid shutoff valve

AH22 is energized and flow is supplied to ball valve cylinder CY1,

opening ball valve.

• For D36x50 Series II, solenoid L17 on valve DV24 in fluid shutoff valve

AH13 is energized and flow is supplied to ball valve cylinder CY1,

opening ball valve.

Drilling fluid flow on the display will indicate proportional flow based on the

signal from fluid PPU B3 located on the water pump motor.

Adjustment • For D24x40 Series II, full flow switch S16 energizes solenoid L23 in 2-

speed shift valve DV33 that directs flow to S port of motor MH11,

shifting the motor displacement to low pressure/high flow.

• For D36x50 Series II, full flow switch S16 energizes solenoid L23 in 2-

speed shift valve DV26 that directs flow to S port of motor MH11,

shifting the motor displacement to low pressure/high flow.

• When flow rate is adjusted at the VDC, the rack module sends a signal to

solenoids L20 and L21 that control flow control valves DV30 and DV31 in

combination valve AH3 to adjust flow to motor MH11.

If drilling fluid mode does not operate as expected, see "Troubleshooting/

Testing the Drilling Fluid Function," page 13-13.

Page 405 of 476

D24x40/D36x50 Series II Navigator HDD Service Theory

13-9

Drilling Fluid

Drilling Fluid Mode (with FMC or Aplex SC-65L Pump)

To operate drilling fluid mode with Aplex pump:

• Operator must be in seat.

• Remote Lockout system must be in RUN mode.

• Engine must be running.

• Hydraulic enable button on RH keypad must be pressed.

• Front vise must be open.

• Fluid system ON/OFF switch S43 must be toggled to ON position.

To operate momentary full flow in drilling fluid mode:

• Fluid full flow button S16 must be pressed and held.

To adjust flow while in drilling fluid mode:

• Flow control button on the VDC must be turned to the desired rate.

When required operating conditions are met:

• The left joystick sends a signal to engine bay module A2 which energizes

solenoids L20 and L21 in combination valve AH3.

• Solenoids L20 and L21 shift valve DV30 and DV31 and flow goes to

pump motor MH11.

• Motor MH11 drives water pump PMP4, pushing drilling fluid to the ball

valve.

• For D24x40 Series II, solenoid L17 on valve DV34 in fluid shutoff valve

AH22 is energized and flow is supplied to ball valve cylinder CY1,

opening ball valve.

• For D36x50 Series II, solenoid L17 on valve DV24 in fluid shutoff valve

AH13 is energized and flow is supplied to ball valve cylinder CY1,

opening ball valve.

• When flow rate is adjusted at the VDC, the rack module sends a signal to

solenoids L20 and L21 that control flow control valves DV30 and DV31 in

combination valve AH3 to adjust flow to motor MH11.

Drilling fluid flow on the display will indicate proportional flow based on the

signal from fluid PPU B3 located on the water pump motor.

If drilling fluid mode does not operate as expected, see "Troubleshooting/

Testing the Drilling Fluid Function," page 13-13.