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The information contained is for DEALER REFERENCE PURPOSES ONLY.

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If additional printed manuals are required for your shop/office location, order by
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D36x50 Series II Navigator®
Horizontal Direction Drill
with R.A.T.T.

Service
Manual

D36x50 SERIES II_S1_01

Serial No. 176 -
Order No. 105400Y37
This manual contains service requirements and
procedures needed by an experienced service person
to complete necessary service and repairs on the
machine. Study and understand these requirements
and procedures thoroughly before servicing or
repairing the machine. There are also many
components which are not user-serviceable. Do not
attempt any service which you do not fully understand,
nor any service that you cannot do adequately and
safely with the tools and equipment available to you.
Failure to do so could result in personal injury or
equipment damage. If you encounter a problem that
you do not understand or cannot solve, contact your
Vermeer service representative.
The instructions, illustrations and specifications in this
manual are based on the latest information available at
the time of publication. Your machine may have product
improvements and options not yet contained in this
manual.
Vermeer Manufacturing Company 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 and VERMEER Logo are registered
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 Manufacturing Company is aware of the
following component suppliers trademarks.
CUMMINS is the trademark of the Cummins Inc.
LOCTITE and VIBRA-SEAL are trademarks of Loctite
Corporation.
FLUKE is a trademark of Fluke Corporation.
TEFLON is a trademark of E.I. DuPont de Nemours
and Company.
SUNDSTRAND is a trademark of Sauer-Sundstrand
Corp.
EATON and CHAR-LYNN are trademarks of Eaton
Corporation.
TRIHAWK is a trademark of Earth Tool Company.

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

Copyright © 2007
All rights reserved.
Vermeer Manufacturing Company
1210 Vermeer Road East, P.O. Box 200
Pella, Iowa 50219-0200, USA
D36x50 Series II Navigator HDD Service Table of Contents

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

Reference Publications ............................................................................................................................................ 1-2
Vermeer Publications ......................................................................................................................................... 1-2
Vendor Publications ........................................................................................................................................... 1-2
Warranty Considerations .............................................................................................................................. 1-2
Vermeer Warranty ..................................................................................................................................................... 1-2
John Deere Warranty ................................................................................................................................................ 1-2
Safety .............................................................................................................................................................. 1-3
Do Not Modify Machine ............................................................................................................................................ 1-3
Replace Shields ........................................................................................................................................................ 1-3
Maintain Operator Presence System....................................................................................................................... 1-3
Avoid Moving Parts................................................................................................................................................... 1-4
Avoid Entanglement - Stay Away ............................................................................................................................ 1-4
Rotating Wrench Contact ......................................................................................................................................... 1-4
Avoid Fluid Under Pressure..................................................................................................................................... 1-5
Work in Ventilated Area............................................................................................................................................ 1-5
Raised Machine Can Fall .......................................................................................................................................... 1-5
Terminology ................................................................................................................................................... 1-6
Inputs and Outputs ................................................................................................................................................... 1-6
Reference Designators ............................................................................................................................................. 1-6
Diagrams and Schematics ....................................................................................................................................... 1-6
Chapter Organization................................................................................................................................................ 1-6
Theory .................................................................................................................................................................. 1-7
Troubleshooting ................................................................................................................................................. 1-7
Repair................................................................................................................................................................... 1-7
Addendum ........................................................................................................................................................... 1-7
Troubleshooting Guidelines ......................................................................................................................... 1-8
Problem-Solving Analysis........................................................................................................................................ 1-8
Rule Out Operator Error ..................................................................................................................................... 1-8
Define the Problem ............................................................................................................................................. 1-9
Research the Machine ...................................................................................................................................... 1-10
Electrical Troubleshooting..................................................................................................................................... 1-11
Common Electrical Problems .......................................................................................................................... 1-11
Hydraulic Troubleshooting .................................................................................................................................... 1-12
Leakage Path Analysis ..................................................................................................................................... 1-12
Pumps and Motors ........................................................................................................................................... 1-13
Directional Control Valves ............................................................................................................................... 1-14
Cylinders ........................................................................................................................................................... 1-14
Required Tools ........................................................................................................................................................ 1-15
Hydraulic Connections ........................................................................................................................................... 1-15
Avoid Trapped Pressure .................................................................................................................................. 1-15
Avoid Oil Contamination .................................................................................................................................. 1-16
Connecting Flow Meters .................................................................................................................................. 1-16
Connecting a Needle Valve .............................................................................................................................. 1-17
Connecting Pressure Gauges.......................................................................................................................... 1-17
Thermometer or Pyrometer.................................................................................................................................... 1-17
Digital Multimeter .................................................................................................................................................... 1-18
Measuring Voltage ............................................................................................................................................ 1-18
Measuring Resistance ...................................................................................................................................... 1-18
Testing for Continuity....................................................................................................................................... 1-19
Measuring Current ............................................................................................................................................ 1-19
Table of Contents D36x50 Series II Navigator HDD Service

Repair Guidelines ........................................................................................................................................ 1-20

Shop Requirements................................................................................................................................................. 1-20
Special Tools & Test Equipment......................................................................................................................1-20
Personnel and Lifting Requirements..................................................................................................................... 1-20
Replacement Parts .................................................................................................................................................. 1-20
Part Numbers/Hose Lengths/Fitting Orientation............................................................................................1-20
Parts Ordering ...................................................................................................................................................1-20
Torque Values.......................................................................................................................................................... 1-20
Shutdown Procedure .................................................................................................................................... 2-1
Starting the Engine........................................................................................................................................ 2-2
Cold Weather Starting............................................................................................................................................... 2-3
Specifications ................................................................................................................................................ 2-4
Machine Reference and Orientation ........................................................................................................................ 2-4
Engine Specifications ................................................................................................................................... 2-5
Machine Specifications................................................................................................................................. 2-5
Fuel and Lubricants .................................................................................................................................................. 2-7
Machine Interlocks ........................................................................................................................................ 2-7
Starting Interlocks ..................................................................................................................................................... 2-7
Operator Presence Interlock .................................................................................................................................... 2-8
Remote Lockout ........................................................................................................................................................ 2-8
Machine Performance ............................................................................................................................................... 2-8
Preoperation Check ............................................................................................................................................2-9
Tools Needed.......................................................................................................................................................2-9
Checking Machine Performance .................................................................................................................. 2-9
Machine Performance Standards............................................................................................................... 2-10
Machine Performance Procedures ............................................................................................................ 2-11
Control Settings....................................................................................................................................................... 2-11
Engine Starting and Warm-Up................................................................................................................................ 2-12
Drill Rotation Performance ..................................................................................................................................... 2-13
Thrust/Pullback Operation...................................................................................................................................... 2-14
Thrust/Pullback Performance ..........................................................................................................................2-15
Ground Drive, Rod Loader, Vise, Stakedown, Stabilizer/Rack Angle, and Water Shutoff Performance......... 2-16
Ground Drive Performance..................................................................................................................................... 2-18
Ground Drive .....................................................................................................................................................2-18
Rod Loader Performance .................................................................................................................................2-20
Vise Performance ..............................................................................................................................................2-22
Stakedown Performance ..................................................................................................................................2-23
Rack Angle Performance..................................................................................................................................2-26
Stabilizer Function Performance .....................................................................................................................2-27
Water Shutoff Valve Performance ...................................................................................................................2-29
Schematic....................................................................................................................................................... 3-1
Component Locations................................................................................................................................... 3-2
Power Supply................................................................................................................................................. 3-3
Ignition Switch S1 ..................................................................................................................................................... 3-4
Specifications ................................................................................................................................................ 3-4
Charging......................................................................................................................................................... 3-5
Battery Charging ....................................................................................................................................................... 3-5
Battery (BT1) .............................................................................................................................................................. 3-5
D36x50 Series II Navigator HDD Service Table of Contents

Operation ............................................................................................................................................................. 3-5

Wire Connections ............................................................................................................................................... 3-6
Ground Disconnect Switch S1................................................................................................................................. 3-6
Thermal Breakers...................................................................................................................................................... 3-7
Engine Component Locations ...................................................................................................................... 3-8
Operation Overview....................................................................................................................................... 3-9
Fuel Control......................................................................................................................................................... 3-9
Throttle Control................................................................................................................................................... 3-9
Neutral Start ........................................................................................................................................................ 3-9
Specifications ................................................................................................................................................ 3-9
Starting Circuit Electrical Schematic ......................................................................................................... 3-11
Coolant Temperature Warning Circuits ..................................................................................................... 3-12
Fuel Delivery ................................................................................................................................................ 3-13
Fuel Gauge Circuit .................................................................................................................................................. 3-13
Throttle Circuit ............................................................................................................................................. 3-14
Troubleshooting .......................................................................................................................................... 3-16
Pretest Inspection ................................................................................................................................................... 3-16
Battery BT1................................................................................................................................................... 3-16
Ignition Switch ............................................................................................................................................. 3-17
Breaker CB1 ................................................................................................................................................. 3-18
Breakers F1–F10 .......................................................................................................................................... 3-19
Ground Disconnect Switch......................................................................................................................... 3-20
Continuity Test ........................................................................................................................................................ 3-20
Measure Battery Voltage ........................................................................................................................................ 3-20
Check for Power at Controllers ............................................................................................................................. 3-21
Battery Charging Circuit......................................................................................................................................... 3-21
Engine Troubleshooting ............................................................................................................................. 3-21
Introduction ............................................................................................................................................................. 3-21
Basic Troubleshooting ........................................................................................................................................... 3-22
Check Out “Common” and Related Systems....................................................................................................... 3-22
Inspecting Control Circuits and Mechanical Components ................................................................................. 3-23
Engine Coolant Temperature Monitoring Circuit...................................................................................... 3-27
Air Intake Monitors ...................................................................................................................................... 3-29
Air Cleaner ............................................................................................................................................................... 3-29
Turbocharger/Intake ............................................................................................................................................... 3-30
Fuel Delivery ................................................................................................................................................ 3-32
Fuel Tanks, Lines, Filters, and Strainers .............................................................................................................. 3-33
Fuel Gauge Circuit .................................................................................................................................................. 3-34
Supply Voltage Test ......................................................................................................................................... 3-34
Open Sensor Test ............................................................................................................................................. 3-35
Sensor Ground Test ......................................................................................................................................... 3-35
Fuel Sender (B1) Resistance Test ................................................................................................................... 3-35
Ignition START Circuit ................................................................................................................................ 3-36
Alternator ALT1 ....................................................................................................................................................... 3-38
Throttle Circuit ............................................................................................................................................. 3-39
Overview......................................................................................................................................................... 4-1
Table of Contents D36x50 Series II Navigator HDD Service

Theory............................................................................................................................................................. 4-1
Functions ................................................................................................................................................................... 4-1
Components .............................................................................................................................................................. 4-1
Component Locations............................................................................................................................................... 4-2
Hose Connections — Fluid Supply and Return...................................................................................................... 4-3
Hydraulic Schematic ................................................................................................................................................. 4-4
Oil Supply Function................................................................................................................................................... 4-5
Pump PMP3................................................................................................................................................................ 4-5
Operation .............................................................................................................................................................4-5
Rotation Closed-Loop Pump PMP1 ......................................................................................................................... 4-7
Operation - Charge Pressure Mode ...................................................................................................................4-7
Operation - High Pressure Mode .......................................................................................................................4-8
Thrust Closed-Loop Pump PMP2........................................................................................................................... 4-10
Operation - Charge Pressure Mode .................................................................................................................4-10
Operation - High Pressure Mode .....................................................................................................................4-11
Oil Filtering Function .............................................................................................................................................. 4-12
With Functions Operating or At Rest ..............................................................................................................4-12
Oil Cooling Function ............................................................................................................................................... 4-13
Operation ...........................................................................................................................................................4-13
Specifications .......................................................................................................................................................... 4-14
Troubleshooting .......................................................................................................................................... 4-15
Excessive Noise/Vibration ...............................................................................................................................4-15
Pretest Inspection ................................................................................................................................................... 4-17
Test Equipment Needed.......................................................................................................................................... 4-18
Troubleshooting/Testing Pump PMP1................................................................................................................... 4-18
Troubleshooting/Testing Pump PMP2................................................................................................................... 4-18
Troubleshooting/Testing PFC Pump PMP3 .......................................................................................................... 4-18
Troubleshooting/Testing the Oil Cooling Function.............................................................................................. 4-20
Hydraulic Fluid Sampling ........................................................................................................................... 4-20
Preventive Maintenance ......................................................................................................................................... 4-20
After Repair .............................................................................................................................................................. 4-21
Fluid Sample Collection Points........................................................................................................................4-22
Component Repair ...................................................................................................................................... 4-23
Return Valve Manifold A12 ..................................................................................................................................... 4-24
Remove ..............................................................................................................................................................4-24
Disassembly ......................................................................................................................................................4-25
PFC Pump PMP3 ..................................................................................................................................................... 4-26
Remove ..............................................................................................................................................................4-26
Install ..................................................................................................................................................................4-27
Multifunction Valve for Rotation Pump or Thrust Pump ..................................................................................... 4-27
Cartridge Repair ................................................................................................................................................4-27
Electric Displacement Control (EDC) .................................................................................................................... 4-30
Operation ...........................................................................................................................................................4-30
Shaft Seal and Shaft Replacement ........................................................................................................................ 4-31
Return Filters/Manifold ........................................................................................................................................... 4-34
Oil Cooler HE1 ......................................................................................................................................................... 4-35
Component Locations................................................................................................................................... 5-1
Operation Overview....................................................................................................................................... 5-2
Rotation Motors...................................................................................................................................................5-2
Rotation Pump.....................................................................................................................................................5-2
Charge Pump .......................................................................................................................................................5-2
3-Speed/Loop Flush Valve .................................................................................................................................5-2
D36x50 Series II Navigator HDD Service Table of Contents

Operation ............................................................................................................................................................. 5-2

System Specifications................................................................................................................................... 5-3
Hose Connections ......................................................................................................................................... 5-4
Hoses ......................................................................................................................................................................... 5-5
Hoses ......................................................................................................................................................................... 5-6
Rotation Pump Schematic........................................................................................................................................ 5-7
Charge Pump............................................................................................................................................................. 5-8
Operation ............................................................................................................................................................. 5-8
Multifunction Valves ................................................................................................................................................. 5-9
Operation ............................................................................................................................................................. 5-9
Electric Displacement Control (EDC) .................................................................................................................... 5-10
Operation ........................................................................................................................................................... 5-10
Torque Limiter Circuits ............................................................................................................................... 5-11
Torque Limiters ....................................................................................................................................................... 5-12
Forward.............................................................................................................................................................. 5-12
Reverse .............................................................................................................................................................. 5-12
3-Speed Loop Flush Valve Circuits ........................................................................................................... 5-13
Low Speed Function ............................................................................................................................................... 5-14
Medium Speed Function......................................................................................................................................... 5-14
High Speed Function .............................................................................................................................................. 5-14
Rotation Motors ........................................................................................................................................... 5-15
Basic Electrical Troubleshooting ............................................................................................................... 5-16
Open Circuit Test .................................................................................................................................................... 5-17
High Resistance Test.............................................................................................................................................. 5-17
Short Circuit Test .................................................................................................................................................... 5-17
Basic Hydraulic Troubleshooting .............................................................................................................. 5-18
Mechanical Component Inspection ........................................................................................................... 5-20
Pretest Inspection........................................................................................................................................ 5-21
Required Test Equipment ........................................................................................................................... 5-22
Pressure Check ....................................................................................................................................................... 5-23
Oil Sampling ............................................................................................................................................................ 5-23
Basic Troubleshooting Tables ................................................................................................................... 5-26
Inspect Related Functions or Circuits ....................................................................................................... 5-29
Pump Test Procedure.................................................................................................................................. 5-30
Analyzing Test Results........................................................................................................................................... 5-34
Diagnostic Observations Full Load................................................................................................................. 5-34
Inspect Electric Displacement Control (EDC) ...................................................................................................... 5-35
Adjusting Pump Neutral Setting ............................................................................................................................ 5-36
Inspect System Relief Valves ................................................................................................................................ 5-37
Pressure Checks and Adjustments ........................................................................................................... 5-37
Charge Pressure - Check ....................................................................................................................................... 5-37
Pump Case Pressure Test...................................................................................................................................... 5-39
Test Objective ................................................................................................................................................... 5-39
Special Tools and Materials............................................................................................................................. 5-39
Conditions ......................................................................................................................................................... 5-39
Procedure .......................................................................................................................................................... 5-39
Pump Multifunction Valve Inspection........................................................................................................ 5-40
Table of Contents D36x50 Series II Navigator HDD Service

Charge Pump Relief Valve Inspection ....................................................................................................... 5-41

Charge Pressure - Adjust ....................................................................................................................................... 5-42
Rotation Motors Case Drain Flow Test...................................................................................................... 5-43
Analyzing Motor Test Results ................................................................................................................................ 5-44
Replace Drive Chuck............................................................................................................................................... 5-44
Special Tools and Materials .............................................................................................................................5-44
Drive Chuck Sub-Saver Installation/Removal........................................................................................... 5-45
Special Tools and Materials ................................................................................................................................... 5-45
Thread Locking Compound Considerations......................................................................................................... 5-45
Install Sub-Saver ..................................................................................................................................................... 5-46
Remove Sub-Saver.................................................................................................................................................. 5-46
Rear Seal Removal/Installation .................................................................................................................. 5-47
Special Tools and Materials ................................................................................................................................... 5-47
Remove Seal ............................................................................................................................................................ 5-47
Install Seal................................................................................................................................................................ 5-48
Gearbox Removal/Installation .................................................................................................................... 5-48
Special Tools and Materials ................................................................................................................................... 5-48
Remove Gearbox ..................................................................................................................................................... 5-49
Install Gearbox ........................................................................................................................................................ 5-51
Motor Replacement ..................................................................................................................................... 5-52
Special Tools and Materials ................................................................................................................................... 5-52
Removal ................................................................................................................................................................... 5-52
Install Motors ........................................................................................................................................................... 5-53
Rotation Shaft and Front Seal Removal/Installation ................................................................................ 5-55
Special Tools and Materials ................................................................................................................................... 5-55
Remove Rotation Shaft and Front Seal ................................................................................................................. 5-56
Install Rotation Shaft and Front Seal..................................................................................................................... 5-57
Returning System to Service...................................................................................................................... 5-60
Filter Kit Parts .............................................................................................................................................. 5-61
Flushing the Rotation System.................................................................................................................... 5-62
Special Tools ........................................................................................................................................................... 5-62
Procedure................................................................................................................................................................. 5-62
Overview......................................................................................................................................................... 6-1
System and Component Locations ............................................................................................................. 6-1
Overview......................................................................................................................................................... 6-3
Engine ..................................................................................................................................................................6-3
Thrust/Pullback Pump ........................................................................................................................................6-3
Thrust/Pullback Charge Pump ...........................................................................................................................6-3
Rotation Charge Pump .......................................................................................................................................6-3
Thrust Limiter (RockFire) ...................................................................................................................................6-3
Anti-Crash and Slowdown Circuits ...................................................................................................................6-3
2-Speed Solenoid ................................................................................................................................................6-3
Operation .............................................................................................................................................................6-3
System Specifications .................................................................................................................................. 6-4
Hose Connections ......................................................................................................................................... 6-5
Hoses.......................................................................................................................................................................... 6-6
Hoses.......................................................................................................................................................................... 6-7
Electrical Diagram - Thrust/Pullback ........................................................................................................... 6-8
D36x50 Series II Navigator HDD Service Table of Contents

Hydrostatic Pump (PMP2) ............................................................................................................................. 6-9

Operation ................................................................................................................................................................... 6-9
Port Locations................................................................................................................................................... 6-10
Charge Pump ............................................................................................................................................... 6-11
Operation ................................................................................................................................................................. 6-11
Multifunction Valves .................................................................................................................................... 6-12
Operation ................................................................................................................................................................. 6-12
Thrust/Pullback Controls ............................................................................................................................ 6-13
Operation Overview ................................................................................................................................................ 6-13
Thrust/Pullback Joystick ............................................................................................................................ 6-14
Controller Pin Identification ................................................................................................................................... 6-14
Harness Connector Pin Identification ................................................................................................................... 6-15
EDC Control Circuit ................................................................................................................................................ 6-16
EDC Ground Circuit ................................................................................................................................................ 6-17
Slowdown/Anti-Crash Circuit ..................................................................................................................... 6-18
Operation ................................................................................................................................................................. 6-19
Slowdown .......................................................................................................................................................... 6-19
Stop .................................................................................................................................................................... 6-19
Anti-Crash ......................................................................................................................................................... 6-19
RockFire/Trihawk Pressure and Mode Switches ...................................................................................... 6-20
RockFire/Trihawk Pressure and Mode Switches ...................................................................................... 6-21
Thrust Limiter............................................................................................................................................... 6-21
Operation ........................................................................................................................................................... 6-21
2-Speed Carriage Control Circuit ............................................................................................................... 6-22
Troubleshooting the Hydrostatic Circuit ................................................................................................... 6-23
Indicators Used For Troubleshooting Closed Loops .......................................................................................... 6-24
Pump Noise ....................................................................................................................................................... 6-24
Fluid Temperature ............................................................................................................................................ 6-25
Movement—One Direction Only ...................................................................................................................... 6-25
Movement—Neither Direction.......................................................................................................................... 6-26
Movement—Gearbox Creeps in Stop.............................................................................................................. 6-27
Nulling the Pump .............................................................................................................................................. 6-28
Control—Response is Sluggish ...................................................................................................................... 6-29
Checking Bypass Valves........................................................................................................................................ 6-30
Motor Torque ........................................................................................................................................................... 6-31
Charge Pump Inlet Restriction Measurement ...................................................................................................... 6-32
Charge Pressure Measurement ............................................................................................................................. 6-33
Function Pressure Measurement .......................................................................................................................... 6-34
Case Pressure Measurement ................................................................................................................................. 6-35
Case Drain Flow Measurement .............................................................................................................................. 6-36
Case Drain Flow Analysis ................................................................................................................................ 6-37
Testing Joysticks .................................................................................................................................................... 6-38
Testing Proximity Switches ................................................................................................................................... 6-39
Adjusting Proximity Switch ............................................................................................................................. 6-39
Multifunction Valves .................................................................................................................................... 6-40
Charge Pressure Relief Valve PRL1........................................................................................................... 6-41
Adjusting Charge Pressure Relief Setting ................................................................................................ 6-42
Charge Pump Replacement ........................................................................................................................ 6-42
Table of Contents D36x50 Series II Navigator HDD Service

Pump PMP2.................................................................................................................................................. 6-43

Returning System to Service ...........................................................................................................................6-45
Motor Removal/Installation......................................................................................................................... 6-46
Special Tools and Materials ................................................................................................................................... 6-46
Remove Motors ....................................................................................................................................................... 6-46
Install Motors ........................................................................................................................................................... 6-49
Returning System to Service...................................................................................................................... 6-50
Remove Trapped Air From Hydraulic Circuit........................................................................................................ 6-50
Carriage Removal/Installation .................................................................................................................... 6-51
Special Tools and Materials ................................................................................................................................... 6-51
Remove Carriage ..................................................................................................................................................... 6-51
Install Carriage ........................................................................................................................................................ 6-54
Overview......................................................................................................................................................... 7-1
Circuit Components .................................................................................................................................................. 7-1
Circuit Schematic ...................................................................................................................................................... 7-2
Component Locations............................................................................................................................................... 7-3
Hydraulic Connections ............................................................................................................................................. 7-5
Circuit Operation ....................................................................................................................................................... 7-6
PFC Pump ............................................................................................................................................................7-6
Ground Drive Valve Assembly A4 .....................................................................................................................7-7
Drill/Track Valve DV27, Seat Switch Relay K7, Seat Switch S26, Solenoid L24 ............................................7-7
Brake Valves DV31 and DV32 ............................................................................................................................7-8
Troubleshooting ............................................................................................................................................ 7-9
Check Out Related Circuits and Components........................................................................................................ 7-9
Basic Troubleshooting Questions ........................................................................................................................... 7-9
Troubleshooting Electrical Circuits....................................................................................................................... 7-10
Troubleshooting the Hydraulic Circuit .................................................................................................................. 7-11
Mechanical Components ........................................................................................................................................ 7-11
O-Ring Installation................................................................................................................................................... 7-12
Flow Test for PMP3 ................................................................................................................................................. 7-13
Set Up .................................................................................................................................................................7-13
Conducting the Test..........................................................................................................................................7-14
Understanding the Results...............................................................................................................................7-15
Calculating Theoretical Flow and Acceptable Flow.......................................................................................7-15
SYMPTOM: Some Hydraulic Power but Machine Will Not Move......................................................................... 7-16
Towing the Machine ................................................................................................................................................ 7-18
Conditions .........................................................................................................................................................7-18
Procedure ..........................................................................................................................................................7-18
Valve Service ............................................................................................................................................... 7-19
Cartridges ..........................................................................................................................................................7-20
Coils ...................................................................................................................................................................7-20
Housings ............................................................................................................................................................7-20
Assembly ...........................................................................................................................................................7-20
Solenoid Coils.............................................................................................................................................. 7-21
Coil Specifications ............................................................................................................................................7-21
Coil Waterproofing .................................................................................................................................................. 7-22
Troubleshooting .......................................................................................................................................... 7-23
Pretest Inspection ................................................................................................................................................... 7-23
Troubleshooting Machine Performance................................................................................................................ 7-25
D36x50 Series II Navigator HDD Service Table of Contents

Possible Results ............................................................................................................................................... 7-25

Testing Ground Drive Performance ...................................................................................................................... 7-26
Troubleshooting/Testing Ground Drive Function................................................................................................ 7-27
Troubleshooting Transport/Rack Valve Manifold A8........................................................................................... 7-28
Test Equipment Needed ......................................................................................................................................... 7-28
Specifications.......................................................................................................................................................... 7-29
Component Repair/Replace ................................................................................................................................... 7-29
Component Repair....................................................................................................................................... 7-30
Transport/RackValve Assembly A8....................................................................................................................... 7-30
Remove .............................................................................................................................................................. 7-30
Install ................................................................................................................................................................. 7-30
Directional Valves DV10, DV11 and DV12............................................................................................................. 7-31
Load Check Plug ..................................................................................................................................................... 7-32
Relief Valve PV9 ...................................................................................................................................................... 7-33
Brake Valves DV31 and DV32 ................................................................................................................................ 7-34
Track Motors MH5 and MH6 ................................................................................................................................... 7-35
Remove .............................................................................................................................................................. 7-35
Special Tools..................................................................................................................................................... 7-35
Disassembly ...................................................................................................................................................... 7-36
Assembly ........................................................................................................................................................... 7-40
Timing ................................................................................................................................................................ 7-42
Install ................................................................................................................................................................. 7-45
Track Chain ............................................................................................................................................................. 7-45
Remove .............................................................................................................................................................. 7-45
Install ................................................................................................................................................................. 7-46
Track Tension Tightener ........................................................................................................................................ 7-47
Remove .............................................................................................................................................................. 7-47
Install ................................................................................................................................................................. 7-47
Track Tension Adjustment............................................................................................................................... 7-48
Planetary Gears....................................................................................................................................................... 7-49
Remove .............................................................................................................................................................. 7-49
Disassembly ...................................................................................................................................................... 7-50
Assemble ........................................................................................................................................................... 7-51
Install ................................................................................................................................................................. 7-54
Overview......................................................................................................................................................... 8-1
Components .............................................................................................................................................................. 8-1
Rod Handling Terms ................................................................................................................................................. 8-2
Overview .................................................................................................................................................................... 8-2
Performance Checks ................................................................................................................................................ 8-2
Troubleshooting........................................................................................................................................................ 8-2
Electrical Diagram ........................................................................................................................................ 8-3
Component Locations ................................................................................................................................... 8-5
Hydraulic Connections.................................................................................................................................. 8-8
Operation........................................................................................................................................................ 8-9
PFC Pump PMP3 ................................................................................................................................................. 8-9
Hydraulic Enable Valve DV29 and Solenoid L26.............................................................................................. 8-9
Hydraulic Enable Circuit ........................................................................................................................................ 8-10
Rod Loader Manifold A6................................................................................................................................... 8-12
Function Operation...................................................................................................................................... 8-13
Extend or Retract Arms.................................................................................................................................... 8-13
Raise or Lower Lifts ......................................................................................................................................... 8-13
Table of Contents D36x50 Series II Navigator HDD Service

Rod Loader Add Sequence......................................................................................................................... 8-13

Troubleshooting .......................................................................................................................................... 8-14
Check Out Related Circuits and Components...................................................................................................... 8-14
Basic Troubleshooting Questions ......................................................................................................................... 8-14
Troubleshooting Electrical Circuits....................................................................................................................... 8-15
Troubleshooting the Hydraulic Circuit .................................................................................................................. 8-16
Mechanical Components ........................................................................................................................................ 8-16
Machine Performance ............................................................................................................................................. 8-17
Possible Results ...............................................................................................................................................8-17
Testing Rod Loader Performance.......................................................................................................................... 8-18
Troubleshooting the Rod Loader Load Function ................................................................................................. 8-20
Troubleshooting Rod Lift Function ....................................................................................................................... 8-22
Test Equipment Needed.......................................................................................................................................... 8-23
Specifications .......................................................................................................................................................... 8-23
Component Repair/Replace.................................................................................................................................... 8-23
Component Repair ...................................................................................................................................... 8-24
Rod Loader Valve Manifold A6............................................................................................................................... 8-24
Remove ..............................................................................................................................................................8-24
Directional Valves DV13, DV12, and DV9 .............................................................................................................. 8-25
Remove ..............................................................................................................................................................8-25
Rod Lift Cylinders CY1 and CY2 ............................................................................................................................ 8-26
Remove ..............................................................................................................................................................8-26
Disassemble ......................................................................................................................................................8-27
Assemble ...........................................................................................................................................................8-27
Rod Loader Motor MH7 ........................................................................................................................................... 8-28
Remove ..............................................................................................................................................................8-28
Disassemble ......................................................................................................................................................8-29
Assemble ...........................................................................................................................................................8-35
Rod Box.................................................................................................................................................................... 8-42
Remove ..............................................................................................................................................................8-42
Install ..................................................................................................................................................................8-43
Flow Test for PMP3 ..................................................................................................................................... 8-43
Setting Up ................................................................................................................................................................ 8-44
Conducting the Test................................................................................................................................................ 8-45
Understanding the Results..................................................................................................................................... 8-46
Calculating Theoretical Flow and Acceptable Flow.......................................................................................8-46
Rod Transfer Arm Barrier Limit Switch ..................................................................................................... 8-47
Anti-Crash Switch........................................................................................................................................ 8-47
Alignment of Rod Loader Arms to Rod Row ............................................................................................ 8-48
Rod Alignment to Drive Chuck................................................................................................................... 8-49
Special Tools ........................................................................................................................................................... 8-49
Procedure................................................................................................................................................................. 8-49
Overview......................................................................................................................................................... 9-1
D36x50 Series II Navigator HDD Service Table of Contents

Theory............................................................................................................................................................. 9-1
Components .............................................................................................................................................................. 9-1
Component Locations .............................................................................................................................................. 9-2
Hose Connections..................................................................................................................................................... 9-4
Electrical Schematic ................................................................................................................................................. 9-5
Hydraulic Schematic................................................................................................................................................. 9-6
Shared Components ................................................................................................................................................. 9-7
Combination Valve Assembly A9 ............................................................................................................................ 9-8
Operation ............................................................................................................................................................. 9-8
Stabilizer Function......................................................................................................................................... 9-9
Stabilizer LOWER Mode ........................................................................................................................................... 9-9
Operation ............................................................................................................................................................. 9-9
Stabilizer RAISE Mode............................................................................................................................................ 9-10
Operation ........................................................................................................................................................... 9-10
Troubleshooting .......................................................................................................................................... 9-11
Test Equipment Needed ......................................................................................................................................... 9-11
Specifications.......................................................................................................................................................... 9-11
Pretest Inspection ................................................................................................................................................... 9-12
Troubleshooting Machine Performance ............................................................................................................... 9-13
Possible Results: .............................................................................................................................................. 9-14
Testing Stabilizer Performance ............................................................................................................................. 9-14
Troubleshooting Stabilizer Function..................................................................................................................... 9-15
Troubleshooting Combination Valve A9............................................................................................................... 9-16
Component Repair/Replace ................................................................................................................................... 9-17
Component Repair....................................................................................................................................... 9-17
Combination Valve Manifold A9 ............................................................................................................................ 9-17
Remove .............................................................................................................................................................. 9-17
Install ................................................................................................................................................................. 9-17
Stabilizer Valve Manifold A25 ................................................................................................................................ 9-18
Stabilizer Cylinder CY5........................................................................................................................................... 9-19
Remove .............................................................................................................................................................. 9-19
Disassembly ...................................................................................................................................................... 9-20
Assembly & Install ............................................................................................................................................ 9-21
Stabilizer Cylinder Lock Check Valve CV18 ......................................................................................................... 9-21
Remove .............................................................................................................................................................. 9-21
Disassembly ...................................................................................................................................................... 9-22
Stabilizer .................................................................................................................................................................. 9-23
Circuits ......................................................................................................................................................... 10-1
Overview....................................................................................................................................................... 10-1
Components ............................................................................................................................................................ 10-1
Component Locations ............................................................................................................................................ 10-2
Hydraulic Connections ........................................................................................................................................... 10-3
Electrical Circuit...................................................................................................................................................... 10-4
Vise Hydraulic Circuit ............................................................................................................................................. 10-5
Operation Overview ................................................................................................................................................ 10-6
Operation...................................................................................................................................................... 10-7
PFC Pump PMP3 ............................................................................................................................................... 10-7
Hydraulic Enable Valve DV29 and Solenoid L26............................................................................................ 10-7
Hydraulic Enable Solenoid L26 Control Circuit ............................................................................................ 10-8
Front Vise Circuit Operation ................................................................................................................................ 10-10
Front Vise Clamp ............................................................................................................................................ 10-10
Table of Contents D36x50 Series II Navigator HDD Service

Front Vise Unclamp ........................................................................................................................................10-11

Rear Vise Circuit Operation.................................................................................................................................. 10-12
Rear Vise Clamp ..............................................................................................................................................10-12
Rear Vise Unclamp..........................................................................................................................................10-13
Rear Vise Rotation Circuit Operation .................................................................................................................. 10-13
Shared Components ............................................................................................................................................. 10-14
Troubleshooting ........................................................................................................................................ 10-14
Pretest Inspection ................................................................................................................................................. 10-15
Test Equipment Needed........................................................................................................................................ 10-16
Troubleshooting Machine Performance.............................................................................................................. 10-17
Possible Results: ............................................................................................................................................10-17
Testing Vise Performance .................................................................................................................................... 10-18
Troubleshooting/Testing the Vise Functions ..................................................................................................... 10-19
Front Vise Function ........................................................................................................................................10-19
Rear Vise Clamp Function..............................................................................................................................10-20
Rear Vise Rotate Function..............................................................................................................................10-21
Specifications ........................................................................................................................................................ 10-22
Component Repair/Replace.................................................................................................................................. 10-22
Component Repair .................................................................................................................................... 10-23
Vise Valve Manifold A8 ......................................................................................................................................... 10-23
Removal ...........................................................................................................................................................10-23
Disassembly ....................................................................................................................................................10-24
Front and Rear Vise Cylinders CY19 and CY17.................................................................................................. 10-25
Removal ...........................................................................................................................................................10-25
Disassembly ....................................................................................................................................................10-26
Vise Rotate Cylinder CY7...................................................................................................................................... 10-27
Disassembly ....................................................................................................................................................10-28
Assembly .........................................................................................................................................................10-29
Overview....................................................................................................................................................... 11-1
Theory........................................................................................................................................................... 11-1
Components ............................................................................................................................................................ 11-1
Component Locations............................................................................................................................................. 11-2
Hose Connections ................................................................................................................................................... 11-3
Schematic ................................................................................................................................................................ 11-4
Specifications .......................................................................................................................................................... 11-5
Shared Components ................................................................................................................................... 11-5
Rack Lift Function ....................................................................................................................................... 11-6
Rack RAISE Mode ................................................................................................................................................... 11-6
Operation ...........................................................................................................................................................11-6
Rack LOWER Mode ................................................................................................................................................. 11-7
Operation ...........................................................................................................................................................11-7
Troubleshooting .......................................................................................................................................... 11-8
Pretest Inspection ................................................................................................................................................... 11-8
Test Equipment Needed........................................................................................................................................ 11-10
Troubleshooting Machine Performance.............................................................................................................. 11-10
Possible Results: ............................................................................................................................................11-11
Testing Rack Angle Performance ........................................................................................................................ 11-11
Troubleshooting/Testing the Rack Lift Function................................................................................................ 11-12
Testing .............................................................................................................................................................11-13
Troubleshooting Drill/Track Valve DV27 ............................................................................................................. 11-14
Component Repair/Replace.................................................................................................................................. 11-14
D36x50 Series II Navigator HDD Service Table of Contents

Component Repair..................................................................................................................................... 11-15

Valve Bank Assembly A5 ..................................................................................................................................... 11-15
Remove ............................................................................................................................................................ 11-15
Install ............................................................................................................................................................... 11-15
Directional Valve DV25 ......................................................................................................................................... 11-16
Load Check Plug ................................................................................................................................................... 11-17
Relief Valve PV5 .................................................................................................................................................... 11-18
Rack Lift Cylinders CY13 and CY14 .................................................................................................................... 11-19
Disassembly .................................................................................................................................................... 11-20
Assembly & Install .......................................................................................................................................... 11-21
Rack Lift Cylinder Lock Check Valves CV8 and CV9......................................................................................... 11-22
Overview....................................................................................................................................................... 12-1
Circuits ......................................................................................................................................................... 12-1
Component Locations ............................................................................................................................................ 12-2
Hydraulic Connections ........................................................................................................................................... 12-3
Component Overview.................................................................................................................................. 12-4
PFC Pump PMP3 ............................................................................................................................................... 12-4
Load Sense Solenoid Valve L25 ...................................................................................................................... 12-4
Stakedown Manifold A7.................................................................................................................................... 12-4
Stakedown Motors MH9 and MH10 ................................................................................................................. 12-4
Operation ........................................................................................................................................................... 12-4
Specifications .............................................................................................................................................. 12-4
Hose Diagram - PFC Pump to Stakedown Manifold ............................................................................................ 12-5
Hydraulic Schematic............................................................................................................................................... 12-6
Electrical Diagram ....................................................................................................................................... 12-7
Stake Up Circuit Operation .................................................................................................................................... 12-8
Stake Down Circuit Operation ............................................................................................................................... 12-8
Stakedown Motor Counter Clockwise Operation (Stake Out)............................................................................. 12-9
Stakedown Motor Clockwise Operation (Stake In) .............................................................................................. 12-9
Troubleshooting ........................................................................................................................................ 12-10
SYMPTOM: Stakedown Operation Slow or Lacks Force................................................................................... 12-10
SYMPTOM: Stakedown Will Not Operate............................................................................................................ 12-10
Pretest Inspection ................................................................................................................................................. 12-12
Troubleshooting Machine Performance ............................................................................................................. 12-14
Possible Results: ............................................................................................................................................ 12-14
Testing Stakedown Performance ........................................................................................................................ 12-15
Troubleshooting/Testing Stakedown Function.................................................................................................. 12-16
Test Equipment Needed ....................................................................................................................................... 12-19
Specifications........................................................................................................................................................ 12-19
Component Repair/Replace ................................................................................................................................. 12-19
Component Repair..................................................................................................................................... 12-20
Stakedown Valve Assembly A7 ........................................................................................................................... 12-20
Remove ............................................................................................................................................................ 12-20
Disassemble .................................................................................................................................................... 12-21
Install ............................................................................................................................................................... 12-21
Stakedown Motors MH9 and MH10...................................................................................................................... 12-22
Remove ............................................................................................................................................................ 12-22
Motor Breakdown ........................................................................................................................................... 12-23
Install ............................................................................................................................................................... 12-24
Stakedown Cylinders CY10 and CY11 ................................................................................................................ 12-25
Remove ............................................................................................................................................................ 12-25
Table of Contents D36x50 Series II Navigator HDD Service

Disassemble ....................................................................................................................................................12-25
Install ................................................................................................................................................................12-26
Overview....................................................................................................................................................... 13-1
Theory........................................................................................................................................................... 13-1
Components ............................................................................................................................................................ 13-1
Component Locations............................................................................................................................................. 13-2
Hose Connections ................................................................................................................................................... 13-3
Schematics .............................................................................................................................................................. 13-4
Auto Greaser Function................................................................................................................................ 13-6
Greasing Mode ........................................................................................................................................................ 13-6
Operation ...........................................................................................................................................................13-6
Troubleshooting .......................................................................................................................................... 13-7
Pretest Inspection ................................................................................................................................................... 13-7
Troubleshooting/Testing the Auto Greaser Function .......................................................................................... 13-9
Test Equipment Needed.......................................................................................................................................... 13-9
Specifications ........................................................................................................................................................ 13-10
Component Repair/Replace.................................................................................................................................. 13-10
Component Repair .................................................................................................................................... 13-11
Auto Greaser Valve A21........................................................................................................................................ 13-11
Remove ............................................................................................................................................................13-11
Disassemble ....................................................................................................................................................13-11
Auto Greaser Cylinder CY6 .................................................................................................................................. 13-12
Remove ............................................................................................................................................................13-12
Disassemble ....................................................................................................................................................13-13
Assemble .........................................................................................................................................................13-13
Overview....................................................................................................................................................... 14-1
Theory........................................................................................................................................................... 14-1
Components ............................................................................................................................................................ 14-1
Specifications .......................................................................................................................................................... 14-2
Component Locations............................................................................................................................................. 14-3
Hose Connections ................................................................................................................................................... 14-6
Hydraulic Schematic ............................................................................................................................................... 14-7
Electrical Schematic ............................................................................................................................................... 14-8
Operation ...........................................................................................................................................................14-9
Drill Fluid OFF........................................................................................................................................................ 14-10
Operation .........................................................................................................................................................14-10
Wash Wand ............................................................................................................................................................ 14-10
Operation .........................................................................................................................................................14-10
Troubleshooting ........................................................................................................................................ 14-10
Pretest Inspection ................................................................................................................................................. 14-11
Test Equipment Needed........................................................................................................................................ 14-12
Testing Machine Performance ............................................................................................................................. 14-13
Possible Results .............................................................................................................................................14-13
Testing Water Shutoff Valve Performance.......................................................................................................... 14-14
Troubleshooting/Testing the Drilling Fluid Function......................................................................................... 14-15
Troubleshooting/Testing Fluid Control Module A20.......................................................................................... 14-18
Water Control Module ............................................................................................................................... 14-18
Inputs/Outputs ....................................................................................................................................................... 14-18
Function Check ..................................................................................................................................................... 14-19
No Water Output ........................................................................................................................................ 14-20
D36x50 Series II Navigator HDD Service Table of Contents

Pump Performance.................................................................................................................................... 14-22

Component Repair/Replace ................................................................................................................................. 14-24
Component Repair..................................................................................................................................... 14-25
Combination Valve Manifold A9 .......................................................................................................................... 14-25
Remove ............................................................................................................................................................ 14-25
Install ............................................................................................................................................................... 14-26
Flow Control Valves FV3 and FV4 ....................................................................................................................... 14-27
Remove ............................................................................................................................................................ 14-27
Install ............................................................................................................................................................... 14-27
Fluid Shutoff Valve Assembly A26 and Shift Valve Assembly A27.................................................................. 14-27
Remove ............................................................................................................................................................ 14-27
Disassembly .................................................................................................................................................... 14-28
Fluid Shutoff Cylinder CY15 and Ball Valve ....................................................................................................... 14-29
Remove ............................................................................................................................................................ 14-29
Cylinder Disassembly .................................................................................................................................... 14-30
Ball Valve Disassembly .................................................................................................................................. 14-31
Ball Valve Assembly ....................................................................................................................................... 14-32
Fluid Pump PMP4 — Aplex or FMC ..................................................................................................................... 14-33
Remove ............................................................................................................................................................ 14-33
Fluid Pump PMP4 – Aplex SC-45......................................................................................................................... 14-34
Valve Disassembly ......................................................................................................................................... 14-34
Piston Cup and Piston Rod Disassembly..................................................................................................... 14-36
Piston and Crankcase Disassembly ............................................................................................................. 14-37
Fluid Pump PMP4 – FMC ...................................................................................................................................... 14-38
Piston Cup Seal Removal/Installation................................................................................................................. 14-38
Special Tools and Materials........................................................................................................................... 14-38
Remove Piston Cup Seals ............................................................................................................................. 14-39
Install Piston Cup Seals ................................................................................................................................. 14-42
Suction and Discharge Valve Removal/Installation........................................................................................... 14-46
Special Tools and Materials........................................................................................................................... 14-46
Remove Valves ............................................................................................................................................... 14-46
Install Valves ................................................................................................................................................... 14-48
Motor MH10 – Eaton 4000 Series......................................................................................................................... 14-51
Special Tools................................................................................................................................................... 14-51
Disassembly .................................................................................................................................................... 14-51
Assembly ......................................................................................................................................................... 14-55
Install Speed Sensor ...................................................................................................................................... 14-57
Timing .............................................................................................................................................................. 14-59
Overview....................................................................................................................................................... 15-1
Theory........................................................................................................................................................... 15-1
Functions ................................................................................................................................................................. 15-1
Components ............................................................................................................................................................ 15-2
Component Locations ............................................................................................................................................ 15-3
Electrical Schematic ............................................................................................................................................... 15-5
Hydraulic Schematic............................................................................................................................................... 15-6
Hydraulic Lockout Function................................................................................................................................... 15-7
Operation ........................................................................................................................................................... 15-7
Backup Engine Shutdown Function for Hydraulic Lockout ......................................................................... 15-7
Engine Shutdown Lockout Function..................................................................................................................... 15-8
Option Procedure ............................................................................................................................................. 15-8
Operation ........................................................................................................................................................... 15-8
Table of Contents D36x50 Series II Navigator HDD Service

Troubleshooting .......................................................................................................................................... 15-9

General System Information................................................................................................................................... 15-9
Base Module Indicators. ....................................................................................................................................... 15-10
Power On................................................................................................................................................................ 15-12
Remote Unit On ...............................................................................................................................................15-12
Base Module Run ............................................................................................................................................15-12
Lockout Mode ........................................................................................................................................................ 15-13
Power Off ............................................................................................................................................................... 15-13
Remote Registration ............................................................................................................................................. 15-14
Battery Condition .................................................................................................................................................. 15-15
Low Battery......................................................................................................................................................15-15
Discharged Battery .........................................................................................................................................15-15
Recharge Battery ............................................................................................................................................15-15
Performing Remote Lockout Functions ............................................................................................................. 15-16
Resuming Operation After Remote Lockout....................................................................................................... 15-17
Flashing Lights................................................................................................................................................15-17
Troubleshooting/Testing the Remote Lockout Function................................................................................... 15-18
Remote Unit .....................................................................................................................................................15-18
Base Module ....................................................................................................................................................15-19
Verify Software ................................................................................................................................................15-19
Hydraulic or Engine Shutdown Lockout Mode.............................................................................................15-20
Battery ..............................................................................................................................................................15-20
Battery Charger ...............................................................................................................................................15-21
Terminal Test ...................................................................................................................................................15-21
Flow Chart for Determining Machine Problem (Without Remote) .................................................................... 15-22
Flow Chart for Determining Machine Problem (With Remote) .......................................................................... 15-23
Overview....................................................................................................................................................... 16-1
Theory........................................................................................................................................................... 16-1
Circuits ..................................................................................................................................................................... 16-1
Components ............................................................................................................................................................ 16-2
Component Locations............................................................................................................................................. 16-3
Strike Alert Module Daily Tests.............................................................................................................................. 16-4
Current Test .......................................................................................................................................................16-4
Voltage Test .......................................................................................................................................................16-4
Electrical Schematic ............................................................................................................................................... 16-5
Voltage Strike Circuit .............................................................................................................................................. 16-6
Operation ...........................................................................................................................................................16-6
Current Strike Circuit .............................................................................................................................................. 16-6
Operation ...........................................................................................................................................................16-6
Troubleshooting/Testing ............................................................................................................................ 16-7
Determining What To Troubleshoot ................................................................................................................16-7
Daily Test ...........................................................................................................................................................16-7
Control Panel Light ................................................................................................................................................. 16-8
Strike Alert Module Lights ...................................................................................................................................... 16-9
Component Repair .................................................................................................................................... 16-10
Voltage Stake E1 ................................................................................................................................................... 16-10
Strike Alert Coil Assembly L25 ............................................................................................................................ 16-11
D36x50 Series II Navigator HDD Service Table of Contents

Overview....................................................................................................................................................... 17-1
LED Display ............................................................................................................................................................. 17-1
Service Screen Button............................................................................................................................................ 17-2
Seat Switch .............................................................................................................................................................. 17-4
Trim Switches.......................................................................................................................................................... 17-5
Drill Selector ............................................................................................................................................................ 17-6
Transducer Manifold............................................................................................................................................... 17-6
Rotation PPU ........................................................................................................................................................... 17-7
PPU Wiring .............................................................................................................................................................. 17-8
Rotation Sensor Phase - Adjust ............................................................................................................................ 17-9
Controllers ............................................................................................................................................................. 17-11
Pin Assignments ................................................................................................................................................... 17-12
MC024010 Controller ............................................................................................................................................ 17-12
MC050010 Controller ............................................................................................................................................ 17-13
Universal Program ................................................................................................................................................ 17-14
Handle Calibration ................................................................................................................................................ 17-16
Front Vise/Auto-Drill Interlock ............................................................................................................................. 17-16
Auto Drill Mode-Enable and Vise “CLAMP” Interaction .................................................................................... 17-16
Parameters ............................................................................................................................................................ 17-17
Parameter Settings ............................................................................................................................................... 17-20
TEMPORARY MEMORY PRESSURE SETTINGS ................................................................................................ 17-21
PERMANENT MEMORY PRESSURE SETTINGS ................................................................................................ 17-21
Fault Codes ........................................................................................................................................................... 17-23
RATT LIMITS.......................................................................................................................................................... 17-24
R.A.T.T. .................................................................................................................................................................. 17-25
Disassembly/Assembly ........................................................................................................................................ 17-25
Breakout Bench .................................................................................................................................................... 17-26
Torque Push .......................................................................................................................................................... 17-27
Torque Pull ............................................................................................................................................................ 17-28
Bent Sub Assembly .............................................................................................................................................. 17-28
Filling R.A.T.T. ....................................................................................................................................................... 17-46
Oil Gauge Assembly ............................................................................................................................................. 17-47
This page intentionally left blank.
D36x50 Series II Navigator HDD Service Using the Manual

Chapter 1: General Information

General Information
D18x22

USING THE MANUAL

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

Vermeer Manufacturing Company reserves the right to make changes at

any time without notice or obligation.

Procedures given in this manual provide one method for completing a given
task. Additional information may be available through Vermeer Service
Support resources.

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

Operating instructions are found in the D36x50 Series II Navigator

Operator’s Manual. Lubrication and maintenance procedures are found in the
D36x50 Series II Navigator Maintenance Manual. Refer to “Reference
Publications,” for ordering information.

1-1
 Warranty Considerations D36x50 Series II Navigator HDD Service
General Information

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

• D36x50 Series II Navigator Horizontal Directional Drill Operator’s

Manual, order number 105400X92, cabled manual # 296260950
• D36x50 Series II Navigator Horizontal Directional Drill Maintenance
Manual, order number 105400X94
• D36x50 Series II Navigator Horizontal Directional Drill Parts Manual,
order number 105400ZFI
• 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 The following vendor publications are optional reference materials:

• John Deere Engine Manual

Contact the appropriate local dealer for this information. Vermeer

Manufacturing Company does not verify the validity of vendor information
within the context of the D36x50 Series II Navigator HDD machine
configuration.

WARRANTY CONSIDERATIONS
Vermeer Warranty
Vermeer 1 year Limited Warranty is printed inside the front cover of the
D36x50 Series II Operator’s Manual. The warranty requires that all service
work be conducted by an authorized Vermeer representative or the warranty
shall become void.

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 Yellow Pages of
the phone directory or contact John Deere Engine Warranty Service Dept.

1-2
D36x50 Series II Navigator HDD Service Safety

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

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

safety alert symbol.

Safety signs with signal word “DANGER”, “WARNING”, or “CAUTION”

are located near specific hazards.

DANGER: Imminent hazards which, if not avoided, will result in serious

personal injury or death.

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

could result in serious personal injury or death.

CAUTION: Potential hazards or unsafe practices which, if not avoided,

could result in minor personal injury or product or property damage.

Do Not Modify Machine

Make no modifications to your equipment unless specifically recommended
or requested by Vermeer Manufacturing Company.

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

Maintain Operator Presence System

This machine is equipped with an Operator Presence system. This system is
intended for operator safety and must be maintained in good, functional
condition.

1-3
 Safety D36x50 Series II Navigator HDD Service
General Information

Avoid Moving Parts

Keep hands, feet and clothing away from power-driven parts.

Keep shields in place and properly secured.

Avoid Entanglement - Stay Away

Entanglement in the rotating drill rod and cutting tool can result in death or
serious injury.

Stay away from rotating drill rod and cutting tool.

Do not wear loose clothing that could catch on rotating equipment.

Drilling and thrust control levers must self-center to NEUTRAL and stop
rod motion.

Rotating Wrench Contact

Serious injury or death could result if struck by a wrench on the drill rod if
rotation is started. Never use hand wrenches to break rod joints. Break rod
joints only with the power vises on the machine.

1-4
D36x50 Series II Navigator HDD Service Safety

General Information
Avoid Fluid Under Pressure
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.

Work in Ventilated Area

Exhaust fumes can be fatal.

If operating the machinery in an enclosed area, remove the exhaust fumes

with an exhaust pipe extension to the outside.

Raised Machine Can Fall

Never allow anyone to work under a raised machine or components unless
mechanically supported with suitable blocking.

1-5
 Terminology D36x50 Series II Navigator HDD Service
General Information

TERMINOLOGY

Inputs and Outputs

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

Reference Designators
Reference designators are assigned to each component shown on the
schematics and other reference diagrams. The Addendum in the back of the
manual includes a legend describing the reference designators and symbols
and how they are used in the schematics and text.

Each designator identifies a specific component. The designator is comprised

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

Diagrams and Schematics

Functional diagrams, schematics, wire harness connections, and hydraulic
hose connection diagrams are located throughout the theory and
troubleshooting sections. The diagrams represent function circuitry and
components. Large format schematics and diagrams are located in the
Addendum section in the back of manual. See the following Chapter
Organization information.

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

Each chapter will have a detailed table of contents preceding it and will be
divided into three sections, theory, troubleshooting, and repair.

1-6
D36x50 Series II Navigator HDD Service Terminology

General Information
Theory The theory sections are arranged starting with an overview to each function.
The overview consists of a schematic, a list of circuits and components, and a
graphic depicting component locations.

Theory sections describe what happens when the controls are activated, and
how funtion components work together. Illustrations, along with the text,
will aid in understanding how the functions work.

Troubleshooting These sections describe how to test suspected faulty circuits and positively
determine which components are in need of being replaced.

Repair When it is determined through troubleshooting that components are

malfunctioning, the repair sections contain detailed instructions on how to
repair or replace each component and any special steps or procedures
needed before returning the machine to service.

Addendum Reference materials such as complete machine electrical and hydraulic

schematics as well as wire harness diagrams too large to fit on standard
pages, are located in the Addendum in the back of this manual on 11 x 17″
foldouts.

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 Troubleshooting Guidelines D36x50 Series II Navigator HDD Service
General Information

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

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

Ensure you are familiar with machine operation (or refer to the Operator’s
Manual) and verify with the operator that all interlocks are satisfied, that
any E-stop switches have not been activated and other simple items.

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D36x50 Series II Navigator HDD Service Troubleshooting Guidelines

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

• Learn what function is not working and whether it is too slow, too fast or
not working at all.
• Ask if the operator has recently used all the other actuators and whether
they seemed to be working normally. If not, ask the operator to try to use
these actuators. If there are multiple problems, there could be a common
cause to all of them.
• Inspect the machine. Verify that the problem is not something obvious,
like low hydraulic fluid, broken lines or wires.
• Ask other questions to further define the problem, such as:
—Did the problem appear suddenly, or did machine performance
deteriorate over time?
—When was the problem first noticed, and had there been any changes
made to the machine or the working conditions prior to the problem’s
appearance?
—Were any odd smells, sounds or machine actions noticed at the same
time as the problem?
—Is the problem intermittent or continuous?
—If intermittent, does is occur when the machine is cold, or fully
warmed up?
—Does it occur in cold weather, hot weather, dry weather, humid
weather?
• Make an overall observation of the situation, noting symptoms and
relevant changes.

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 Troubleshooting Guidelines D36x50 Series II Navigator HDD Service
General Information

Research the Familiarize yourself with the Service Manual by reading the General and
Machine Machine Information chapters.

These chapters, explain how the machine is configured, and how the manual
is set up. If you are not familiar with, or have limited knowledge of the
machine’s functions, read the theory of operation for all or selected chapters.

Begin troubleshooting by doing the following:

• Describe and compare the problem situation with known operating

conditions prior to breakdown.
• Describe all known differences such as symptoms, noises, and smells
noticed when the failure occurred.
• Note which functions perform normally and which do not.
NOTE: The troubleshooting procedures in this manual cover the electrical
and hydraulic circuits. First ensure a mechanical problem is not the cause of
the failure before using the troubleshooting procedures.

All functions with hydraulic circuits share the fluid conditioning

components. If all those functions experience related problems, these
components should be investigated.

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D36x50 Series II Navigator HDD Service Troubleshooting Guidelines

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

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

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

Measurements taken with a multimeter can be used to troubleshoot for

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

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

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

In a normal working circuit, voltage is applied to the resistive load where it

is dropped proportionately over each resistor in the circuit. The amount of
voltage drop is dependent on the value of each resistor. Open circuits cannot
drop voltage.

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

Measurements taken with a multimeter can be used to troubleshoot an open

circuit. Use the meter to test for voltage while moving to accessible points in
the circuit to find the open and isolate the failed component or wire harness
section.
Continued on next page...

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 Troubleshooting Guidelines D36x50 Series II Navigator HDD Service
General Information

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

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

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

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

speed. The amount of leakage is influenced by four factors:

• pressure difference across clearances

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

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D36x50 Series II Navigator HDD Service Troubleshooting Guidelines

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

The general rule used for pump efficiency loss is:

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

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

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

The most common symptoms associated with excessive pump/motor leakage

are:

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

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

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 Troubleshooting Guidelines D36x50 Series II Navigator HDD Service
General Information

The most common symptoms associated with excessive pump/motor case

pressure are:

• Shaft seal leakage

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

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

The most common symptoms associated with excessive directional control

valve leakage are:

• Increased actuator drifting while directional control valve is in the

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

Cylinders Hydraulic cylinders consists of a moveable piston and rod assemblies.

Pistons have seals to prevent leakage across the piston.

The most common symptoms associated with excessive cylinder leakage are:

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

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

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D36x50 Series II Navigator HDD Service Troubleshooting Guidelines

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

Hydraulic Connections

WARNING: Pressurized fluid can penetrate body tissue and result in

serious injury or death. Leaks can be invisible. Keep away from any
suspected 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.

Avoid Trapped Never disconnect hoses or lines unless the engine is shut down.
Pressure

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 Troubleshooting Guidelines D36x50 Series II Navigator HDD Service
General Information

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

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

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

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

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D36x50 Series II Navigator HDD Service Troubleshooting Guidelines

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

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

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

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

IMPORTANT: If the gauge ever “pegs” (indicates pressure at the maximum

reading), the gauge is ruined. Discard it immediately.

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

The pyrometer is a non-contact thermometer. Place the projected red dot on

the surface and wait at least one second. The temperature of the surface is
shown in the indicator window.

Several readings may be required during the same test. It is important to

take the readings with the projected dot focused on the same spot on the
surface.

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 Troubleshooting Guidelines D36x50 Series II Navigator HDD Service
General Information

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

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

1. Turn off power to the circuit or device.

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

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

Resistance flow. Set multimeter to measure resistance. If needed, see the instruction
booklet for your multimeter to determine proper settings. Then do the
following:

1. Turn off power to the circuit or device.

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

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D36x50 Series II Navigator HDD Service Troubleshooting Guidelines

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

1. Turn off power to the device or circuit.

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

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

to indicate continuity.

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

1. Turn off power to the circuit or device.

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

1-19
 Repair Guidelines D36x50 Series II Navigator HDD Service

REPAIR GUIDELINES
General Information

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

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

105400T69) for special tools and test equipment.

Personnel and Lifting Requirements

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

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

20General Information

Replacement Parts
Part Numbers/Hose Refer to the most current parts manual order number 105400ZFI for part
Lengths/Fitting numbers, hose lengths, and fitting orientations.
Orientation

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

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

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D36x50 Series II Navigator HDD Service Shutdown Procedure

Chapter 2: System Information

SHUTDOWN PROCEDURE

System Information
IMPORTANT: If the machine is shut down in LOCKOUT mode, the remote
transmitter must be available upon machine start-up to cancel LOCKOUT
mode and enter RUN mode.

1. Shut off drilling fluid pump.

2. Reduce engine speed to idle.
3. Wait two minutes to shut off engine when shutting down after operating
at full power.
4. Shut off engine and remove key.
5. Press remote transmitter power off button and hold for 2 seconds to shut
off remote transmitter.
6. Remove battery pack from remote transmitter and install in charging
compartment.
7. Return remote transmitter to docking station.
For your safety and the safety of others, use shutdown procedure before
working on the machine for any reason, including servicing, cleaning,
unplugging, or inspecting.

If working on the drill string or drill tools at a remote location away from the
machine, follow Remote Lockout procedure in this section.

A variation of the above procedure may be used if instructed within this

manual or if an emergency requires it.

2-1
 Starting the Engine D36x50 Series II Navigator HDD Service

STARTING THE ENGINE

1. Shut off drilling fluid pump.
System Information

2. Set throttle at idle.

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

5. Adjust throttle to get an even idle speed and allow engine to warm up for
3–5 minutes.
IMPORTANT: Do not idle engine for more than 10 minutes. Low
combustion chamber temperatures will not allow fuel to burn completely
and can cause engine damage.

6. Turn remote transmitter on.

NOTE: The Remote Lockout system self-test upon start-up, indicated by
two short beeps, and then enters LOCKOUT mode.

7. Press run button and hold for 2 seconds to select RUN mode.
8. Press hydraulic enabled button.

2-2
D36x50 Series II Navigator HDD Service Starting the Engine

Cold Weather Starting

Engine

System Information
Before operating in cold weather, refer to engine operation manual for
recommended engine oil, fuel, and starting procedures.

Hydraulic Fluid
Refer to specifications section, “Lubricants,” 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 up engine.
• Gradually increase engine RPM for up to 30 minutes to allow hydraulic
oil to warm up. To assist in warming up the hydrostatic system, move
control levers back and forth.
NOTE: Slow engine down if hydraulic pump squeals because it does not get
enough oil.

For frequent starts below 10°F (-12°C), consult your Vermeer dealer.

2-3
 Specifications D36x50 Series II Navigator HDD Service

SPECIFICATIONS
Machine Reference and Orientation
System Information

Left, right, front, and rear of the machine is shown in the diagram below.
The control station is on the right side of the machine.

LEFT

FRONT

REAR

RIGHT

2-4
D36x50 Series II Navigator HDD Service Engine Specifications

ENGINE SPECIFICATIONS
Model John Deere 4045HF275

System Information
Maximum power 140 hp at 2400 rpm
Engine oil capacity 15.8 qt (15 L) with filter
Fuel type and capacity Diesel 45 gal (170 L)
Coolant and coolant 9.75 gal (37 L)
system capacity
Electrical system 12 volts DC
Alternator 65 amp
Battery BCI group size 31
Cold cranking amps 950 CCA (30 sec) 0°F (-18C) 185
minutes of reserve capacity (25-amp
output) at 80°F (27°C)

MACHINE SPECIFICATIONS
Specification Value

Machine Dimensions
weight without 15-ft rod box 15,700 lb (7,120 kg)
weight without 10-ft rod box 15,250 lb (6,916 kg)
weight with 15-ft rod box 21,920 lb (9,940 kg)
weight with 10-ft rod box 19,800 lb (8,979 kg)
overall length 23 ft 1'' (6.2 m)
overall width 82" (208 cm)
overall height (at top of rod box) 75" (198 cm) with rack up

2-5
 Machine Specifications D36x50 Series II Navigator HDD Service

Specification Value

Thrust/Pullback System
System Information

maximum thrust at rated pressure 16,200 lb (7346 kg) 15-ft 2-3/8 dia.
29,400 lb (13333 kg) 15-ft 2-5/8 dia.
36,000 lb (16326 kg) 10-ft
maximum pullback force at rated pressure 36,000 lb (1,6326 kg)
pump make/model Sundstrand 90 series
pump pressure limiter setting (multifunction 6000 psi (413 bar)
valve) for PULLBACK
pump multifunction valve pressure setting 6000 psi (413 bar) 10-ft rod
for THRUST 2700 psi (186 bar) 15-ft 2-3/8 dia. rod
4900 psi (338 bar) 15-ft 2-5/8 dia. rod
thrust limiter setting (RockFire mode) for 0–3000 psi (0–207 bar)
THRUST
pump nominal flow @ 2500 rpm 32 gpm (121 L/min)
Rotation System
low rotation speed @ 2500 engine rpm 89 rpm
medium rotation speed @ 2500 engine rpm 119 rpm
high rotation speed @ 2500 engine rpm 178 rpm
pump make/model Sundstrand 90 series
pump pressure limiter setting (multifunction 6000 psi (413 bar)
valve) for FORWARD rotation
pump pressure limiter setting (multifunction 6000 psi (413 bar)
valve) for REVERSE rotation
torque limiter setting for FORWARD 4100 psi (280 bar)
rotation
torque limiter setting for REVERSE rotation 1500 psi (105 bar)
pump nominal flow @ 2500 rpm 32 gpm (121 L/min)
PFC (Implement) System
pump make/model Sundstrand 45 series
high pressure compensator setting 3000 psi (210 bar)
pump nominal flow @ 2500 rpm 42 gpm (159 L/min)
Water System
pump makes/models Aplex SC-45, FMC L0918HD, Aplex SC-651
pump maximum nominal flow SC-45 - 50/25 gpm, L0918HD - 53 gpm, SC-651 - 70 gpm
pump maximum rated pressure SC-45 - 492/985 psi, L0918HD - 1300 psi, SC-651 - 850 psi

2-6
D36x50 Series II Navigator HDD Service Machine Interlocks

Fuel and Lubricants

Lubricant Capacity Specifications / Notes

System Information
Fuel 45 gal (170 L) An engine operation manual is supplied with each
machine. Refer to the manual for engine service
Engine Oil refer to engine
requirements.
specifications
Hydraulic Fluid 60 gal (227 L)
Vermeer HyPower 46 or ISO 46: -13° to 86°F (-25° to 30°C)
Vermeer HyPower 68 or ISO 68: -4° to 104°F (-20° to 40 °C)
Vermeer HyPower 100 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.

IMPORTANT: Use of any oils other than those

All-Purpose Gear Lube
(rotation gearbox)
General Lubricating Oil
Vermeer Xtra Gold 10W30
Grease
Vermeer Ultra LC Grease
recommended, without written factory approval, will
jeopardize the warranty.
maintain check plug Oils must conform to API GL5 or MIL-L-2105D
level specifications.
-20° to 100°F (-30° to 40°C): 80W-90
20° to 120°F (-10° to 50°C): 85W-140
as required SAE10W30
as required Lithium complex, extreme pressure NLGI Grade
2

To minimize condensation in bearings, grease

machine after it is shut down for the day.

Fittings and grease applicator nozzle must be clean

before applying grease. Replace all missing fittings.

MACHINE INTERLOCKS
Starting Interlocks
• The emergency stop switch at the transport control station must be
pulled out to start the engine.
• The battery ground disconnect switch in the engine compartment must
be turned to the clockwise to start the engine.

2-7
 Machine Interlocks D36x50 Series II Navigator HDD Service

Operator Presence Interlock

• Operator presence switch located in drill station seat must be closed (seat
occupied). The machine is considered in DRILL mode while seat is
System Information

occupied, and TRANSPORT mode while it is empty. If the seat switch is

closed, transport controls at the rear of the machine will not function. If
the seat switch is open, drill rotation and thrust functions will not
operate.

Remote Lockout
• Remote Lockout disables the drilling controls (rotation, thrust/pullback
and drilling fluid pump) when in HYDRAULIC LOCKOUT mode. If
pressure is sensed by the pressure switches in the drill function
hydraulic circuits while in HYDRAULIC LOCKOUT, the engine shuts
down. It cannot be started until the Remote Lockout system receives a
RUN signal from its remote transmitter.
• If the machine is in ENGINE LOCKOUT mode when the engine is shut
down, the remote transmitter must be present and sending a RUN signal
before the engine will start.

Machine Performance
If a function does not perform as expected, refer to the hydraulic schematic
and operate other machine functions that are supplied by the same pump.
On a service call, some functions probably will not be performing up to
expectations. If not, refer to the troubleshooting section in that particular
function chapter. Check machine functions after repairs have been
completed to ensure machine performance is at specification.

2-8
D36x50 Series II Navigator HDD Service Checking Machine Performance

Preoperation Check If the machine is not operating within specifications, begin by visually
checking for any obvious failures such as, broken, kinked, or loose hoses and
fittings on supply, pressure, and return to hydraulic components.

System Information
Ensure there are no broken, missing, corroded, or loose wires and
connections on the ground and power wires that supply the electrical circuit
components. If any are found, repair or replace.

Tools Needed • Stopwatch

• Pen or Pencil
• Calculator (optional)
• White Marker
• Reflective Tape
• Phototach
• Pyrometer or Magnetic Thermometer

Checking Machine Performance

Performance check procedures contained in this section consist of

• Rotation Performance
• Thrust/Pullback Performance
• Ground Drive Performance
• Rod Loader Performance
• Vise Performance
• Stakedown Performance
• Rack Angle.
• Stabilizer Performance
• Water Delivery Performance
This section also contains a table of Performance Check Standards and
Tolerances, and control and indicator locations for each circuit.

2-9
 Machine Performance Standards D36x50 Series II Navigator HDD Service

MACHINE PERFORMANCE STANDARDS

The following table summarizes the standards established for the D36x50
System Information

Series II.

Table 1. Performance Standards

ACTUATOR NOMINAL
Drill Rotation
Clockwise Low - 89, medium - 119, high - 178
Counterclockwise Low - 89, medium - 119, high - 178
Thrust/Pullback
Forward Low - 150 ft per min
Reverse Low - 150 ft per min
GROUND DRIVE
Forward 8.75 rpm at the motor
Reverse 8.75 rpm at the motor
ROD LOADER
Lift Cylinder Extend 1.5 sec
Lift Cylinder Retract 1.5 sec
Selector Extend 1.5 sec
Selector Retract 1.8 sec
VISE
Front Extend 1.4 sec
Front Retract 1.6 sec
Rear Extend 1.4 sec
Rear Retract 1.6 sec
Rear Rotate CW 1.7 sec
Rear Rotate CCW 3.0 sec
STAKEDOWN
Cylinder Extend 1.9 sec
Cylinder Retract 1.5 sec
Rotation Motor Clockwise 20 rpm
Rotation Motor CCW 20 rpm
RACK ANGLE
Retract 10.00 sec
Extend 10.00 sec
STABILIZER
Retract 5 sec
Extend 5 sec

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D36x50 Series II Navigator HDD Service Machine Performance Procedures

MACHINE PERFORMANCE PROCEDURES

Performance procedures that follow cover machine control settings, control

System Information
and indicator locations and definitions for machine functions.

Performing the checks in this section will determine if PFC pump PMP3 and
diverter valve assembly A9 are functioning properly.

Control Settings
With the machine stopped, engine off, and ignition switch in the OFF
position, set the following switches to the positions indicated.

Table 2. Control Settings

Switch Nomenclature Ref Des Position

Ground Disconnect S1 ON
Stakedown Thrust And Rotate S32,S33 OFF
Rear Vise S35 RELEASE
Rear Vise Rotate S36 OFF
Front Vise S34 RELEASE
RockFire/Trihawk (option) S23 OFF
Water S15 OFF

2-11
 Machine Performance Procedures D36x50 Series II Navigator HDD Service

Engine Starting and Warm-Up

All tests of hydraulic operation in this manual are based on engine operating
speeds and hydraulic fluid temperatures. It is imperative that, after start-up
System Information

the engine be sufficiently warmed to ensure consistent operation and

hydraulic fluid is circulated to warm fluid throughout the system to 85 ±
10°F (29.3 ± 5.7°C) as measured at the return port to the tank. To achieve
these conditions, perform the following steps.

1. After performing the preoperational inspection, turn ignition switch to

START position to start the engine. Allow the engine to run at low idle
for several minutes to properly warm and circulate engine oil.
2. After warming, increase engine speed to 2,500 ± 100 rpm.
3. If possible, operate rotation and thrust joysticks to move carriage
forward and back on rack and rotate drill head, pausing periodically to
check temperature of fluid returning to tank with pyrometer or contact
thermometer. Continue until desired hydraulic fluid temperature is
reached. Then proceed to applicable machine performance procedure.

2-12
D36x50 Series II Navigator HDD Service Machine Performance Procedures

Drill Rotation Performance

PERFORMANCE CHECK PROCEDURE PASS FAIL
Drill Rotation

System Information
Clockwise (Forward) Rotation
Counterclockwise (Reverse) Rotation
ACTION REQUIRED
1. If one or both fail, procede to the Rotation chapter troubleshooting
section
1. Ensure switches listed in "Control Settings," page 2-11, are in correct
positions.
2. If "Preoperation Check," page 2-9, has not been performed, conduct
inspection before proceeding.
3. If "Engine Starting and Warm-Up," page 2-12, has not been performed,
refer to procedure and perform before proceeding.
4. Enable Remote Lockout.
5. Simultaneously start stopwatch and move the control handle to the
CLOCKWISE rotation position. Count the drill rotations for 60 seconds.
6. Simultaneously start stopwatch and move the left control handle to the
COUNTERCLOCKWISE rotation position. Count the drill rotations for
60 seconds

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 Machine Performance Procedures D36x50 Series II Navigator HDD Service

Thrust/Pullback Operation
System Information

Function Pass Fail

Thrust\Pullback
Thrust Mode
Pullback Mode
Action Required
1. If one or both modes fail, procede to the Thrust/Pullback chapter troubleshooting section

2-14
D36x50 Series II Navigator HDD Service Machine Performance Procedures

Thrust/Pullback 1. Ensure switches listed in "Control Settings," page 2-11, are in correct
Performance positions.
2. If "Preoperation Check," page 2-9, has not been performed, conduct

System Information
inspection before proceeding.
3. If "Engine Starting and Warm-Up," page 2-12, has not been performed,
refer to procedure and perform before proceeding.
4. Enable Remote Lockout.
5. Ensure rotation carriage is in the farthest rearward position. If
necessary, move carriage to the extent of travel by pulling back on the
right control handle.
6. Simultaneously start stopwatch and move the control handle to the
FORWARD or THRUST position. Stop the timing when the rotation
carriage reaches the end of travel. Time required for the rotation
carriage to move to the fully forward position should be approximately 9
seconds.
7. Time carriage travel in the REVERSE or PULLBACK direction by
pulling back on the control handle. The time required for carriage travel
should be approximately 9 seconds.

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 Machine Performance Procedures D36x50 Series II Navigator HDD Service

Ground Drive, Rod Loader, Vise, Stakedown, Stabilizer/Rack Angle, and

Water Shutoff Performance
System Information

Performance Check Procedure Pass Fail

Ground Drive
Right Track
Left Track
Rod Loader
Rod Lift Cylinder Drop
Rod Lift Cylinder Raise
Rod Select Extend
Rod Select Retract
Vise
Front Vise Clamp
Front Vise Release
Rear Vise Clamp
Rear Vise Release
Rear Vise Rotate Counterclockwise
Rear Vise Rotate Clockwise
Stakedown
Front Vise Clamp
Front Vise Release
Rear Vise Clamp
Rear Vise Release
Rear Vise Rotate Counterclockwise
Rear Vise Rotate Clockwise
Water Shutoff Valve
Water Valve Closes
Water Valve Opens
Action Required
1. If one specific mode of any function fails (example: rod loader select extend) fails, refer to the
specific troubleshooting procedures for the valve that controls that mode.
2. If all modes of a specific function fail (i.e., rod loader select extend and retract), troubleshoot the
specific valve associated with that function.
3. If all functions fail, troubleshoot the pump PMP3 and valve manifold
A9 components.

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D36x50 Series II Navigator HDD Service Machine Performance Procedures

The following circuit performance procedures are grouped together because

control valve assembly A9 affects PFC pump PMP3 hydraulic flow all these
functions. No corrective action should be taken until the performance of all
these functions have been evaluated. The following checks require the use of

System Information
a stopwatch, pyrometer, and phototach.

The following equipment/materials are required to perform these checks.

• Stopwatch
• Pyrometer or Contact Thermometer
• White Marker or Reflective Tape
• Phototach

2-17
 Machine Performance Procedures D36x50 Series II Navigator HDD Service

Ground Drive Performance

This check is based on the assumption that the common hydraulic
components, pump PMP3 and diverter manifold valve assembly A9 are
System Information

operating normally. Because of this assumption, it is required that all

functions supplied by this pump be evaluated.

The following equipment/materials are required to perform these checks.

• Stopwatch
• Pyrometer or Contact Thermometer
• White Marker or Reflective Tape
• Phototach
Ground Drive 1. Ensure "Preoperation Check," page 2-9 and engine starting and warm-up
procedures have been performed.
2. With engine running, use phototach to verify engine speed of 2,200 ± 100
rpm.
3. Enable Remote Lockout.
4. Press hydraulic enable push button
S30 to enable rod loader, vise, and S30
water valve circuits.

5. Lower the stabilizer all the way

down using the control switches (1)
at the rear control panel. 1

Continued on next page...

2-18
D36x50 Series II Navigator HDD Service Machine Performance Procedures

6. At rear control panel, operate rack

angle control lever (1), to lower the
rack until both tracks are
completely clear of ground/floor.

System Information
7. Simultaneously start stopwatch and
move track control handle (left (2)
or right (3) track) to maximum
FORWARD position. Count 1
revolutions of track for 60 seconds, 2 3
then release control handle. Track
should rotate at approximately 8
rpm.
8. Repeat step 6 for REVERSE direction of track. Track should rotate at
approximately 8 rpm.
9. Return tracks to ground/floor by decreasing rack angle and raising
stabilizers.

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 Machine Performance Procedures D36x50 Series II Navigator HDD Service

Rod Loader 1. Ensure switches listed in "Control Settings," page 2-11, are in correct
Performance positions with the exception of the front vise switch. For rod loader
functions to work correctly, the front vise must be clamped.
System Information

2. If "Preoperation Check," page 2-9, has not been performed, conduct

inspection before proceeding.
3. If "Engine Starting and Warm-Up," page 2-12, has not been performed,
refer to procedure and perform before proceeding.
4. Enable Remote Lockout.
5. Press hydraulic enable push button S30
to enable rod loader circuits.
S30

NOTE: The performance values listed for the rod loader circuit are for
reference purposes only. All functions should require about 2 seconds for
completion. Due to these short time frames, operational conditions of these
circuits should not be determined by the results of these tests alone. If
circuit operation is in question, refer to rod loader troubleshooting section.

6. Push rod lift switch S37 (1). Rod lift

cylinders will extend in approximately 2
seconds.

1 S39
1
7. Push rod lift switch again. Rod lift
cylinders will retract in approximately 2
seconds

Continued on next page...

2-20
D36x50 Series II Navigator HDD Service Machine Performance Procedures

8. Push rod selector extend switch S38. Loader

selector arms will move to the drill string in S38
approximately 2 seconds.

System Information
9. Push rod selector retract switch S39 to
RETRACT position. Loader selector arms
will move toward the rod box in
approximately 2 seconds.

S39

2-21
 Machine Performance Procedures D36x50 Series II Navigator HDD Service

Vise Performance NOTE: 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.
System Information

1. Ensure switches listed in "Control Settings," page 2-11, are in correct

positions.
2. If "Preoperation Check," page 2-9, has not been performed, conduct
inspection before proceeding.
3. If "Engine Starting and Warm-Up," page 2-12, has not been performed,
refer to procedure and perform before proceeding.
4. Enable Remote Lockout.
5. Press hydraulic enable push button
S30 to enable implement hydraulic S30
circuits.

6. Move front vise switch S34 forward to

S34
CLAMP position. Front vise cylinder will
fully extend in approximately 2 seconds.

7. Move front vise switch S34 back to

RELEASE position. Front vise cylinder will
fully retract in 2 seconds.

Continued on next page...

2-22
D36x50 Series II Navigator HDD Service Machine Performance Procedures

8. Move rear vise switch S35 to CLAMP

position. Rear vise clamp cylinder will fully S35
extend in approximately 2 seconds.

System Information
9. Move rear vise switch S35 to RELEASE
position. Rear vise clamp cylinder will fully S36
retract in 2 seconds.
10. Press rear vise rotate switch S36 to
ROTATE CCW position. Rear vise rotate
cylinder will fully extend in approximately 2
seconds.

11. Press rear vise rotate switch S36 again. Rear vise rotate cylinder will
fully retract in approximately 2 seconds.

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

1. Ensure switches listed in "Control Settings," page 2-11, are in correct

positions.
2. If "Preoperation Check," page 2-9, has not been performed, conduct
inspection before proceeding.
3. If "Engine Starting and Warm-Up," page 2-12, has not been performed,
refer to procedure and perform before proceeding.
4. Enable Remote Lockout.
5. Press hydraulic enable push button
S30 to enable implement hydraulic
circuits.
S30

Continued on next page...

2-23
 Machine Performance Procedures D36x50 Series II Navigator HDD Service

6. Select left or right stakedown circuit

using LEFT/RIGHT switch S31.
S31
System Information

NOTE: Raise the rack to its fully raised position and remove stakedown
augers before continuing.

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

Continued on next page...

2-24
D36x50 Series II Navigator HDD Service Machine Performance Procedures

7. Ensure chosen stakedown cylinder is at its most extended (raised)

position.
8. Move stakedown valve switch S32
(1) to the LOWER position.

System Information
Stakedown cylinder will fully retract 1
in approximately 3 seconds.

9. Move stakedown valve switch (1) to

the RAISE position. Stakedown
cylinder will fully extend in
approximately 3 seconds.
10. Repeat process for the opposite cylinder.
11. Move stakedown rotation valve
switch S33 to CLOCKWISE position
(CW). Measure rotation speed of S33
motor using phototach or counting
rotations for 60 seconds. Rotation
speed will be approximately 20 rpm.

12. Move stakedown rotate switch to counterclockwise position (CCW).

Measure rotation speed of motor using phototach or counting rotations
for 60 seconds. Rotation speed will be approximately 20 rpm.

2-25
 Machine Performance Procedures D36x50 Series II Navigator HDD Service

Rack Angle 1. Ensure switches listed in "Control Settings," page 2-11, are in correct
Performance positions.
2. If "Preoperation Check," page 2-9, has not been performed, conduct
System Information

inspection before proceeding.

3. If "Engine Starting and Warm-Up," page 2-12, has not been performed,
refer to procedure and perform before proceeding.
4. Enable Remote Lockout.
5. Press hydraulic enable button S30 to
enable Auxiliary circuits. S30

6. Ensure rack cylinders are fully extended so that the rack is fully raised.
7. If necessary, move rack control lever
(1) at the transport station to RAISE 1
position until rack angle cylinders
are fully extended.

NOTE: If necessary, disconnect and remove stakedown augers from motor

shafts before proceeding to ensure damage does not occur to workplace floor.
Then raise stakedown cylinders to their maximum height.

Continued on next page...

2-26
D36x50 Series II Navigator HDD Service Machine Performance Procedures

8. Simultaneously start stopwatch and

move rear control panel rack angle 1
control lever (1) to the LOWER
position. Stop timing when rack

System Information
angle cylinders are fully retracted.
Time required for rack angle to move
from fully raised to fully lowered
position should be 12.00 ± 2 seconds.

9. Repeat step 7 moving control lever (1) to RAISE position. Time required
for rack angle to move from fully lowered to fully raised position should
be 11 ±2 seconds.

Stabilizer Function 1. Start machine.

Performance
2. Enable Remote Lockout.
3. Press hydraulic enable push button S30 to enable circuits.
4. Ensure stabilizer cylinders are fully
retracted. If necessary, move S27
stabilizer switch S27 to RAISE
position until stabilizer cylinder is
fully retracted.

Continued on next page...

2-27
 Machine Performance Procedures D36x50 Series II Navigator HDD Service

5. Simultaneously start stopwatch and move control panel stabilizer switch

to the LOWER position. Stop timing when stabilizer cylinder is fully
extended. Time required for stabilizer cylinder to move from fully raised
to fully lowered position should be approximately 7 seconds.
System Information

6. Return stabilizer to a position where stabilizer just meets floor/ground.

2-28
D36x50 Series II Navigator HDD Service Machine Performance Procedures

Water Shutoff Valve 1. Ensure switches listed in "Control Settings," page 2-11, are in correct
Performance positions with the exception of the front vise switch. For water shutoff
functions to work correctly, the front vise must be clamped.

System Information
2. If "Preoperation Check," page 2-9, has not been performed, conduct
inspection before proceeding.
3. If "Engine Starting and Warm-Up," page 2-12, has not been performed,
refer to procedure and perform before proceeding.
4. Enable Remote Lockout.
5. Press hydraulic enable push button
S30 to enable implement hydraulic S30
circuits.

6. While observing water shutoff

cylinder, move wash wand switch
S18 to ON position. Water shutoff
cylinder will rapidly retract to shut
off water (drilling fluid) flow to drill
rod.

S18

7. Move wash wand switch to OFF position. Water shutoff cylinder will
rapidly extend.
8. Note the results of step 7.
9. After completing this procedure, refer to "Ground Drive, Rod Loader, Vise,
Stakedown, Stabilizer/Rack Angle, and Water Shutoff Performance," page 2-
16 for continuation of troubleshooting.

2-29
This page intentionally left blank.
D36x50 Series II Navigator HDD Service Schematic

Chapter 3: Power

SCHEMATIC
BATTERY BT1

ALTERNATOR STARTER GROUND

DISCONNECT

Power
SWITCH S1

CONNECTOR
P2
40-Amp
STRIKE ALERT CIRCUIT
MODULE A17
BREAKER
CB1 CONNECTOR
P3
LEFT JOYSTICK
BREAKER F1

RIGHT JOYSTICK
BREAKER F2

SLOWDOWN/STOP, ANTI
CRASH, GEARBOX FLUSH,
BREAKER F3
LIGHTS BREAKER F4
STABILIZER, ROCKFIRE
BREAKER F5
CONNECTOR IGNITION
P8 SWITCH S2

SEAT SWITCH, HYD.

REMOTE LOCKOUT A10 ENABLE, EDC BREAKER F6

STAKEDOWN
REMOTE LOCKOUT RELAY
BREAKER F7
12-VOLT OUTLET
BREAKER F8
HYD ENABLE RELAY
BREAKER F9
ENGINE START
BREAKER F10
CONNECTOR P11

3-1
 Component Locations D36x50 Series II Navigator HDD Service

COMPONENT LOCATIONS
FUE LEFT JOYSTICK
ALTERNATOR BREAKER F1 RIGHT JOYSTICK THRUST SLOWDOWN/
BREAKER F2 ANTI-CRASH BREAKER F3

LIGHTS BREAKER
Power

F4

STABILIZER,
ROCKFIRE, WATER
MODULE BREAKER F5
SEAT SWITCH,
CIRCUIT
HYD. ENABLE,
BREAKER
EDC CONTROLLER
CB3 F6
BREAKER
12-VOLT STAKEDOWN,
OUTLET REMOTE LOCKOUT
BREAKER F8 RELAY, FLEET
MANAGEMENT
BREAKER F7

ENGINE HARNESS CONNECTOR P2

GROUND
DISCONNECT
CIRCUIT BREAKER
SWITCH S7
CB1

3-2
D36x50 Series II Navigator HDD Service Power Supply

POWER SUPPLY
The Power Distribution circuits provide battery voltage to the ignition
circuit and breakers that supply voltage to other functions of the machine.
The schematic shows component electrical connections and their
relationship to each other

When the ground disconnect switch is in the closed position, battery voltage

Power
is provided at the positive terminal of the starter solenoid L38. From there it
is routed to terminal B of the alternator, and 40-amp circuit breaker CB1.

The 40-amp circuit breaker CB1 supplies voltage directly to breaker F1, and
the B post of ignition switch S2. With the ignition switch in the START or
RUN position, terminal I of ignition switch S2 provides voltage to breakers
F2 and F3, as well as Remote Lockout module A10 through connector P11.
Battery voltage is also supplied from ignition switch terminal A to Strike
Alert module A17 through connector P8, breakers F4 – F8, and John Deere
engine ECU through connectors P3 and P2.

After the engine is started, alternator ALT1 provides voltage to charge the
battery so engine operation and machine electrical functions can be
sustained.

The negative post of the battery BT1 is connected to the ground disconnect
switch and the engine. The opposite post of the ground disconnect switch is
connected to the frame.

3-3
 Specifications D36x50 Series II Navigator HDD Service

Ignition Switch S1
The ignition switch (1) is a multiple
position key-operated switch. When 12
volts is received at terminal B of the
1
ignition switch from circuit breaker CB1.
Switch positions, their terminal
connections, and operations are:
Power

• OFF - no current will flow through the

switch.
• ON (AC) - a path is connected from the 1
positive terminal of the battery through
the 40-amp circuit breaker CB1, to the
ignition switch terminal B. When the
ignition switch key is rotated to the ON position B, A, and I terminals are
connected. The A terminal will supply current directly to the Strike Alert
module and supplies breakers F4 through F8. The I terminal will supply
voltage to Remote Lockout module A10 and breakers F2 and F3.

SPECIFICATIONS
The specifications
provided in the table at Specification Value
right are for the
electrical system in General
general. For individual governed engine RPM 2500 rpm
component
specifications, refer to Alternator
the appropriate section rated amperage 63A @ 12V
in this manual.
Battery
950 cold cranking amps,
cold cranking amps (CCA)
30 seconds, 0°F (-18°C)
185 min, 25 amp output at
reserve capacity
80°F (27°C)
BCI group size 31

3-4
D36x50 Series II Navigator HDD Service Charging

CHARGING
Battery Charging
The alternator delivers 13.8 to 14.7 volts to charge the battery.

The table below shows the connections and their functions.

Alternator (12-Volt, 100-Amp)
Terminal Wire Color
B Red 10-ga
D Blue 16-ga
W Brown 16-ga
Power
Function
Carries 12 volts to charge battery
Carries alternator field excitation. Dash warning
terminal indicates internal alternator problem if lit.
Supplies unrectified AC voltage to RPM display,
Used to determine engine RPM

Battery (BT1)
The battery is located inside the battery box compartment on the right side
of the machine.

The 12-volt negative-ground, BCI group 31 battery provides voltage to the

starter solenoid L38, 40-amp circuit breaker CB1, and the B post of the
alternator. When in good condition, the battery produces approximately 950
cold cranking amps. After start-up, the battery is recharged by the
alternator.

Operation When fully charged the battery supplies 12.66 volts DC maximum potential
between the positive post and negative post.

3-5
 Charging D36x50 Series II Navigator HDD Service

Wire Connections

TERMINAL WIRE SIZE & COLOR FUNCTION

to battery disconnect switch, grounds
(1) NEG 2/0 Black #302
machine electrical system
provides 12 volts to + post of starter
(2) POS 2/0 Red #100
solenoid
Power

Ground Disconnect Switch S1

Ground disconnect switch S1 (1) is a
key-operated 2-position switch with 1
chassis ground connected to one post.
The other post of the disconnect switch
is connected to the negative battery
post by wire 302, and to the engine.

When the key is turned to the OFF

(open) position, no ground is applied to
the battery negative terminal.
Therefore, the battery will not conduct
and no current flows.

When the key is in the ON (closed) position, the battery has a sufficient
ground to conduct when required.

The ground disconnect switch terminals can be accessed through the engine
compartment.

3-6
D36x50 Series II Navigator HDD Service Charging

Thermal Breakers
Nine thermal breakers protect circuit
components from high current F1
conditions that may develop in any of F2
the machine electrical circuits.
breakers 1–8 receive 12 vDC when the F3
ignition switch is in either the AC or ON F4

Power
position and supply the following F7 F5
functions.
F8 F6
• 12 volt outlet 15A F8
• Stakedown, Remote Lockout relay
circuits 15A F7
• Seat switch, hydraulic enable, EDC 15A F6
• RockFire, stabilizers 15A F5
• Lights circuits 15A F4
• Slowdown/stop, anti crash, gearbox flush 15A F3
• Right joystick 15A F2
• Left joystick 15A F1
Breaker F9 supplies 12vDC to the B post on the ignition switch and 12 volt
outlet breaker F8.

• Main 40-amp circuit breaker CB3

CB3

3-7
 Engine Component Locations D36x50 Series II Navigator HDD Service

ENGINE COMPONENT LOCATIONS

ENGINE DIAGNOSTIC
TACHOMETER/DISPLAY SCROLL BUTTON S40
A22
Power

COOLANT TEMPERATURE IGNITION SWITCH S2

GAUGE GA4
STARTER SOLENOID L38
FUEL GAUGE
GA5

COOLANT TEMP
SWITCH

AIR TEMPERATURE
FUEL TEMP SWITCH
SENSOR
ENGINE HARNESS FUEL SOLENOID
CONNECTOR

ENGINE OIL
Engine ECU PRESSURE
SWITCH

3-8
D36x50 Series II Navigator HDD Service Operation Overview

OPERATION OVERVIEW
Fuel Control Fuel supplied to the engine is controlled by the engine control module. The
control module is powered at terminal G by the ignition switch S2 through
emergency stop switch S49.

Throttle Control Switches S45 and S46 located at the front and rear control stations provide
throttle control by providing input to the engine control module at pin D.

Power
Neutral Start Neutral start functions are controlled by switches in the joystick controllers
A18 and A19. Both rotation and thrust/pullback functions must be in
NEUTRAL for the engine to start.

SPECIFICATIONS
Specification Value

Engine
make/model John Deere 4045 HF275
governed engine RPM 2500 rpm
maximum power 140 hp ( 104 kW) at
2400 rpm
maximum engine inclination 30° all directions

Continued on next page...

3-9
 Specifications D36x50 Series II Navigator HDD Service

Specification Value

Battery
required 1
BCI group size 31
cold cranking amps (CCA) 950 cold cranking amps,
Power

30 seconds, 0°F (-18°C)

reserve capacity 185 minutes, 25-amp output
at 80°F (27°C)
length 13" (33 cm)
width 6-3/4" (17 cm)
height 9-3/8" (24 cm)
Cooling System
coolant mixture of 50% water and
50% ethylene glycol base
antifreeze to -34°F (-37°C)
protection
engine coolant capacity gal 9.75 (37 L)

Fuel System

fuel tank capacity 45 gal (170 L)

Lubrication System
oil capacity with filter: 15.8 qt (15 L)
without filter:14.0 qt (13 L)
engine oil type refer to engine manual
supplied with each machine.

Electrical System
system voltage/alternator 12-volt, 63-amp

3-10
D36x50 Series II Navigator HDD Service Starting Circuit Electrical Schematic

STARTING CIRCUIT ELECTRICAL SCHEMATIC

DISCONNECT
SWITCH S1

Power
ENGINE
ECU A23
ENGINE
START RELAY K1 SHUTDOWN
STARTER OVERRIDE
SOLENOID L38 SWITCH S41

CIRCUIT
BREAKER CB1

START ENABLE RELAY K2

IGNITION
SWITCH
REAR SHUTDOWN RELAY K3 S2

REMOTE REAR STOP

LOCKOUT A10 SWITCH S11

CONNECTOR
P3

CONNECTOR P11

3-11
 Coolant Temperature Warning Circuits D36x50 Series II Navigator HDD Service

COOLANT TEMPERATURE WARNING CIRCUITS

Power

Ignition
Switch
S2

Code Warning Light

Scroll DS13
Display Temp Gauge S40
A22 GA4

Engine coolant temperature is

monitored by the coolant temp sensor.

The engine coolant temperature sensor

(1) provides signal to the engine ECU.
The ECU provides a variable signal to
temp gauge GA4. Warning light DS13
will flash indicating the engine coolant
temperature is too high. Code scroll
switch S40 is used to display engine
error codes on display A22. Refer to
engine operator’s manual for detailed information.

WARNING: Hot fluid under pressure can scald. Allow engine to cool before
opening radiator cap.

3-12
D36x50 Series II Navigator HDD Service Fuel Delivery

FUEL DELIVERY
Fuel Gauge Circuit
The fuel gauge GA5 receives voltage from breaker F6. Ground is provided to
the gauge through terminal bus TB1. Sending unit B2 is grounded at
terminal bus TB1 through connector P5.

Power
TERMINAL
BUSS TB1

CONNECTOR P5

BREAKER F6
FUEL GAUGE
GA5

FUEL LEVEL
SENDER B2

3-13
 Throttle Circuit D36x50 Series II Navigator HDD Service

THROTTLE CIRCUIT

REAR THROTTLE
SWITCH S25
Power

THROTTLE RESISTOR
CONNECTOR PACK R1
P2

JOHN DEERE ENGINE

CONTROL MODULE

LEFT JOYSTICK A13

THROTTLE INCREASE S14

THROTTLE DECREASE S15

Continued on next page...

3-14
D36x50 Series II Navigator HDD Service Throttle Circuit

Engine speed is controlled by the front throttle increase switch S14, front
throttle decrease switch S15, or the rear throttle switch S25.
Power is supplied to the rear throttle switch by the engine ECU through
wire 794. When the rear throttle switch is in the middle position power
passes through it to the joystick throttle control switches from pin#4
through wire 804.

When throttle increase switch S14 on the joystick is depressed and held, or

Power
rear throttle rocker switch S25 is pushed to the INCREASE position, signal
voltage passes through the switch and through a 3000 ohm resistor in
resistor pack R1. From there it is routed to connector P2, pin S of the engine
ECU. The voltage change created by the resistor is recieved by the engine
ECU and engine RPM will increase.

When throttle decrease switch S15 on the joystick is depressed and held, or
rear throttle rocker switch S25 is pushed to the DECREASE position, signal
voltage passing through the switch passes through a 360 ohm resistor in
resistor pack R1. From there it is routed to connector P2, pin S of the engine
ECU. The voltage change created by the resistor is recieved by the engine
ECU and it will decrease engine RPM.

When throttle control switches on the joystick are not depressed, and rear
throttle rocker switch S25 is in the center position, signal voltage passing
through the switches passes through a 1200 ohm resistor in resistor pack
R1. From there it is routed to connector P2, pin S of the engine ECU. The
voltage change created by the resistor is recieved by the engine ECU and it
will maintain engine RPM at the last adjusted setting.

When the engine is started, engine RPM will be at low idle (900 rpm).

3-15
 Troubleshooting D36x50 Series II Navigator HDD Service

TROUBLESHOOTING
Pretest Inspection
Before testing circuits, check for broken, missing, corroded, or loose wires
and cable connections on the ground and power wires that supply electrical
circuit components. Ensure battery cables and ground straps are in good
Power

condition and connections are tight. Replace damaged or corroded wires

before troubleshooting any circuit.

BATTERY BT1
The battery supplies power directly to the starter solenoid, 40-amp circuit
breaker CB10, and the alternator. It is charged by the charging circuit.

1. With the multimeter set to measure DC voltage, place probes on the

positive and negative terminals of the battery.
Expected result: The reading should be 12 vDC, ± 1.2 vDC. If not,
recharge the battery.
2. Disconnect spark plug wires on the engine. While measuring DC voltage
at the battery terminals, turn key to START (crank the engine).
Expected result: The voltage reading will stay above 9 volts. If not,
recharge battery and test again (unless the battery was recharged in
Step 1). If the recharged battery will not stay above 9 volts, replace
battery.
NOTE: If the battery is damaged or has reached the end of its useful life, it
will not hold a full charge at cooler temperatures. If this occurs, the battery
should be replaced.

3-16
D36x50 Series II Navigator HDD Service Ignition Switch

IGNITION SWITCH
Ignition switch S2 controls power supplied to most of the machine electrical
circuits.

Power
1. Turn battery disconnect switch to OFF position, and disconnect the
negative battery cable.

Locate ignition switch and access terminals on the back of switch. With
ignition switch in the ON position, check for continuity at terminals B
and A.
Expected result: Continuity at both terminals when key is in ON
position, open for both terminals when key is at OFF position.

2. Wire 102 connects to terminal B of the ignition switch. This wire

provides battery voltage to the ignition switch. Locate and remove
breaker F9 from its holder. Check wire continuity from battery to
breaker holder. Check continuity of wire from the breaker holder to the
ignition switch.

Expected Result: Continuity between TB4 and switch. If no continuity is

shown, check plug P2 at pin 13 for loose connection, or possible broken
wire.
Continued on next page...

3-17
 Breaker CB1 D36x50 Series II Navigator HDD Service

If results match the table, the switch is good - check continuity from the
switch ends of the wires to the starter and harness ends to locate and repair
bad wire(s) if necessary. If results do not match the table, replace the key
switch.

Key set to: Continuity Open

Power

Off Terminals S, I, B and A

On Terminals I, B and A Terminal S
Start Terminals B, I and S Terminal A

BREAKER CB1
40A circuit breaker CB1, supplies battery voltage to the ignition switch and
to thermal breaker F8.

Greater current draw than the breaker rating produces heat causing an
open circuit. When the breaker cools, contacts inside will be restored, and
continuity in the circuit will be restored. Before troubleshooting a circuit
with a breaker in it, verify that 12 vDC, ± 1.2 volts is present at the input
side of the breaker. Allow time for the breaker to cool before checking the
breaker for continuity.

3-18
D36x50 Series II Navigator HDD Service Breakers F1–F10

BREAKERS F1–F10
15A circuit breakers F1–F10, supply battery voltage to the various circuits
of the machine.

Greater current draw than the breaker rating produces heat causing an
open circuit. When the breaker cools, contacts inside will be restored, and
circuit continuity will be restored. Before troubleshooting a circuit with a

Power
breaker in it, verify that 12 vDC, ± 1.2 volts is present at the input side of
the breaker. If no voltage is present when the ignition switch is in the correct
orientation, check the ignition switch for proper operation or check for
wiring problems.

If you suspect a circuit is faulty because a breaker needs replacing:

Locate the faulty segment, then test smaller portions of the segment to
isolate the broken wire or poor connection. Repair connection or replace
broken wire, or replace cable to the panel or the field harness, as required.

3-19
 Ground Disconnect Switch D36x50 Series II Navigator HDD Service

GROUND DISCONNECT SWITCH

1
Continuity Test
Power

1. Check ground disconnect switch S1 positions for continuity. With cables

connected, turn switch to disconnected position.
2. Set multimeter to measure continuity and
test terminal (1). 2
Expected result: Terminal (1) should not
have continuity to engine and frame ground.
If not, continue. If so, replace switch.
3. Turn switch to the connected position.
3
Expected result: Both terminals (1) and (2)
should have continuity to ground. If so,
continue. If not, replace switch.
4. Leave switch in the connected position and
remove cables.
5. Test continuity at both terminals.
Expected result: The terminals should have
continuity. If so, switch is functioning
properly. If not, replace switch.

Measure Battery Voltage

1. With key OFF and ground disconnect switch S1 open, check voltage at
battery.
Expected result: 12.6 volts DC, ± 1.2 volts. If so, the battery is in good
condition. If less, recharge battery.

3-20
D36x50 Series II Navigator HDD Service Engine Troubleshooting

Check for Power at Controllers

1. Close ground disconnect switch S1.
2. Turn ignition switch S2 to ON position.
3. Check for voltage at pin 1 of Remote Lockout controller A10 and Strike
Alert module A17. Look at power indicator on the charging station for
the Remote Lockout transmitter.

Power
If battery voltage is available at terminal 1 of both modules, 40-amp circuit
breaker CB1 is good and wiring connections to the battery and disconnect
switch are good.

Battery Charging Circuit

If the battery is not being charged:

• Inspect terminals and connections on both battery cables for corrosion at

the battery, alternator and frame. If needed, clean connections and
terminals.
• Inspect alternator belt condition and tension. Consult engine manual for
proper belt tension.
• Load test the battery. Old or damaged batteries will not accept a full
charge.
It is less likely, but possible that the wire or cables are damaged internally.

• Check continuity of cables from end to end. Replace any that show
resistance.
If these items appear to be working, replace alternator or contact an engine
service facility to have it rebuilt or repaired.

ENGINE TROUBLESHOOTING
Introduction
NOTE: While the engine warranty is in effect, only an authorized John
Deere Service Facility may work on the engine (including the engine wire
harness). Unauthorized service on the engine or engine components will void
the warranty. Before performing any maintenance procedures on the engine,
consult the John Deere Operator’s Manual for safety guidelines and
instructions.

3-21
 Engine Troubleshooting D36x50 Series II Navigator HDD Service

Basic Troubleshooting
• Inspect for a mechanical problem.
• Determine if machine common components are operating correctly.
• Determine if related functions are working correctly.
• Determine that controls are functioning properly.
Power

Check Out “Common” and Related Systems

• Always Look for problems in circuits or components of related functions
before doing any difficult test procedures.
• Check the electrical overall schematic and verify that shared components
and related circuits are OK.
• Look for electrical circuits operating on the same circuit breaker or
switch.
• If a related function shares components and is not functioning properly,
repair those components first, then proceed with troubleshooting if
necessary.

3-22
D36x50 Series II Navigator HDD Service Engine Troubleshooting

Inspecting Control Circuits and Mechanical Components

Unless the problem is obvious, the successful troubleshooter will investigate
these fundamental questions:

1. Is the power source (battery and 15A ignition circuit breaker) OK?
Electrical actuators such as relays and coils may operate correctly down
to as low as 10.8V, but any system voltage measuring below 12.5V can be

Power
suspect, especially if it is poorly grounded.
2. Are the grounds adequate? The circuit must be complete to ground,
and the voltage drop in the ground circuit must be no higher than 0.5V.
3. Is the current path complete? Many problems can be traced to a
broken wire or faulty pin connection in a plug.
4. Are the switches functioning properly? The ignition switch, thrust/
pullback neutral switch, and rotation neutral switch must be closed to
operate the starter relay, starter solenoid, and the fuel solenoid pull-in
winding in order. The ignition switch and the emergency stop button
switch must be closed to operate the fuel solenoid hold-in winding in
order for the engine to continue running.
5. Are electrical components functioning properly? The fuel solenoid
has a pull-in and a hold-in winding. The starter relay must operate and
make electrical contact. The starter solenoid and starter must operate
correctly.
6. Are the mechanical components OK? Even if all electrical functions
are OK, engine mechanical or fuel system problems may prevent the
engine from starting or turning over. Always check for mechanical
malfunctions—such as defective bearings, binding linkages, and loose
fasteners

3-23
 Engine Troubleshooting
Symptom Problem
Engine does not turn Low battery voltage.
over
Power
The ground path may be missing,
there is to much resistance in the
circuit, or the voltage drop is more than
0.5V, all electrical operation can be
affected.
The ignition switch is not delivering
voltage to the neutral switches to
energize the start relay coil.
Both joystick neutral switches are not
closed.
The start relay is not functioning
properly.
There is damage to wiring, connectors
or connector pins that is not allowing
them to connect properly, or there is a
short to power, resistance, or ground
that is causing an intermittent or
constant problem.
The starter solenoid or starter are
defective.
3-24
D36x50 Series II Navigator HDD Service
Solution
Check the battery disconnect.
Check battery state of charge and load
capacity.
Check all grounding locations.
Check ground voltage drop between
the ground buss and battery negative
terminal under no-load and loaded
conditions. Repair any condition
causing high ground voltage drop in
either condition.
Check that voltage is being
provided to the start relay coil.
Check neutral switch operation.
Check that the start relay is
operating and that voltage is being
applied to both the starter solenoid and
the fuel solenoid.
Check the entire current path.
Inspect visually or use an ohmmeter or
voltmeter.
Check solenoid and starter
operation.
D36x50 Series II Navigator HDD Service Engine Troubleshooting

Symptom Problem Solution

Engine turns over Incorrect starting procedure
but will not start.
If low battery state-of-charge or other
conditions prevent the engine from
turning over fast enough, the engine
Verify correct starting procedure.
Check cranking speed with a reliable
tachometer; rectify any condition
causing cranking speed below 125

Power
will not start. rpm at 10°F (-12° C) or above.
No fuel. Check fuel in tank.
Exhaust restricted. Check and correct exhaust restriction.
Fuel filter plugged or full of water. Replace fuel filter of drain water from
filter.
Injection pump not getting fuel in fuel Check fuel flow at supply pump or
system. bleed fuel system.
Faulty injection pump or nozzles. Consult authorized repair facility for
repair or replacement.

Symptom Problem Solution

Engine hard to start Improper starting procedure. Review starting procedure.

or will not start.
No fuel Check fuel tank.
Air in fuel line. Bleed fuel line.
Cold weather. Use cold weather starting aids, if so
equipped.
Slow starter speed. See “Starter Cranks Slowly”.
Crankcase oil too heavy. Use oil of proper viscosity
Improper type of fuel. Consult fuel supplier; use proper type
fuel for operating conditions.
Water, dirt, or air in fuel system. Drain, flush, fill, and bleed system.
Clogged fuel filter. Replace filter element.
Dirty or faulty injection nozzles. Have authorized servicing dealer or
engine distributor check injectors.
Electronic fuel system problem See your John Deere servicing dealer.

3-25
 Engine Troubleshooting D36x50 Series II Navigator HDD Service

The engine speed controller can be controlled from the seat if the operator is present (seat switch is closed)
or from the rear control station (seat switch is open). Closing the seat switch energizes the rear control relay
coil which disconnects power from the rear control station and applies it to the front throttle control.

Symptom Problem Solution

Engine speed can Circuit breaker #3 (rack angle/stabilizer) not Check circuit breaker status
Power

only be controlled powered. and wiring.

from the operator
station.
Engine speed can The DSR not providing power to the seat Check and correct low voltage
only be controlled switch. condition.
from the rear
controls.
Intermittent or If the ground path is missing, is too resistive, or Check that both the front and
permanently loss of is not 0.5V or less, all electrical operation can rear throttle control grounds
throttle control. be effected. (from terminal #5 of each
switch) are good. Check
ground voltage drop between
the ground buss and battery
negative terminal under no-
load and loaded conditions.
Repair any condition causing
high ground voltage drop in
either condition.
Any damage to wiring, connectors or connector Check the entire current path.
pins that are not seated or mated correctly or Inspect visually or use an
any unintended short to power, resistance, or ohmmeter or voltmeter.
ground can cause intermittent or constant
problems.
Throttle control switches defective or wired Check throttle control switch
incorrectly. If the switches are defective or if operation.
the jumpers are not wired correctly, the
controls will not work correctly.

3-26
D36x50 Series II Navigator HDD Service Engine Coolant Temperature Monitoring Circuit

ENGINE COOLANT TEMPERATURE MONITORING CIRCUIT

IGNITION
SWITCH
S2

TERMINAL
BUS TB8

Power
WARNING
TEMPERATURE
LIGHT GAUGE GA1
DS10
CODE
SCROLL
BUTTON S73
Coolant temperature is monitored by
the coolant temperature gauge GA1. S73 1

If engine warning light is flashing, A30

indicating engine problems, use the
code scroll button S73 to scroll through
the display A30. Refer to engine
operator’s manual for SP/FMI code
identification. Allow sufficient time for
radiator and engine to cool before GA1
investigating.
Continued on next page...

3-27
 Engine Coolant Temperature Monitoring Circuit D36x50 Series II Navigator HDD Service

WARNING: Hot fluid under pressure can scald. Allow engine to cool before
opening radiator cap.
Power

NOTE: Never add pure antifreeze to a cooling system. Vermeer Mfg. Co.
recommends using a 50/50 mixture. Never use high-silicate antifreeze or
antifreeze that is higher than 60/40 mixture.

1. Inspect radiator to ensure there are no restrictions that may reduce air
flow through the core. Bent cooling fins can reduce the efficiency of the
radiator. Use a fin comb to straighten cooling fins.
2. Over time dirt and debris will collect in the radiator, use compressed air
to blow out radiator core, making sure to blow in the opposite direction of
engine fan airflow.
3. After engine has cooled, open cap on the radiator. If coolant is not
visible, add coolant to top of fill neck. Use a low-silicate (ethylene glycol)
antifreeze and clean water mixture.
4. Bring engine up to operating temperature with radiator cap loose, then
top off fluid if necessary and close cap.
5. Observe coolant temperature gauge and engine warning light.

3-28
D36x50 Series II Navigator HDD Service Air Intake Monitors

AIR INTAKE MONITORS

The air intake components are crucial to the performance of the engine. If
engine performance is reduced, other machine functions will be
compromised. If the engine lacks power, investigate the following
components

Air Cleaner

Power
If the air cleaner filter element becomes clogged, the engine will not receive
enough combustion air to perform properly.

1. View air restriction indicator. If the indicator shows that the filter is
dirty, replace primary filter element.
2. Inspect secondary or safety filter element. Replace if necessary.
3. Visually inspect for any cracked, broken, or missing hoses, connectors, or
clamps, and replace if found.

3-29
 Air Intake Monitors D36x50 Series II Navigator HDD Service

Turbocharger/Intake
NOTE: The engine turbocharger is part of the engine and is covered under
the manufacturer’s warranty. Warranty will be voided by attempting to
remove or repair these components before the warranty has lapsed. If the
warranty is still in effect, contact an authorized engine service facility.

A number of turbocharger problems can effect engine efficiency. Possible

Power

indications include:

• Engine lacks power.

• Black exhaust smoke
• Excessive engine oil consumption
• Blue exhaust smoke
• Turbocharger is noisy.

Possible Problem Possible Effect What to do

Engine lacks power

Black exhaust smoke Clogged air filter element Replace element(s).
Excessive engine oil
consumption
Engine lacks power
Black exhaust smoke Obstructed air intake duct to turbo Remove obstruction or
Excessive engine oil compressor replace damaged parts as
consumption required.
Blue exhaust smoke
Remove obstruction or
Engine lacks power
Obstructed air outlet duct from compressor replace damaged parts as
Black exhaust smoke
to intake manifold required.
Noisy turbocharger

Engine lacks power Refer to engine manual and

Black exhaust smoke Obstructed intake manifold check for obstruction.
Noisy turbocharger

Air leak in duct from air cleaner to Correct leak by replacing

Noisy turbocharger
compressor seals or tightening fasteners
as required.
Engine lacks power
Black exhaust smoke Correct leak by replacing
Air leak in duct from compressor to
Excessive engine oil seals or tightening fasteners
aftercooler or from aftercooler to intake
consumption as required.
manifold inlet
Blue exhaust smoke
Noisy turbocharger

3-30
D36x50 Series II Navigator HDD Service Air Intake Monitors

Possible Problem Possible Effect What to do

Engine lacks power

Black exhaust smoke
Refer to the engine manual
Excessive engine oil
Air leak at intake manifold to engine joint and replace gaskets or
consumption
tighten fasteners as
Blue exhaust smoke
required.
Noisy turbocharger

Power
Engine lacks power
Black exhaust smoke
Excessive engine oil
Refer to engine manual and
consumption Obstruction in exhaust manifold
remove obstruction.
Blue exhaust smoke
Noisy turbocharger

Engine lacks power Remove obstruction or

Black exhaust smoke replace faulty components
Obstruction in muffler or exhaust stack
as required.

Engine lacks power Refer to the engine manual

Exhaust gas leak in turbine inlet to exhaust
Black exhaust smoke and replace or tighten
manifold joint
Noisy turbocharger fasteners as required.

Excessive engine oil

Remove obstruction or
consumption Obstructed turbocharger oil drain
replace line as required.
Blue exhaust smoke

Excessive engine oil

Refer to the engine manual
consumption Obstructed engine crankcase vent
and clear obstruction.
Blue exhaust smoke

Excessive engine oil Change engine oil and oil

Turbocharger center housing sludged or
consumption filter. Overhaul turbocharger
coked
Blue exhaust smoke as required.

Engine lacks power Fuel injection pump or fuel injectors Refer to the engine manual.
Black exhaust smoke incorrectly adjusted Replace or adjust faulty
component(s) as required.
Engine lacks power Refer to the engine
Black exhaust smoke operator’s manual and
Engine camshaft timing incorrect
adjust engine timing or
replace worn parts.

Engine lacks power

Black exhaust smoke
Refer to the engine service
Excessive engine oil Worn engine piston rings or liners (blow by)
manual and repair engine as
consumption
required.
Blue exhaust smoke

3-31
 Fuel Delivery D36x50 Series II Navigator HDD Service

Possible Problem Possible Effect What to do

Engine lacks power

Black exhaust smoke
Excessive engine oil
consumption
Blue exhaust smoke
Noisy turbocharger
Power
Clean using a non-caustic
cleaner and soft brush. Find
Dirt caked on compressor wheel and/or
and correct source of
diffuser vanes
unfiltered air and change
engine oil and oil filter.

Engine lacks power

Black exhaust smoke Analyze failed turbocharger.
Excessive engine oil Find and correct cause of
Damaged turbocharger
consumption failure. Overhaul or replace
Blue exhaust smoke turbocharger as required.
Noisy turbocharger

FUEL DELIVERY

WARNING: Fuel and fumes can explode and burn. Never refuel machine
while smoking or with engine running. Fill fuel tank outdoors. Clean up
spilled fuel. Do not allow any hot or burning material near the machine.

If the engine will not run or performance is not adequate, the fuel delivery
system should be investigated.

If a problem in the electronic control of the fuel is suspected, or if it is

believed that the injector pump or fuel injectors are not delivering adequate
fuel, inspect the non-engine fuel system components, including the tanks,
lines, and filters.

NOTE: The injector pump, and fuel injectors are considered to be part of the
John Deere engine and are covered under the engine manufacturer’s
warranty. You can void this warranty by attempting to remove or repair
these components before the warranty has lapsed. If the warranty is still in
effect, contact an authorized engine service facility.

3-32
D36x50 Series II Navigator HDD Service Fuel Delivery

Fuel Tanks, Lines, Filters, and Strainers

1. Visually inspect for any cracked, broken, or missing fuel lines, fittings,
connectors, or clamps, and replace if found.
Any water in the fuel can cause the engine to run improperly. Condensation
occurs as fuel is heated when passing through the fuel system and cools
when returned to fuel tank. If water in the fuel is suspected:

Power
2. Drain and clean the fuel tank.
3. Replace fuel filter (1). 1
4. Refer to the Maintenance Manual for
1
information on replacing the engine
fuel filters. Drain any water from
the fuel/water separator.
NOTE: Filling the fuel tank at the end
of each day of operation will drive out
moist air and prevent condensation. Do
not fill the tank to top of fill neck. Fuel
expands when it warms and may
overflow.

3-33
 Fuel Delivery D36x50 Series II Navigator HDD Service

Fuel Gauge Circuit

If the fuel gauge GA2 fails to indicate, check circuit wiring and terminal
connections for corroded, broken, or damaged wires.

ZAP
Power

FUEL LEVEL ALERT

SENDER B1

TB8

P6

FUEL
GAUGE
GA2

TB3
TB5
CIRCUIT
BREAKER
CB8
Supply Voltage Test 1. Access terminals on the rear of fuel gauge GA2.
2. Turn ignition switch to the ON position. Set multimeter to measure DC
voltage. Place red probe to battery + input terminal of gauge. Place black
probe to ground terminal.
Expected result: A reading of approximately 12 volts indicates gauge is
receiving acceptable voltage from circuit breaker CB8.
3. No voltage reading at the gauge could indicate circuit breaker is not
functioning. If voltage is present at gauge proceed with open sensor test.
Continued on next page...

3-34
D36x50 Series II Navigator HDD Service Fuel Delivery

Open Sensor Test 4. With ignition ON, remove sensor lead from terminal S at back of gauge.
Expected result: The gauge should read minimum scale (empty). If not,
replace gauge.
Sensor Ground Test 5. With ignition switch ON, install sender lead back to gauge.
6. Short signal wire from the gauge to ground.
Expected result: The gauge should read full scale. If so, the gauge is OK.

Power
If not, test the signal wire from sender for solid connection and
continuity. Replace if faulty wire.
7. Test fuel sender B1 resistance. If OK, replace gauge.
Fuel Sender (B1) 8. With ignition switch in the OFF position, disconnect wire harness from
Resistance Test sender. Set multimeter to measure resistance (ohms).
Expected result: The ohms reading will be proportional to the level of the
fuel in the tank. The resistance should read between 33Ω full and 240Ω
empty. If so, troubleshoot electrical supply and ground for sending unit.
If not, replace sender.

3-35
 Ignition START Circuit D36x50 Series II Navigator HDD Service

IGNITION START CIRCUIT

REMOTE LOCKOUT
CIRCUIT BREAKER
CB1

GROUND DISCONNECT CIRCUIT

SWITCH S1 BREAKER
Power

CB11

BATTERY
STARTER
RELAY K2 SOLENOID L38 CIRCUIT
BREAKER
STARTER CB10
RELAY K2

CONNECTOR P1
P5
JOYSTICK JOYSTICK
A19 A18
SHUTDOWN
RELAY K7

REMOTE
LOCKOUT
SHUTDOWN
OVERRIDE
SWITCH S74

TERMINAL IGNITION
BUSS TB4 SWITCH S2

TERMINAL
BUSS TB5

3-36
D36x50 Series II Navigator HDD Service Ignition START Circuit

If a problem exists in the START circuit and the engine will not turn over,
troubleshoot as follows:

1. Ensure joystick controls A18 and A19 are in the NEUTRAL position.
2. Ensure ground disconnect switch is in the ON position.
3. Ensure Remote Lockout is functioning correctly.
4. Refer to engine operator’s manual for specifics on engine ECU

Power
troubleshooting.
NOTE: The starter M1 is considered to be part of the engine and covered
under the manufacturer’s warranty. You can void this warranty by
attempting to remove or repair this component before the warranty has
lapsed. If the warranty is still in effect, contact an engine manufacturer’s
service facility.

5. Perform a voltage test at the starter solenoid. With the multimeter set to
measure DC voltage, turn ignition switch to the START position. A
reading of approximately 12 volts indicates the starter solenoid is
receiving acceptable voltage. If there is acceptable voltage, replace
starter. If not, continue.
6. Test starter relay K2 for continuity. The easiest way to test an individual
relay is to remove it from the machine.
7. Set multimeter to measure
continuity (ohms).
Expected result: Terminal 86
should have continuity to ground.
With wires disconnected, terminals
85 and 86 should have continuity.
With terminal 85 grounded and 12
volts at terminal 86, terminals 30
and 87 should have continuity. If so,
continue. If not, replace relay.
8. Perform a continuity test on all
wires in the circuit. If there is no
continuity, indicating an open
circuit or break in wire, replace that
section of wire harness. If there is
continuity, continue.
9. Refer to component troubleshooting
tests in the power distribution troubleshooting chapter and test ignition
switch. If faulty, replace switch.

3-37
 Ignition START Circuit D36x50 Series II Navigator HDD Service

If the batteries fail to maintain their charged, the charge circuit should be
investigated. Begin troubleshooting as follows:

1. Ensure all connections and wires around the batteries and alternator are
tight and in good condition. Identify both (+) and (-) battery posts and
visually inspect for corrosion around the battery cable terminals. Clean if
necessary.
Power

2. Refer to battery test. If OK, continue.

Checking battery charge condition at regular intervals will indicate if the
charging system is functioning properly. A problem exists when the batteries
are constantly in a condition of low charge. The battery voltage indicator
light DS13 can be used to determine battery charge circuit status.

If the battery is in a low charge condition, the indicator light will not come
on when the machine is running. This indicates that voltage provided to
charge the battery is below the voltage required for the Strike Alert circuit
to operate.

Alternator ALT1
NOTE: The alternator ALT1 is part of the engine and covered under the
engine manufacturer’s warranty. You can void this warranty by attempting
to remove or repair this component before the warranty has lapsed. If the
warranty is still in effect, contact an authorized engine service facility.

Locate alternator's B+ terminal. Inspect wires at this terminal to ensure

they are clean and connection is tight.

1. Ensure alternator belt is tight.

2. Ensure battery is at full state of charge, approximately 12.66 volts DC
each.
3. Start engine and allow it to reach operating temperature.
4. Increase engine RPM to full throttle.
5. With multimeter set to measure DC voltage, connect positive lead to the
battery + stud on the alternator and negative lead on the bracket of the
alternator.
Expected result: The alternator output voltage should be at least half a
volt (.5V) above the combined battery voltage. If not, replace alternator.

3-38
D36x50 Series II Navigator HDD Service Throttle Circuit

THROTTLE CIRCUIT
REAR CONTROL
FRONT
RELAY K3 REMOTE
CIRCUIT THROTTLE
LOCKOUT
BREAKER CONTROL
CB4 SWITCH
S45

Power
SEAT CONNECTOR
SWITCH S51 FROM P14
DSR RELAY
TERMINAL
BUSS
TB9

JOHN
DEERE
ENGINE
REAR
ECU
THROTTLE CONNECTOR
A13
CONTROL P5
SWITCH S25

THROTTLE
P3 INCREASE
RELAY K2

THROTTLE
DECREASE
RELAY K3

TERMINAL BUSS TB7 TERMINAL BUSS TB9

The throttle actuator motor M1 can be controlled by either of two switches.

When either switch is pressed and held, the engine speed increases to
approximately 2500 rpm. When either switch is moved and held in the
opposite direction, engine speed decreases to low idle (approximately 900
rpm). If rear throttle switch is pressed when seat switch is open, and there is
no corresponding function, do the following:

Continued on next page...

3-39
 Throttle Circuit D36x50 Series II Navigator HDD Service

1. Test voltage at throttle motor M1. With ignition switch in the ON

position and seat switch open, disconnect throttle actuator plug from
harness. Hold rear throttle switch S25 in the increase position while
touching the positive lead of voltmeter to pin A and the negative lead to
pin C.
Expected result: Voltmeter should read approximately 12 volts. If so,
replace throttle actuator. If voltage is not present, go on to step 2.
Power

2. Do continuity test on relay K3. With engine shut down, remove relay.
Check for continuity between pins 87A - 30 and 86 - 85.
Expected result: Multimeter should show continuity. If not, replace relay
with new component and test circuit function. If so, proceed to step 3.
3. Check function of rear throttle relay K3 by applying positive lead of 12
volt power supply to pin 86 and negative lead to pin 85.
Expected result: When power is applied to relay, continuity should be lost
at pin 87A. If so, install relay and proceed to next step. If not replace
relay with new component and test circuit function.
4. Test voltage at rear throttle switch S25 with ignition switch in the ON
position, and multimeter set to measure DC volts. Touch red lead of
voltmeter to terminal 2 and black lead to ground.
Expected result: A reading of approximately 12 volts indicates the switch
is receiving acceptable voltage from relay K3. If so, continue with next
step. If not, test power wire from switch back to relay for continuity. If
open, indicating a break (open circuit), replace that section of wire
harness.
5. With the ignition switch in the ON position, set multimeter to measure
volts. Touch red probe to terminal 3 and black probe to ground. Press
switch to throttle increase position and test for volts.
Expected result: The multimeter should indicate approximately 12 volts.
If so, test power wire from switch to throttle actuator for continuity. If
open, indicating a break (open circuit), replace that section of wire
harness.

3-40
D36x50 Series II Navigator HDD Service Overview

Chapter 4: Hydraulic Fluid Distribution

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

All remaining machine hydraulic components are considered specific to

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

THEORY
Functions

Hydraulic Fluid Distribution

The following functions are included in this chapter:

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

Components
The following components are discussed in this section:

• PFC Pump PMP3

• Rotation Pump PMP1
• Thrust Pump PMP2
• Hydraulic Tank RES1, including:
• Suction Screen FL5
• Return Manifold A12
• Return Filter FL3 and FL4
• Fluid Cooler HE1
• Remote Lockout Manifold A4

4-1
 Theory D36x50 Series II Navigator HDD Service

Component Locations
RETURN FILTERS FL3 & FL4
RETURN MANIFOLD A12

HYDRAULIC
TANK RES1

REMOTE LOCKOUT
MANIFOLD A4
Hydraulic Fluid Distribution

ENGINE

ROTATION
PFC PUMP THRUST PUMP PMP1
PMP3 PUMP PMP2

4-2
D36x50 Series II Navigator HDD Service Theory

Hose Connections — Fluid Supply and Return

REMOTE LOCKOUT/CHECK
CHECK VALVE MANIFOLD A4

FROM THRUST MOTORS, ROTATION MOTORS

AND 2-SPEED VALVE MANIFOLD A2
OIL COOLER
HE1

HYDRAULIC
TANK RES1

FROM VISE,
ROD LOADER, RETURN

Hydraulic Fluid Distribution

MANIFOLD
STABILIZER,
STAKEDOWN,
AND GREASER
VALVES.

FROM WATER PUMP MOTOR

RETURN MANIFOLD A12 MH8
FROM TRACK CONTROL
VALVE A5
PFC PUMP
PMP3

THRUST PUMP PMP2

ROTATION PUMP PMP1

COMBINATION
MANIFOLD A9

4-3
 Theory D36x50 Series II Navigator HDD Service

Hydraulic Schematic
ROD LOADER
REMOTE LOCKOUT/ MANIFOLD A6
STABILIZER
ROTATION CHECK MANIFOLD A4 MANIFOLD
MOTORS A25
TRACK CONTROL
MH3 & MH4 VALVE A5

WATER MANIFOLD
ROTATION A26 & A27
PUMP PMP1

WATER
PUMP
MOTOR
MH8

STAKEDOWN
MANIFOLD A7
Hydraulic Fluid Distribution

ROD
SHIFT/ LOADER
BRAKE MOTOR
MANIFOLD A2 MH7
THRUST PUMP
PMP2 VISE
MH2 VALVE
MANIFOLD
A8

OILCOOLER
HE1

MH1

RETURN FILTERS
MANIFOLD FL3 & FL4
A12

HYDRAULIC
PFC PUMP PMP3 TANK RES1

COMBINATION DUMP
VALVE A9

4-4
D36x50 Series II Navigator HDD Service Theory

Oil Supply Function

Pump PMP3

COMBINATION DUMP
VALVE A9

Hydraulic Fluid Distribution

PFC PUMP PMP3

TANK RES1

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

• Fluid is drawn from the fluid tank RES1 which contains approximately
55 gal (208 L) of hydraulic fluid, through the 200-micron suction screen,
to inlet port of PFC pump PMP3.
• Pump PMP3 will remain in low pressure standby mode at 250 psi (17
bar). The pump produces only enough flow to make up for internal
leakage.
• Leakage in pump PMP3 goes directly to port T and drains back into the
hydraulic tank RES1 and is re-distributed.
When a hydraulic function is actuated during vise, rod loader or drilling
fluid functions or during transport or machine anchoring:

Continued on next page...

4-5
 Theory D36x50 Series II Navigator HDD Service

• PFC pump PMP3 distributes fluid through the combination valve

manifold A9 to the ground drive, stabilizer, rack angle, rod loader, vises,
stakedown, optional greaser if equipped, and drilling fluid functions.
• Load sense valve DV28 allows circuit pressure from the vise, stakedown,
greaser, rodloader, and water circuits to adjust the pump displacement
to increase the flow required at only the pressure required to operate the
function.
• PFC pump PMP3 will strive to maintain the flow required, under all
working conditions of the machine.
• If the load in the system produces a hydraulic pressure that is equal to
the 3000 psi (206 bar) high pressure setting of PFC Pump PMP3, the
pump will go into high pressure standby mode until the load is overcome
or the control valves are returned to neutral.

NOTE: If performance problems are noted in the rod loader, vises,

stakedown, optional greaser if equipped, and drilling fluid functions, as well
as the stabilizer, rack lift, and ground drive functions, but rotation and
thrust/pullback functions are OK, PFC pump PMP3 should be investigated.
Hydraulic Fluid Distribution

See "Troubleshooting/Testing PFC Pump PMP3," page 4-18.

4-6
D36x50 Series II Navigator HDD Service Theory

Rotation Closed-Loop Pump PMP1

CHARGE FILTER F1
TO THRUST / PULLBACK
BRAKE VALVE A2

TO LOOP FLUSH
VALVE A3

PUMP PMP1

Hydraulic Fluid Distribution

TO LOOP
FLUSH
VALVE A1
TANK RES1

TO TANK RES1
TORQUE LIMIT
MANIFOLD A1

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

A charge pump is part of pump PMP1 and is driven off the main pump shaft.
The charge pump is necessary to:

• supply cool oil to the system

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

4-7
 Theory D36x50 Series II Navigator HDD Service

The charge pressure must be at its specified pressure under all conditions to
prevent damage to the system. The charge relief valve in the pump serves to
maintain charge pressure at a setting of 350 psi (24 bar).
Upon engine start-up:

• Oil is forced by atmospheric pressure through suction screen located in

the oil tank RES1, to the charge pump.
• Flow from the charge pump enters and exits low pressure charge filter
FL1, then enters both sides of the closed loop through dual charge check
valves. These check valves are integral to the pump multifunction
valves.
• When the closed loop is entirely full of oil, flow from charge pump is
diverted through the neutral charge pressure relief valve, and into the
pump case (port L1).
Operation - High A multifunction valve is used in each closed-loop port to limit the system
Pressure Mode pressure and to allow charge oil to keep the closed loop filled.

If the closed loop oil pressure exceeds a preset limit of 6000 psi (413 bar), it
Hydraulic Fluid Distribution

goes over relief until the multifunction valve destrokes the rotation pump.
The multifunction valve pressure limiter sends a pilot signal to reduce the
swashplate angle (destroking the pump). The pump maintains pressure, but
there is almost no flow. Each multifunction valve has a check valve which
allows charge pump oil to keep the low side of the loop filled and
pressurized.

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

While the rotation function is in operation:

• One side of the loop will be under high pressure (load-generated

pressure).
• The opposite side of the loop is at charge pressure, plus case pressure.
• As soon as the pump swashplate moves off center position, oil will flow
from either the A or the B port depending on the position of the control
handle.
Continued on next page...

4-8
D36x50 Series II Navigator HDD Service Theory

• Oil will flow through the high pressure side of the closed loop to rotation
motors MH1 and MH2 to allow variable speed, bi-directional rotation of
the motor.

NOTE: If drill rotation function does not operate as expected, see

troubleshooting section of the Rotation chapter.

Hydraulic Fluid Distribution

4-9
 Theory D36x50 Series II Navigator HDD Service

Thrust Closed-Loop Pump PMP2

CHARGE FILTER F2

THRUST
PUMP PMP2
TO THRUST
MOTOR MH1 & MH2

REMOTE LOCKOUT
CHECK VALVE A4
Hydraulic Fluid Distribution

TO THRUST
MOTOR MH1 & MH2

TANK RES1

THRUST
LIMITER
VALVE A11

Operation - Charge Thrust pump PMP2 supplies fluid to the thrust/pullback hydrostatic closed
Pressure Mode loop. When the control is in NEUTRAL position (pump swashplate
centered), both sides of the closed loop are at charge pressure.

A charge pump is part of pump PMP2 and is driven off the main pump shaft.
The charge pump is necessary to:

• supply cool oil to the system

• maintain positive pressure in the main system loop
• provide pressure to operate the servo control system
• make up for component internal leakage
The charge pressure must be at its specified pressure under all conditions to
prevent damage to the system. The charge relief valve in the pump serves to
maintain charge pressure at a setting of 350 psi (24 bar).
Continued on next page...

4-10
D36x50 Series II Navigator HDD Service Theory

Upon engine start-up:

• Oil is forced by atmospheric pressure through suction screen located in

the oil tank RES1, to the charge pump.
• Flow from the charge pump enters and exits low pressure charge filter
FL2, then enters both sides of the closed loop through dual charge check
valves inside the pump. These check valves are integral to the pump
multifunction valves.
• When the closed loop is full of oil, flow from charge pump is diverted
through the neutral charge pressure relief valve, and into the pump case
(port L1), and out the case drain line to the tank.
Operation - High A multifunction valve is used in each closed-loop port to limit the system
Pressure Mode pressure and to allow charge oil to keep the closed loop filled.

If the closed loop oil pressure exceeds a preset limit of 6000 psi (413 bar), it
goes over relief until the multifunction valve destrokes the thrust pump. The
multifunction valve pressure limiter sends a pilot signal to reduce the
swashplate angle (destroking the pump). The pump maintains pressure, but
there is almost no flow. Each multifunction valve has a check valve which

Hydraulic Fluid Distribution

allows charge pump oil to keep the low side of the loop filled and
pressurized.

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

While the thrust function is in operation:

• One side of the loop will be under high pressure (load-generated

pressure).
• The opposite side of the loop is at charge pressure, plus case pressure.
• As soon as the pump swashplate moves off center position, oil will flow
from either the A or the B port depending on the position of the control
handle.
Continued on next page...

4-11
 Theory D36x50 Series II Navigator HDD Service

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

NOTE: If thrust/fullback function does not operate as expected, see

"Troubleshooting the Hydrostatic Circuit," page 6-23.

Oil Filtering Function

FROM OIL COOLER HE1
FROM RETURN MANIFOLD A12

FROM VISE, ROD LOADER,

STABILIZER, WATER, VISE, STAKEDOWN RETURN MANIFOLD
VALVE MANIFOLDS.
FILTERS FL3 AND FL4
Hydraulic Fluid Distribution

TANK RES1

SUCTION SCREEN

TO THRUST PUMP PMP2

TO ROTATION PUMP PMP1
TO PFC PUMP PMP3
With Functions • The 200-micron suction screen installed in the bottom of the tank to the
Operating or At Rest inlet manifold, will capture particles that may reside in the tank as the
fluid is delivered to the pumps.
• The 5-micron return filters FL3 and FL4, filter the fluid as it is returned
to the tank.

During normal operation, if back pressure in the return line reaches 22

psi (1.5 bar), indicating the filter is plugged, the spring located on the
filter frame will allow the filter to move and fluid to bypass into the tank.
Continued on next page...

4-12
D36x50 Series II Navigator HDD Service Theory

• The charge filters FL1 and FL2 fillter the fluid in the charge circuits of
the pumps PMP1 and PMP2, respectively.
• The sight gauge on the oil tank gives the operator a visual reference of
the fluid level. The oil should be visible in the sight glass when the
machine is at rest.

Oil Cooling Function

OIL COOLER HE1

RETURN MANIFOLD

Hydraulic Fluid Distribution

RETURN MANIFOLD A12 FILTERS FL3 AND FL4

TANK RES1

Operation All hydraulic functions on the machine share the hydraulic fluid in tank
RES1. Hydraulic fluid returns to the tank by way of return manifold A12
and directly to tank RES1. When fluid enters return manifold A12:

• Low pressure hydraulic hoses from the case drains on the rotation pump
PMP1 and thrust pump PMP2 and drilling fluid control valve A18
combine the oil at return valve A12.
• Oil is routed to the inlet of cooler HE1 where it is cooled before passing
through return manifold, filters FL3 and FL4, and returning to the tank
RES1.

4-13
 Theory D36x50 Series II Navigator HDD Service

Specifications
Listed below are the electrical and hydraulic specifications for the hydraulic
fluid distribution components, with the exception of rotation pump PMP1
and thrust pump PMP2. The rotation pump specifications are given in the
Drill Rotation chapter. The thrust pump specifications are given in the
Thrust/Pullback chapter.

Electrical:

• Nominal circuit voltage - 12 volts DC.

Hydraulic:

• Hydraulic oil tank capacity - 55 gal (133 L).

• PFC Pump PMP3 normal output flow - variable to 43 gpm (162 L/min)
• PFC Pump PMP3 standby pressure compensator valve setting - 250 psi
(17.2 bar)
• PFC Pump PMP3 high pressure compensator valve setting - 3000 psi
Hydraulic Fluid Distribution

(206.8 bar)

4-14
D36x50 Series II Navigator HDD Service Troubleshooting

TROUBLESHOOTING
Perform the pretest inspection (see "Pretest Inspection," page 4-17) and look
for obvious clues to malfunctions.

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

If there are faults in multiple functions with hydraulic circuits, the

hydraulic fluid distribution components should be investigated.

Actuators or functions that are malfunctioning may exhibit symptoms

including:

• excessive heat
• excessive noise
• excessive vibration

Hydraulic Fluid Distribution

• external leakage

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

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

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

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

Vibration
1. Check fluid level at sight gauge on tank. The level should be visible in
the indicator glass.
2. If not, filter new fluid through a 5-micron filter before adding it to fluid
tank RES1.
3. Refer to Machine Information chapter, "Fuel and Lubricants," page 2-7, for
correct fluid requirements. If problems persist, continue.
4. Check hydraulic fluid for signs of foaming. If foaming is noticed, it is an
indication of air contamination. Air contamination is a symptom of
cavitation and is usually associated with excessive noise.

NOTE: If there is excessive noise, it may come from a pump or pumps

cavitating from an inlet restriction or ingesting air through a leaking
suction hose or pump seal. Another source of excessive noise may be a relief
valve that is faulty or set incorrectly.

Continued on next page...

4-15
 Troubleshooting D36x50 Series II Navigator HDD Service

Cavitation is the formation of gaseous cavities in the liquid. Cavitation will

interfere with lubrication and destroy metal surfaces in the pump. If allowed
to continue, the pump will ultimately fail and contaminate the entire
system.

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

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

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

5. If it is determined that excessive noise is coming from one or more

pumps, continue with step 6. If it is determined that excessive noise is
coming from a relief valve, continue with step 10.
6. Inspect suction lines for restriction or collapse, loose connections, leaking
connections, or hose deterioration. Inspect pumps for seal leakage.
Hydraulic Fluid Distribution

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

7. Inspect tank outlet suction strainer FL5 for contaminates. The suction
strainer must be totally clean. Clean or replace as necessary.
8. Replace charge filters FL1 and FL2. Charge filter FL1 is used in the
closed loop of the drill rotation function. Charge filter FL2 is used in the
closed loop of the thrust/pullback function. If the filter becomes
restricted, adequate charge pressure will not be available.
9. If no problem is found, a pump may be experiencing excessive internal
leakage, refer to pump troubleshooting procedures in chapter 5.
NOTE: A noisy relief valve will have a steady high pitched screeching or
screaming noise. The drill rotation closed-loop hydraulic system has relief
valves integral to pump PMP1. The thrust/pullback closed-loop hydraulic
system has relief valves integral to pump PMP2.

The ground drive and rack lift functions have a relief valve integral to
transport valve A5.

Continued on next page...

4-16
D36x50 Series II Navigator HDD Service Troubleshooting

10. If it is determined that excessive noise is coming from a relief valve as

noted above, refer to the appropriate chapter:
• For drill rotation pump relief valve, forward and reverse torque relief
valves PV2 and PV1, refer to drill rotation function chapter for
information.
• For transport relief valve PV5, refer to ground drive function chapter.

Pretest Inspection

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

Hydraulic Fluid Distribution

leak. Wait for leaking to stop before disconnecting the fitting. Fluid injected
under the skin must be removed immediately by a surgeon familiar with this
type of injury.

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

Check hydraulic circuits for any failures.

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

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

Also review information in the General Information chapter under

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

4-17
 Troubleshooting D36x50 Series II Navigator HDD Service

Test Equipment Needed

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

• Multimeter for continuity tests, voltage measurements, resistance

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

NOTE: The hydraulic component test procedures discussed in this chapter

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

Troubleshooting/Testing Pump PMP1

Hydraulic Fluid Distribution

NOTE: Information on testing and troubleshooting rotation pump PMP1 is

provided in the Rotation chapter 5.

Troubleshooting/Testing Pump PMP2

NOTE: Information on testing and troubleshooting thrust pump PMP2 is
provided in the Thrust/Pullback chapter 6.

Troubleshooting/Testing PFC Pump PMP3

NOTE: PFC pump PMP3 is installed on the rear of thrust pump PMP2. If
pump PMP2 fails, and affects engine RPM, it will directly affect the output
of pump PMP3. Refer to chapter 6 for thrust pump troubleshooting.

1. If there is excessive noise associated with the pump, it may be cavitating

due to inlet restriction or ingesting air due to a leak in the suction hose
or pump shaft seal. If so, refer to "Excessive Noise/Vibration," page 4-15
for further testing instructions.
2. If the pump sounds normal, but there is excessive heat generated by the
drill rotation or drill fluid circuits, refer to "Troubleshooting/Testing the Oil
Cooling Function," page 4-20 for further testing instructions.

4-18
D36x50 Series II Navigator HDD Service Troubleshooting

3. If loss of pressure is indicated at

diagnostic port (1), the pump relief
valves may be faulty or misadjusted,
or internal leakage in the pump may
be the problem. Remove and inspect
1
compensator valves for damage or
contamination. See component repair
section in this chapter for
information. Replace if necessary. If
OK, replace pump.
4. Test efficiency of the pump. Refer to
the Vermeer Industrial Dealerships Technician’s Shop Manual (Vermeer
P/N 105400V80), for information on testing hydraulic pumps.
Pump PMP3 should be replaced if leakage approaches or exceeds 13 gpm (49
L/min) when tested at full throttle when circuit pressure achieves the pump
compensator setting of 3000 psi (207 bar).

Hydraulic Fluid Distribution

4-19
 Hydraulic Fluid Sampling D36x50 Series II Navigator HDD Service

Troubleshooting/Testing the Oil Cooling Function

Excessive Heat/Leakage

Inefficiency in the form of heat can be expected in all hydraulic systems.

However, oil temperature should not exceed 220°F (104°C) continuous
during normal work cycles.

If excess oil temperature is generated from one or more subsystem hydraulic

functions:

1. Use a pyrometer or a dial thermometer with a magnetic base to measure

the temperature of the external walls of the fluid tank. If using a dial
thermometer, ensure it is located below the level of the fluid in the tank.
If fluid temperature is above design specification, continue.
NOTE: Refer to the Vermeer Industrial Dealerships Technician’s Shop
Manual (Vermeer P/N 105400V80), for helpful information on testing
electrical circuits for shorts, opens, and high resistance.
Hydraulic Fluid Distribution

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

HYDRAULIC FLUID SAMPLING

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

4-20
D36x50 Series II Navigator HDD Service Hydraulic Fluid Sampling

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

Draw a sample and compare it to a sample of new oil. It should appear clean,
clear and amber in color. A milky haze or smoky appearance indicates there
is water present. If so, replace oil and filter. Refer to the D36x50 Series II
Navigator Maintenance Manual for details.

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

The particle counter must be able to display ISO codes at 4, 6, & 14-micron
levels and also be able to produce a hard copy of data. The equipment must

Hydraulic Fluid Distribution

also be rated for at least 6000 psi (414 bar).

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

• verifies filter performance

• verifies pump condition
• verifies stored fluid cleanliness
• verifies changing atmospheric contamination
• confirms system flushing efficiency
• helps to troubleshoot and isolate problems
• determines optimum filter replacement intervals
• identifies new filter defects
• detects high corrosive wear
• identifies abrasive wear conditions
• confirms that target cleanliness levels have been achieved
• verifies breather condition
• recognizes filter bypass condition
• determines new fluid cleanliness
• identifies cavitation conditions
• identifies fluid film failure problems
Continued on next page...

4-21
 Hydraulic Fluid Sampling D36x50 Series II Navigator HDD Service

NOTE: If not equipped with this type of sampling machine, fluid samples
can be obtained using hydraulic sampling kit, Vermeer P/N 108892001.
Contact the Vermeer Parts Center for information. The kit includes a
vacuum gun and ten sampling bottles.

To order additional sample bottles, use Vermeer P/N 108890001. Samples

are drawn from the fluid tank, or diagnostic ports at different locations (see
below), sealed in the bottle supplied, and sent to the address supplied with
kit.

Fluid Sampling Criteria:

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

fluid by running the ground drive or trencher or both.
• The engine speed must be set to low idle.
• All components in the hydrostatic circuit from which the sample is being
taken must be connected and pump must be at full stroke.
Hydraulic Fluid Distribution

Fluid Sample
Collection Points

2
1

To sample the drill rotation closed-loop circuit, use diagnostic test port (1) of
return valve assembly A12. To sample the thrust/pullback closed-loop
circuit, use diagnostic test port (2) of return valve assembly A12. To sample
open-loop circuits, use diagnostic test port (3) of return valve assembly A12.

Continued on next page...

4-22
D36x50 Series II Navigator HDD Service Component Repair

Cleanliness Approval Criteria:

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

• If a hydraulic tank sampling is above ISO code 18/16/13, the hydraulic
fluid, charge and return filters, should be replaced. The suction screen
should also be cleaned or replaced. Refer to the D36x50 Series II
Maintenance Manual for instructions.
• If a sample taken from the drill rotation closed loop or thrust/pullback
closed loop is above ISO code 18/16/13, high pressure closed-loop
filtration should be installed and operated for 15 minutes, then
resampled.
• If sample is still above ISO code 18/16/13, the hydraulic fluid, charge and
return filters, should be replaced. Suction screen SR1 should also be
cleaned or replaced. Refer to the D36x50 Series II Navigator Maintenance
Manual for instructions.

Hydraulic Fluid Distribution

COMPONENT REPAIR

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

Continued on next page...

4-23
 Component Repair D36x50 Series II Navigator HDD Service

Return Valve Manifold A12

13 11

10

5
4 7

8
12

2
Hydraulic Fluid Distribution

1 9 4 3
6 12
Remove 1. Label, disconnect, and cap all fittings and hoses.
2. Remove diagnostic fittings (1) from mounting plate (2).
3. Remove bolts (3) and washers (4) holding plate (5) and mounting plate
(2) to hydraulic tank.
4. Remove bolts (6), washers (4), and nuts (7) holding mounting plate (2)
to valve body (8).
5. Remove fittings (9, 10, 11, 12, and 13).
Reverse steps to install valve. Torque bolts (6) and (3) to 35 ft-lb (47 Nm).

4-24
D36x50 Series II Navigator HDD Service Component Repair

Disassembly

1
2

1. Remove check valves (1) and O-rings.

2. Remove port plugs (2).

Hydraulic Fluid Distribution

3. Inspect O-rings and valve body for contamination or wear. Replace O-
rings if necessary. Clean valve body.
Reverse steps above for assembly. Torque check valves (1) to 50 ft-lb (67
Nm).

4-25
 Component Repair D36x50 Series II Navigator HDD Service

PFC Pump PMP3

2
2
3
3
7
Hydraulic Fluid Distribution

4
5

Remove 1. Drain hydraulic tank of fluid.

2. Clean pumps and surrounding area.
Continued on next page...

4-26
D36x50 Series II Navigator HDD Service Component Repair

3. Label, disconnect and cap all hoses and fittings.

4. Support pump (1) at lift point plate (6).
5. Remove mounting bolts (2), washers (3) and nuts (4) holding pump to
pump support plate (7).
6. Disengage shaft from thrust pump PMP2.
7. Lift pump PMP3 from engine bay.
IMPORTANT: If hydraulic pumps are under warranty, all repair must be
done by a Sauer Danfoss Service Center or warranty will be voided.

Install Reverse removal steps to install pump. Apply light coating of oil to splined
shaft of pump.

Torque mounting bolts (2) to 90 ft-lb (120 Nm).

Hydraulic Fluid Distribution

Multifunction Valve for Rotation Pump or Thrust Pump
Cartridge Repair 1. Use a 1-1/4" wrench to hold outer
cartridge.
2. Turn bypass actuator out of outer
cartridge.

Continued on next page...

4-27
 Component Repair D36x50 Series II Navigator HDD Service

3. Remove bypass actuator (1), spring (2), spring seat (3), and check poppet
(4) from the pressure limiter housing (5). Inspect valve and mating seat
in the housing for damage or foreign materials. It will be necesary to
replace housing if seat is damaged.

6
4 3

5 2 1

4. Apply oil to O-ring (6) and install poppet, valve cartridge, spring, and
bypass actuator with O-ring into the housing. Torque actuator to 20 ft-lb
(27 Nm).
Hydraulic Fluid Distribution

4-28
D36x50 Series II Navigator HDD Service Component Repair

5. Start engine and operate at normal speed.

6. Loosen 19 mm lock nut.
7. Insert a 5 mm internal hex
wrench into pressure
adjusting screw.
8. The factory preset pressure
limiter setting is shown on
the model code. It is
referenced to charge
pressure, so the pressure
limiter setting is the
difference between the high
and low pressure sides of the
system loop. Activate or
move the control input so
that pressure increases in
the high pressure side of the
closed circuit to the pressure limiter pressure setting. The pressure

Hydraulic Fluid Distribution

limiter setting is reached when the pressure stops increasing and
remains steady at a given pressure level (as shown on the gauges).
9. Return pump to its “neutral” (zero flow) position and adjust the pressure
limiter setting by rotating the pressure adjusting screw with the internal
hex wrench. Clockwise rotation of the pressure adjustment screw will
increase the pressure setting, and counterclockwise rotation will
decrease the pressure setting. Each complete rotation of the pressure
adjusting screw changes the pressure, approximately 1300 psi (90 bar)
per revolution of adjusting screw.
10. To verify actual pressure setting, actuate or move control input so that
pump again develops pressure in high pressure circuit to the newly
adjusted pressure limiter pressure setting, and read the high pressure
gauge. Then allow the pump to return to its “neutral” position. The
pressure in the high pressure circuit should return to the charge
pressure setting.
11. While holding the pressure adjusting screw stationary, tighten the
pressure adjusting screw lock to 15 ft-lb (20 Nm).
12. Shut down engine, remove gauges and install gauge port plugs. Replace
plastic dust plugs (if used).
The same procedure is used for setting the pressure limit of the other
multifunction valve, but the control input signal must be activated or moved
in the opposite direction so that high pressure develops in the opposite side
of the closed circuit.

4-29
 Component Repair D36x50 Series II Navigator HDD Service

Electric Displacement Control (EDC)

Operation The EDC (1) controls the displacement of the pump.

Hydraulic Fluid Distribution

Within the control, a pressure

control pilot (PCP) proportional
valve solenoid L28 (2) receives
variable electrical input from
joystick control A19 which
operates a spring-centered 4-way
servo valve. This valve ports
hydraulic pressure to either side
of a dual-acting servo piston (3). 2
The servo piston rotates the 3
swashplate, varying the pump’s
displacement or flow, from full
displacement in one direction to full displacement in the opposite direction.
The control is designed so the position of the swashplate is proportional to
the mechanical movement of the joystick. A feedback link monitors
swashplate position to shut off oil flow to the servo piston when the desired
position is reached.

4-30
D36x50 Series II Navigator HDD Service Component Repair

Shaft Seal and Shaft Replacement

Lip-type shaft seals are used on Series 90 pumps and motors. These seals
and/or the shafts can be replaced without major disassembly of unit.
However, replacement usually requires removal of pump or motor from
machine.

1. Position pump with shaft facing up.

Hydraulic Fluid Distribution

Continued on next page...

4-31
 Component Repair D36x50 Series II Navigator HDD Service

NOTE: If unit is positioned horizontally when shaft is removed, cylinder

block could move out of place, making shaft installation difficult.

2. Remove three or four screws holding retainer plate and seal carrier to
housing, using a 10 mm hex wrench (030 and 042 units), a 5 mm internal
hex wrench (055 through 100 units), or a 6 mm internal hex wrench (130
through 250 units). Remove retainer plate.
NOTE: Certain earlier production units use a 1-piece retainer plate and
seal carrier.

3. After removing screws, spring force on shaft may move seal carrier out of
its bore by approximately 1/4 inch (6 mm). If seal carrier does not move
from its bore after removing screws, pry it from its bore as shown and/or
lightly tap end of shaft with a soft mallet.
4. Remove O-ring from seal carrier.
5. Place seal carrier and seal in an arbor press and press out old seal.
6. Inspect seal carrier, new seal and O-ring for any damage or nicks.
Hydraulic Fluid Distribution

7. Using press, press new seal into seal carrier. Be careful not to damage
seal.

NOTE: Outside diameter of seal may be lightly coated with a sealant (such
as Loctite High Performance Sealant #59231) prior to installation. This aids
in preventing leaks caused by damage to seal bore in seal carrier.

Continued on next page...

4-32
D36x50 Series II Navigator HDD Service Component Repair

8. Inspect sealing area on shaft for rust, wear, or contamination.

NOTE: If shaft is not being replaced, proceed to step 12.

9. Remove shaft and roller bearing assembly from pump or motor. Bearing
assembly can be transferred to new shaft.
10. Remove retaining ring that secures roller bearing assembly with snap
ring pliers. Remove roller bearing assembly.
11. Place roller bearing assembly on new shaft and secure with retaining
ring.
12. Wrap spline or key end of shaft with plastic film to prevent damage to
sealing lip on seal during installation.
13. Prior to assembly, lubricate O-ring on outer diameter of seal carrier and
inner diameter of seal with clean petroleum jelly.
14. Assemble seal carrier and seal over shaft and into housing bore. Install
retainer plate (if used).

Hydraulic Fluid Distribution

15. Install screws and torque to 12 ft-lb (16 Nm).
NOTE: Torque screws in a sequenced pattern, then recheck.

4-33
 Component Repair D36x50 Series II Navigator HDD Service

Return Filters/Manifold
3 2
1
7
10

9
8

6
Hydraulic Fluid Distribution

1. Label, disconnect and cap all fittings and hoses.

2. Remove fittings (6).
3. Remove bolts (8) and washers (9).
4. Remove bolts holding filter heads (1) to hydraulic tank.
5. Remove fittings (2, 3 and 4) and plug fittings (10).
Reverse steps to install. Torque bolts attaching filter heads to hydraulic
tank to 20 ft-lb (27 Nm).

4-34
D36x50 Series II Navigator HDD Service Component Repair

Oil Cooler HE1

2
5

Hydraulic Fluid Distribution

1 3

1. Remove engine bay hood.

2. Label, disconnect and cap hoses and fittings (3).
3. Remove engine mounts (2).
4. Remove bolts (4) attaching engine fan cover to cooler assembly.
5. Remove bolts (1) on radiator/cooler assembly mount.
6. Use hoist to lift radiator/cooler assembly from machine.
7. Remove bolts (5) holding oil cooler HE1 in radiator/cooler assembly.

4-35
This page intentionally left blank.
D36x50 Series II Navigator HDD Service Component Locations

Chapter 5: Rotation

COMPONENT LOCATIONS

SHUTTLE RELIEF VALVE PV3

HOT OIL SHUTTLE DV17
SOLENOID L1
3-SPEED LOOP FLUSH MANIFOLD A3 REAR MOTOR SHIFT
VALVE DV5
ROTATION GEARBOX
SOLENOID L35

ROTATION MOTOR MH3

FLOW CONTROL VALVE FV5

Rotation
FRONT MOTOR
SOLENOID L2 SHIFT VALVE
DV6

ROTATION MOTOR MH4

SOLENOID L31 ROTATION

REVERSE TORQUE CONTROL
LIMITER VALVE JOYSTICK A19
DV1

SOLENOID L30
FORWARD TORQUE
LIMITER VALVE
DV2

REVERSE TORQUE
LIMITER RELIEF
PV1

FORWARD TORQUE TORQUE LIMITER

LIMITER RELIEF VALVE A1
PV2

5-1
 Operation Overview D36x50 Series II Navigator HDD Service

OPERATION OVERVIEW
Rotation Motors The engine drives the hydrostatic rotation pump which supplies oil to the
rotation motors. The motors are splined to a common shaft in the drill
gearbox. The gearbox reduces the speed and increases the torque available
to the drive chuck.

Rotation Pump The rotation pump provides a variable output to drive the chuck at speeds
ranging up to the maximum available in each speed range. Three speed
ranges may be selected by shifting one or both of the motors into reduced
displacement mode.

Charge Pump The rotation pump charge pump provides pilot oil pressure to shift the
motors’ speed and displacement. Oil from the charge pump is also supplied
to the rotation closed loop to replace leakage and to allow a percentage of the
closed loop oil to be sent to the hydraulic oil cooler by way of the shuttle
Rotation

valve.

3-Speed/Loop Flush The 3-speed/loop flush valve on top of the gearbox incorporates the hot oil
Valve shuttle valve, the hot oil shuttle relief valve, and the shift solenoids.

Oil from the shuttle is routed into the rotation motor cases, through the
return line into the return manifold and into the tank. This oil is routed out
of the circuit to remove heat from the closed loop.

Operation Correct operation of the system requires that the engine is turning at rated
RPM, oil supply is unrestricted to the charge pump, and the charge filter is
not plugged or “dirty”. The hot oil shuttle must remove sufficient oil from the
loop to keep the closed loop operating temperature within specifications.
Back pressure in the case drain line must not exceed the maximum specified
or the following may result - “blown” seals, insufficient hot oil shuttle flow,
high case temperature, high loop temperature, or erratic operation of the
speed shift function.

5-2
D36x50 Series II Navigator HDD Service System Specifications

SYSTEM SPECIFICATIONS
The following
specifications are for the Specification Value
rotation circuit in
general. For individual General
component Rated engine RPM 2400 rpm
specifications, refer to
the appropriate section Rotation Speeds at 2400 Engine RPM
in this manual. LOW 89 rpm
MEDIUM 119 rpm
HIGH 178 rpm
Pump
Make/Model Sundstrand 90 series
Pressure limiter setting (multifunction

Rotation
6000 psi (420 bar)
valve) for FORWARD rotation
Pressure limiter setting (multifunction
6000 psi (420 bar)
valve) for REVERSE rotation
Torque limiter setting for FORWARD
4100 psi (280 bar)
rotation
Torque limiter setting for REVERSE
1500 psi (105 bar)
rotation
Displacement per revolution 3.35 cid (55 cc)
Nominal flow @ 2400 rpm 32 gpm (121 L/min)
Maximum allowable case pressure (cold) 73 psi (5 bar)
Maximum allowable case pressure
44 psi (3 bar)
(normal operating temperature)
ISO oil cleanliness standard ISO 18/13/16
Charge Pump (oil temperature must be 120°F (50°C) or more)
Displacement per revolution 0.86 cid (14 cc)
350 ± 25 psi (24 ± 1.7 bar)
Relief pressure setting (check in neutral)
@ 1750 rpm
Nominal flow at 2400 rpm 9.3 gpm (35 L/min)
relief 200 psi
Shuttle relief and flow flow 2.0 gpm (7.6 L/min) +/-
10%

5-3
 Hose Connections D36x50 Series II Navigator HDD Service

HOSE CONNECTIONS

3-SPEED LOOP
FLUSH VALVE A3
Rotation

REAR ROTATION
MOTOR MH3

TORQUE LIMITER
VALVE A1

FRONT ROTATION
MOTOR MH4

TO TANK

ROTATION PUMP TO TANK

PMP1

TO TO TANK
2-SPEED
BRAKE VALVE

5-4
D36x50 Series II Navigator HDD Service Hose Connections

Hoses

Port Location and Circuit Function

Pressure Type

Rotation ‘A’ closed

forward: low side pressure
reverse: high side pressure
Remote Gauge ‘GA1
‘B’ side loop pressure
Rotation ‘B’
forward: pressurized flow
reverse: return
Pump Case Drain
nominal pressure
Rotation pump PMP1 closed loop ‘A’ circuit to 3-
loop
speed/loop flush valve A3.
gauge Provides ‘B’ side loop pressure signal to rotation
pressure gauge GA1 at the operator’s station.
closed
Rotation pump PMP1 closed loop ‘B’ port to 3
loop
speed loop flush valve A3 port B.
return Drains rotation pump case (including excess
charge flow) to the return manifold A12.

Rotation
Servo Limit B pilot Provides signal from torque limiter pressure relief
nominal pressure PV2 of 4100 psi (282 bar) to destroke the rotation
pump PMP1; limits ‘B’ side (forward rotation) only.
Servo Limit A pilot Provides signal from torque limiter pressure relief
nominal pressure PV1 of 1500 psi (103 bar) to destroke the rotation
pump PMP1; limits ‘A’ side (reverse rotation) only.
Suction suction Supplies oil to charge pump inlet from tank RES1
whenever engine is turning.
Park Brake Pilot pilot Provides charge pressure to release the ground
charge pressure drive park brake.
Rotation ‘B’Pilot pilot
Provides rotation ‘B’ (forward) pressure signal to
forward: high side pressure
torque limiter valve DV2.
reverse: low side pressure
Rotation ‘A’Pilot pilot
Provides rotation ‘A’ pressure signal to torque
forward: low side pressure
limiter valve DV1.
reverse: high side pressure
*NOTE: the following pressures will normally be found in the circuits indicated:
“high side” pressures = 300–6090 psi (20–420 bar)
“low side” pressure = 300–500 psi (20–35 bar)
“nominal pressure” = 25–100 psi (1.7–6.9 bar)
“charge pressure” = 300–500 psi (20–35 bar) (same as “low side” pressure)

5-5
 Hose Connections D36x50 Series II Navigator HDD Service

Hoses

Hose ID/ Circuit Function

Pressure* Type

Flush - Rear Motor flush

Flush - Front Motor
nominal pressure
Rotation ‘A’ - Rear Motor
Rotation ‘A’ - Front Motor
forward: low side pressure
reverse: high side pressure
2-Speed Control - Rear Motor
apply: charge pressure
release: nominal pressure
Rotation
Carries oil from shuttle relief to flush (cool) the
front or rear motor.
closed
loop Rotation pump (PMP1) closed loop ‘A’ circuit.
Common circuit with Rotation ‘A’ - Front Motor.
pilot Shifts 2-speed motor into high-speed (low
displacement). Receives oil from hot oil shuttle
when solenoid valve is energized. Common circuit
with Flush - Front Motor and Flush - Rear Motor

when solenoid is de-energized.

Rotation ‘B’ - Rear Motor closed
Rotation ‘B’- Front Motor loop
Rotation pump (PMP1) closed loop ‘B’ circuit.
forward: high side pressure
reverse: low side pressure
Case Drain return Drains flush oil to return manifold tank. Common
nominal pressure circuit motor cases with Flush - Front Motor and
Flush - Rear Motor.
2-Speed Control - Front Motor pilot Shifts 2-speed motor into high-speed (low-
apply: charge pressure displacement). Receives oil from hot oil shuttle
release: nominal pressure when solenoid valve is energized. Common circuit
with Case Drain when solenoid is de-energized.
Thrust 2-Speed Solenoid pilot Provides charge pressure to shift thrust motors
charge pressure into high speed when Thrust 2-Speed Solenoid L3
is energized. Common circuit with Thrust 2-Speed
Control when solenoid is de-energized.
Thrust 2-Speed Control pilot Shifts 2-speed thrust motors into high-speed (low-
apply: charge pressure displacement). Receives oil from hot oil shuttle
release: nominal pressure when solenoid valve is energized.
Thrust 2-Speed Drain return
Drains thrust 2-speed shift oil to tank.
nominal pressure
*NOTE: the following pressures will normally be found in the circuits indicated:
“high side” pressures = 300–6000 psi (20–415 bar)
“low side” pressure = 300–500 psi (20–35 bar)
“nominal pressure” = 25–100 psi (1.7–6.9 bar)
“charge pressure” = 300–500 psi (20–35 bar) (same as “low side” pressure)
NOTE: In forward rotation, the pump ‘B’ port sends oil to the rotation motors ‘A’ ports; in reverse the
rotation pump ‘A’ port sends oil to the rotation motors ‘R’ ports.

5-6
D36x50 Series II Navigator HDD Service Hose Connections

Rotation Pump Schematic

FROM FORWARD
TORQUE
LIMITER A1
TO FLUID
FROM REVERSE
CONDITIONING
TORQUE
COMPONENTS
LIMITER A1

TO PORT A
LOOP FLUSH
MANIFOLD A3

Rotation
TO REVERSE
TORQUE
LIMITER A1

TO FROWARD
TORQUE
LIMITER A1

TO PORT B
LOOP FLUSH
MANIFOLD A3)
TO FLUID
FROM FLUID
CONDITIONING
CONDITIONING

5-7
 Hose Connections D36x50 Series II Navigator HDD Service

Charge Pump
Operation The charge pump (1) fills the loop hoses
and other components with oil during
initial start-up. It also replaces oil lost 1
because of internal leakage in circuit
hydraulic components, and oil that is
routed back to the tank through the 3-
speed loop flush valve.

The charge pump replaces hot oil shuttle

flow with cooled and filtered oil from the
tank and provides pressurized oil to
position the swash plate.

The charge pump is a gerotor-type pump. Oil is forced by atmospheric

Rotation

pressure through the suction strainer in the tank, into the charge pump,
through the charge filter, and through the charge check valves to both sides
of the loop when the rotation pump is in neutral. When the rotation pump is
stroked, charge pump oil flows to the low pressure side of the loop. The
remainder of the oil goes across the charge pressure relief, into the pump
case and on to the tank.

5-8
D36x50 Series II Navigator HDD Service Hose Connections

Multifunction Valves

Operation The multifunction valves (1) are used in

the rotation closed loop to limit the CCW
circuit pressure and to allow charge oil
to keep the closed loop filled.

CW

Rotation
If the closed loop oil pressure exceeds a
preset limit, it goes over relief until the
multifunction valve destrokes the
rotation pump.The multifunction valve
pressure limiter sends a pilot signal to
destroke the pump (i.e. to reduce swash
plate angle). The pump maintains
pressure but there is almost no flow. 2
Each multifunction valve has a check
valve (2) inside which allows charge
pump oil to keep the low side of the loop
filled and pressurized.

5-9
 Hose Connections D36x50 Series II Navigator HDD Service

Electric Displacement Control (EDC)

1
Rotation

Operation The EDC (1) controls the displacement of the pump.

Within the control, a pressure

control pilot (PCP) proportional
valve solenoid L28 (2) receives
variable electrical input from
joystick control A19 which
operates a spring-centered 4-way
servo valve. This valve ports
hydraulic pressure to either side
of a dual-acting servo piston (3). 2
The servo piston rotates the 3
swashplate, varying the pump’s
displacement or flow, from full
displacement in one direction to full displacement in the opposite direction.
The control is designed so the position of the swashplate is proportional to
the mechanical movement of the joystick. A feedback link monitors
swashplate position to shut off oil flow to the servo piston when the desired
position is reached.

5-10
D36x50 Series II Navigator HDD Service Torque Limiter Circuits

TORQUE LIMITER CIRCUITS

TO FRONT VISE TO LOAD SENSE
FUSE F6 CLAMP SOLENOID
CONNECTOR RELAY K4
P9

CONNECTOR P14

A15

FRONT VISE CLAMP

SWITCH S34

TERMINAL BUSS
TB1

Rotation
CONNECTOR
P1

TO HIGH SPEED THRUST

SOLENOID L3

ROTATION PUMP
PMP1 TORQUE LIMITER
MANIFOLD A1
L30
REVERSE TORQUE L31
LIMITER VALVE DV1
PV1 PV2

FORWARD TORQUE
Continued on next page... LIMITER VALVE DV2

5-11
 Torque Limiter Circuits D36x50 Series II Navigator HDD Service

Torque Limiters
Forward The forward torque limiter circuits contain components which limit the
pump pressure applied to the rotation motors when the motors are turning
the drill rod in the clockwise direction (when looking downhole). When the
front vise switch S34 is in the CLAMP position or the 3-speed gearbox
switch S42 is in the HIGH position, components in torque limiter manifold
A1 limit pressure applied to the rotation motors when in forward (clockwise)
rotation to 4100 psi (276 bar).

Reverse The reverse torque limiter circuits contain components which limit the
pump pressure applied to the rotation motors when the motors are turning
the drill rod in the counterclockwise direction (when looking down hole).
When the front vise switch S34 is in the CLAMP position or the 3-speed
gearbox switch S67 is in the HIGH position, components in torque limiter
manifold A1 limit pressure applied to the rotation motors when in reverse
Rotation

(counterclockwise) rotation to 1500 psi (103 bar).

5-12
D36x50 Series II Navigator HDD Service 3-Speed Loop Flush Valve Circuits

3-SPEED LOOP FLUSH VALVE CIRCUITS

TERMINAL BUSS TB1

FUSE F6

CONNECTOR CONNECTOR
CONNECTOR P13
P14
P1

ROTATION SPEED
SWITCH S42

Rotation
CONNECTOR
P12

A13 FRONT VISE

SWITCH S34
CONNECTOR
P13

PMP1 DV17

FV5
L35

L2 PV3

L1

FRONT
MOTOR
REAR MH4
MOTOR
MH3

Continued on next page...

5-13
 3-Speed Loop Flush Valve Circuits D36x50 Series II Navigator HDD Service

The 3-speed loop flush valve circuits contain components that control the
flow of oil to the rotation motors. Valve manifold A3 contains components
that control rotation speed. 3-position switch S42 at the forward operator
station controls gearbox rotation speed.

Pump flow is directed to ports A or B of the loop flush valve depending on

the orientation of the electric displacement control valve (EDC) in the
rotation pump. Flow enters the manifold A3 and is directed out of the
manifold ports depending on rotation direction, and speed switch position.

Low Speed Function

When switch S42 is placed in LOW position, there is no electrical power
available to solenoids L1 and L2 in the loop flush valve manifold A3. Oil flow
that comes into the manifold is routed out of the manifold at ports A1 and
A2, or B1 and B2 depending on rotation direction.
Rotation

When pressure in A or B port reaches 73 psi, valve DV17 shifts to connect

the low pressure ports to purge flow from the boost side of the circuit. This
bleeds off hot oil and routes it through the motors into the gearbox for
lubrication. Gearbox oil is routed to the oil cooler, filter, and then to the tank.

Medium Speed Function

If the front vise switch S34 is in the RELEASE position, voltage is available
to terminals 2 & 3 of 3-speed switch S42. When switch S42 is placed in
MEDIUM position, contacts 1–3 close. Electrical power is made available to
solenoid L1 in the loop flush valve. When the solenoid is energized, the valve
DV5 is shifted, and oil is routed to port Y of the rear rotation motor MH3.
This shifts the motor to 2/3 of its original displacement, which increases the
rotation speed to 151 rpm and reduces the maximum torque produced.

High Speed Function

If the front vise switch S34 is in the RELEASE position, voltage is available
to terminals 2 & 3 of 3-speed switch S42. When S42 is placed in HIGH
position, contacts 2–4, and 1–3 close. Electrical power is made available to
solenoids L1 and L2 of loop flush valve A3 and to torque limiter solenoid
valves L30 and L31 (see previous pages for torque limiter circuit operation)
through switch S22. When solenoids L1 and L2 are energized, valves DV5
and DV6 are shifted, and oil is routed to the Y ports of the front MH4 and
rear MH3 rotation motors. This shifts both motors to 2/3 displacement,
increasing rotation speed to 227 rpm, and reducing torque.

5-14
D36x50 Series II Navigator HDD Service Rotation Motors

ROTATION MOTORS
The rotation motors are 42.8 cid (701
cc) motors which are used to rotate the
drill string. Pressure at motor port Y
shifts the displacement to 2/3 of the
original 42.8 cid (701 cc). This increases
drill string rotation speed because the
same amount of oil flow from the pump
will rotate the motor more revolutions.

Port F receives flow from the rotation

hydraulic circuit to flush the motors for
cooling purposes.

Port 1 shows oil flow from the pump case that drains into the rotation

Rotation
gearbox.

Ports A and B receive oil from the rotation pump to rotate the drill string.
Input and output at the ports will vary depending on the position of the
electric displacement control (EDC) of the rotation pump.

5-15
 Basic Electrical Troubleshooting D36x50 Series II Navigator HDD Service

BASIC ELECTRICAL TROUBLESHOOTING

Unless the problem is obvious, investigate these fundamental electrical
related questions:

1. Electrical actuators such as relays and coils may operate correctly down
to as low as 10.8V, but any system voltage measuring below 12.5V can be
suspect, especially if grounds are faulty. Ensure power source circuit
breaker and fuses are functioning correctly.
2. The circuit must be complete to ground, and the voltage drop in the
ground circuit must be no higher than 0.5V.
3. Ensure current path to the electrical component is complete. Many
problems can be traced to a broken wire or faulty pin connection in a
plug.
Rotation

4. Resistance to a relay or a solenoid can be checked. Ensure current path is

complete and the resistance is within tolerance.
5. Even if all electrical components are testing correctly, a valve may leak
or contamination may prevent movement, or relay contacts may stick or
not conduct current.
The diagram on the opposite page shows the electrical connections of the
rotation control electrical circuit components. Use the diagram for locating
wires when testing circuits and components.

Complete wire harness diagrams and schematics are located in the

Addendum section at the back of the manual if needed for reference.

The following procedures are used to test for opens, shorts, or high
resistance in the circuit. If component specifications are not within the
parameters given, they should be replaced.

Continued on next page...

5-16
D36x50 Series II Navigator HDD Service Basic Electrical Troubleshooting

Open Circuit Test

1. Test for an open in the circuit by testing for acceptable voltage on input
and output pins/terminals of plugs and components. Testing at these
points, working through the circuit, will isolate the failed component(s)
by process of elimination. Continue through the circuit until the open is
found.
Expected result: When the positive lead is placed before an open point,
the meter will read voltage. When the lead is placed beyond the open, the
meter will read no voltage, indicating that a complete circuit exists from
the chassis ground to the point where voltage is last measured in the
circuit.
2. Once the open is found, turn ignition switch OFF, unplug wire harness at
the suspected component and test component for continuity or specified
resistance. If the component is OK, test wires, plug connections,
connecting the component for continuity. Replace faulty component or

Rotation
section of wire harness. If voltage is measured at all test points, continue
next by measuring for voltage on ground side.
3. Normal voltage should measure 0.0–0.5 volts. If battery voltage is
measured on ground side, a poor connection or broken wire/cable is
indicated. Test wires connecting the component for continuity. Replace
faulty section of wire harness.

High Resistance Test

Measurements taken from a multimeter can be used to troubleshoot for
unwanted resistance. Use multimeter to test for lower than normal battery
voltage (voltage drop) while moving to accessible points in the circuit wiring.
Replace section of failed wire harness. Refer to the diagram on previous page
for wire numbers and component harness connections.

Short Circuit Test

1. Test for a short in the circuit. When testing the circuit for a short, turn
the ignition switch OFF and set the multimeter to measure resistance
(ohms). Work through the circuit. If the meter measures resistance
through the complete circuit, it may be an intermittent problem causing
the short. In that case, repeat procedure and move wiring harness or tap
on components while watching for a sudden drop in resistance (Ω).
Expected result: If the voltage side of the circuit is shorted to ground, the
meter will read 0.0 Ω. This indicates there is no resistance between check
points (a dead short). Work through the circuit until the short is located.
When the short is removed, the meter will return to a resistance reading.
2. Repair or replace faulty component or section of wire harness. Check
circuit for function.

5-17
 Basic Hydraulic Troubleshooting D36x50 Series II Navigator HDD Service

BASIC HYDRAULIC TROUBLESHOOTING

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

Possible Problem Possible Effect What to do

hydraulic oil level Low hydraulic oil level can cause Fill hydraulic oil to correct level.
low higher than normal oil temperatures, Look for leaks in hydraulic system.
slow or jerky actuator movement, or
pump cavitation.
Rotation

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

5-18
D36x50 Series II Navigator HDD Service Basic Hydraulic Troubleshooting

The hydrostatic drive components are precision-built to very close tolerances

and operate at high pressures. Cleanliness is extremely important when
performing any of the following:
• When setting or checking pressure, oil temperature should be near
normal operating temperature 120°F (49°C).
• Clean components and immediate area before servicing. Use only filtered
hydraulic oil and a clean funnel when adding oil to the system.
• Unless specified in the instructions, tighten all bolts and fittings
according to the recommended torque values provided in the vermeer
shop manual.
• When installing pumps and motors, coat drive splines with anti-seize
compound.
• Whenever replacing charge filters, engine must be cranked without
starting to ensure adequate charge pressure is available. See filter

Rotation
change procedure found in Maintenance Manual.
IMPORTANT: Never bypass neutral start lockouts to start machine.
Internal pump damage can occur if the engine is started and the pumps are
not in NEUTRAL.

• Label hoses for location before disconnecting them. Plug all hoses and cap
all fittings when disconnecting them to prevent contamination of the
hydraulic system.
• All components (tank, hoses, and fittings) must be clean before
installation. Hoses and fittings should be rinsed with clean solvent
filtered through a 10-micron filter and dried with air before installation.
• Filter closed loop systems whenever they have been opened and exposed
to contamination, such as when replacing a hose or component.
• When replacing a closed loop high pressure hose: Ensure engine is shut
off, and wait approximately 5–10 minutes before carefully removing old
hose.
• Do not run a new motor over half speed until the motor is under full
hydraulic pressure. Run approximately 5 minutes to ensure air is out of
the system.
Continued on next page...

5-19
 Mechanical Component Inspection D36x50 Series II Navigator HDD Service

Unless the problem is obvious, investigate these fundamental hydraulic-

related questions:

1. Ensure pump is delivering correct flow. Is the inlet restricted? Is the

pump worn out? Is the electric displacement control (EDC) correctly
controlling pump stroke?
2. Ensure pump (EDC) is functioning correctly. Is the pump neutral set
correctly? Is the circuit relief set correctly?
3. Ensure circuit is delivering correct pressure to the actuator. Are the
actuators original equipment or correct replacements?
4. Ensure there is pressure and flow at the motors. Correct pressure and
flow at the motor ports will rotate the motors unless they are severely
worn, defective, or incorrect replacements.
5. Ensure motors are receiving flow from the control valve.
Rotation

6. Ensure there is no abnormal mechanical resistance to actuator function.

Pressure in a hydraulic system comes only from “line” (“system”)
resistance or from “load” (“actuator”) resistance. Any change from
normal will result in changed performance.
NOTE: A dramatic change in operation between cold conditions and
warmed up conditions indicates pump or motor wear, since hot oil flows
more easily through a worn pump or motor.

MECHANICAL COMPONENT INSPECTION

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

5-20
D36x50 Series II Navigator HDD Service Pretest Inspection

PRETEST INSPECTION
If a problem develops in the rotation circuits and machine performance
indicates the machine is not operating within specifications, begin by
visually checking for any obvious failures. Broken, kinked, or loose hoses
and fittings on supply, pressure, and return to hydraulic components will
affect function performance.

Ensure there are no broken, missing, corroded, or loose wires and

connections on ground and power wires that supply electrical circuit
components. If any are found, repair or replace them.

Refer to the Fluid Conditioning chapter and ensure components are

operational. If OK, continue. If not, correct any problems found.

Rotation
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.

5-21
 Required Test Equipment D36x50 Series II Navigator HDD Service

REQUIRED TEST EQUIPMENT

•Pressure

•Phototach

•Flow Meter
Rotation

•Needle Valve

•Flow Meter, Needle Valve, Pressure Gauge Combination

•Pyrometer

•Digital Multimeter

Continued on next page...

5-22
D36x50 Series II Navigator HDD Service Required Test Equipment

Pressure Check
Rotation circuit pressure can be checked at the pressure gauge in the control
panel.

1. Start engine and set engine speed to full throttle. Verify engine speed at
approximately 2350 rpm.
2. Engage Remote Lockout.
3. Move rotation gearbox to the most forward position and clamp drill into
vise.
4. Place rotation speed switch to LOW setting.
5. With propel lever in NEUTRAL, the rotation pressure gauges on control
panel should read 0.

Rotation
6. Push propel handle to FORWARD so pressure increases in the high
pressure side of the closed circuit to the pressure limiter setting. The
pressure limiter setting is reached when pressure stops increasing and
remains steady as shown on rotation pressure gauge.
Expected result: The pressure gauges should measure approximately
6000 psi (413 bar). If not, return pump to its NEUTRAL setting and
inspect multifunction valves for damage or contamination. Repair,
replace, or adjust as necessary.

Oil Sampling
A closed-loop system should not be opened when testing so contamination is
not introduced into the system. Therefore, before installing any test
equipment to determine component wear, the first step would be to obtain an
oil sample from the closed loop.

Oil sampling systems can analyze the oil without interrupting machine
operation or opening the system. Oil sampling can determine oil viscosity,
temperature, contaminate particle size, type, and concentration.

If oil sample test is not within the acceptable range, and machine
performance is within specifications, replace hydraulic oil as instructed in
the Maintenance Manual.

5-23
 Required Test Equipment D36x50 Series II Navigator HDD Service

IMPORTANT: The pressure and flow ratings of the test equipment used to
conduct the following hydraulic test procedures must be equal to, or greater
than the pressure and flow ratings of the circuit being tested.

The tolerances associated with a given specification are values indicating

the nominal, operating parameters.

High internal leakage (usually associated with pumps and motors) will
cause system overheating and/or a decline in actuator speed. The amount of
leakage is influenced by four factors:

• pressure difference across internal clearances

• oil viscosity
• temperature
• size of internal clearances
Rotation

NOTE: Clearance-related problems are generally viscosity sensitive.

Increased leakage will be less obvious when the fluid temperature is low and
will increase as the fluid temperature increases.

Internal leakage is externally drained from the pump case by a separate

drain line which returns directly to the oil tank.

The rotation motors are drained internally directly into the rotation
gearbox.

The most common symptoms associated with excessive pump and

motor leakage are:

• a loss of rotation speed as the fluid temperature increases

• a moderate to high increase in the operating temperature of the fluid
• drill rotation stalling at low pump speed
• increase in pump case pressure which could result in shaft seal leakage
NOTE: If leakage in a motor or pump approaches or exceeds 30% of the
theoretical (no-load) flow at full-load (maximum-rated pressure), it should
be replaced.

5-24
D36x50 Series II Navigator HDD Service Required Test Equipment

NOTE: The graphics on

the right, illustrate the
different pump port
designations with the
pump removed from
machine.

Left Side View

Rotation
Bottom View

5-25
 Basic Troubleshooting Tables D36x50 Series II Navigator HDD Service

BASIC TROUBLESHOOTING TABLES

1. Are the Engine and Fluid Conditioning components operating correctly? Oil level,
operating temperature, oil cooler operation, and engine speed outside of specifications can cause or
contribute to faulty operation.

Possible Problem Possible Effect What to do

3-speed switch is set If the drill is operated in HIGH speed, Use the appropriate switch setting.
to HIGH or MEDIUM motor torque AND system pressure
will be reduced. If the drill is operated
in MEDIUM, motor torque output will
be reduced.
Hydraulic oil level Low hydraulic oil level can cause a Fill hydraulic oil to correct level.
low variety of problems, including sluggish
or erratic operation.
Rotation

Engine RPM too low Low operating hydraulic pressure.
Actuator speed and power will be
affected.
Overheating A blocked oil cooler, malfunctioning hot
oil shuttle valve, or other conditions
causing overheating of the hydraulic oil
can cause various problems.
Check engine RPM while operating
under load.
Check hydraulic oil cooler. Remove
and clean or repair hot oil shuttle
valve.

2. Is the torque limiter applied or out of adjustment? The torque limiter sends oil to the pump
servo to destroke the pump. Faulty operation, or operation when it is not desired, will limit pump pressure to
approximately 4100 psi (282 bar).

Possible Problem Possible Effect What to do

3-speed switch If an electrical signal is sent to the
malfunction torque limiter causing the torque limiter
to be applied, rotation pressure will be
limited to 4100 psi (275 bar).
Torque limiter If the solenoid valve leaks loop oil to
solenoid valve is the pressure relief, pump pressure will
defective or dirty. be limited to the pressure relief setting.
Torque Limiter If the pressure relief setting is
pressure relief valve incorrect, or the relief or an O-ring is
defective or dirty leaking, pump pressure will be lower
than desired whenever the torque
limiter solenoid valve L30 is energized.
Continued on next page...
Check for unintended torque limiter
“ON” signal from the 3-speed switch
and replace switch if necessary.
Check solenoid valve for leaking:
Either cap off the torque limiter and
pump ports to see if the pump will
operate normally without the limiter OR
test the torque limiter seals utilizing a
“pressure leak test”.
Check pressure relief for leaking: O-
rings, valve torque, valve cavity
condition.

5-26
D36x50 Series II Navigator HDD Service Basic Troubleshooting Tables

3. Is charge pressure is low? Charge pressure and flow is needed to control the pump servo.
Low charge pressure will lead to loss of pump control.

Possible Problem Possible Effect What to do

Low hydraulic oil Oil level must be within sight glass.
level Low oil level can cause air to enter the
charge pump if the inlet screen is not
fully covered with oil.
Charge filter is A plugged filter will restrict charge flow.
plugged
Inlet screen is A restriction (blocked screen or
blocked OR air leak collapsed inlet hose) or suction leak
in inlet (missing components, damage, or
loose fittings) will restrict charge flow.
Check hydraulic oil level and fill if
necessary.
Check charge pressure and replace
the rotation charge filter if charge
pressure is low (refer to repair).
Check inlet vacuum: it should be
between 8'' and 2'' Hg (75–100 kPa)
under standard conditions. If not,
repair restriction or suction leak. Refer

Rotation
to Rotation Repair.
Charge pressure A relief that is out of adjustment or Check charge pressure. Adjust or
relief is out of defective can limit charge flow. replace charge relief if necessary.
adjustment or stuck
Charge pump worn If the charge pump is worn or Check charge pump condition.
or defective damaged, charge flow will be reduced.
Continued on next page...

5-27
 Basic Troubleshooting Tables D36x50 Series II Navigator HDD Service

4. Are the shift solenoids applying shift oil to the motors? In LOW speed, no power is
applied to either speed solenoid L1 or L2, so neither motor receives shift oil. In MEDIUM speed, the rear
motor shift solenoid L1 is energized, causing charge oil to be applied to the ‘Y’ (shift) port of the rear motor.
In HIGH, both solenoids L1 & L2 are energized and oil is applied to the shift ports of both motors.

If the speed solenoids do not receive power when they should, the motors will not shift into MEDIUM or
HIGH. If the speed solenoids receive power when they should not, the motors will stay in MEDIUM or HIGH.

Possible Problem Possible Effect What to do

No power to one or If any of the following occur, shift
both solenoids operation will not be correct: power is
not available to the 3-speed switch, the
switch is bad, connector or plug
defective or pin or socket not seated in
the connector, +12V solenoid ON wire
Rotation
Check for voltage at solenoid terminals
in conjunction with switch operation.
Check coil continuity. Check for good
ground. Check 3-speed switch. Check
power supply circuit.

is grounded or open, solenoid ground

wire is open.
Power always to one If the signal wire is shorted to +12V or Check power at the signal pins at the
or both solenoids if the 3-speed switch is defective, one speed solenoid connector. Check 3-
or both solenoids could be ON at all speed switch.
times.

5. Is the 3-speed/loop flush valve defective? Malfunctions in the loop flush valve components,
including the pressure compensated flow control, the pressure relief, and the speed solenoids, can cause
incorrect operation of the rotation motors. Shuttle oil after the flow control valve is used to shift the motor
speeds. Low or no shift pressure will cause the motors to remain in low speed. Shift pressure that is always
high will prevent the motors from returning to low speed. Oil pressure incorrectly applied to the shift port
could also cause the shift valve to “bypass” so that loop oil flows directly from the ‘B’ side to the ‘A’ side,
without turning the motor.

Possible Problem Possible Effect What to do

Hot oil shuttle valve If the hot oil shuttle DV17 is stuck in
stuck one position, high pressure loop oil can
bypass the motors, causing system
heating and limiting the flow and
pressure to the motors.
Speed solenoid A leaking speed solenoid valve could
valves leaking allow unwanted charge oil to flow to
the motor shift ports.
Flow control If the flow control is stuck closed or
defective blocked, it would prevent shift oil from
being applied to the speed solenoids.
Pressure relief If the pressure relief is defective or set
defective too low, shift pressure might also be
too low.
Continued on next page...
Check that shuttle is shifted
properly. Replace with a known good
shuttle valve or perform a pressure
leak test on the shuttle.
Check for a stuck spool, damaged
O-ring, or damaged valve cavity in
the loop flush valve.
Check shift pressure at diagnostic
port G1, shuttle pressure, and
shuttle flow at gearbox drain line.
Check shift pressure at diagnostic
port G1, shuttle pressure, and
shuttle flow at gearbox drain line.

5-28
D36x50 Series II Navigator HDD Service Inspect Related Functions or Circuits

6. Are the pump or motors defective? The hydrostatic pump must deliver specified flow and
pressure, and the motors must shift speeds correctly and function correctly internally for correct motor
operation.The rotation motors use a spool valve to direct internal oil flow for low or high speed operation. If
the spool valve does not move correctly, the motor can stay in low or high speed or may “bypass” causing
no rotation operation at all.

Possible Problem Possible Effect What to do

Motor shift operation If the shift spool valve is stuck or
incorrect operates erratically, the motor can
either remain in high speed/low torque
OR bypass, preventing shaft rotation.
Pump malfunction or If the pump is badly worn or damaged,
wear it may not deliver sufficient flow or
pressure.
Motor malfunction or If the pump is delivering adequate
Refer to "System Specifications,"
page 5-3 for component information.
After verifying correct operating
conditions and controls, perform a
pressure and flow check on the pump,
bypassing the motor. If flow and

Rotation
pressure are low, replace the pump. If
wear pressure and flow and the shift
flow and pressure are sufficient,
operation is correct, a worn or
replace the motor.
damaged motor will cause incorrect
operation.

INSPECT RELATED FUNCTIONS OR CIRCUITS

• Always look for problems in components that may be common to several
circuits or functions and related functions before doing any test
procedures.
• Check hydraulic and electrical machine schematics and verify that
related functions are working correctly.
• Look at and check electrical circuits operating on the same circuit
breaker or switch such as the front vise switch S34.
• If a related circuit is not functioning correctly, repair that system first,
then proceed with troubleshooting, if necessary.

5-29
 Pump Test Procedure D36x50 Series II Navigator HDD Service

PUMP TEST PROCEDURE

NOTE: The hydraulic troubleshooting tests are based on
non-validated procedures. The circuit schematic shows where to install
testing equipment to perform a particular test and the procedure used to
perform the tests. In some cases it may not be easy to access the component
or clearance may be limited. Therefore, it is up to the discretion of the
technician whether to use the procedure or not.

IMPORTANT: Ensure any hoses or fittings that are added to the test
equipment are the same size and rating as hoses and fittings installed in the
hydraulic circuit. Mismatched hose or fitting sizes can result in erroneous
pressure readings. Mismatched pressure ratings can result in leakage or
personal injury.

When troubleshooting a closed loop hydrostatic circuit, the following

Rotation

measurements can be used to diagnose malfunctions:

• Charge Pressure
• Rotation Circuit Pressure
• Pump or Motor Case Pressure and Flow
• Charge Pump Inlet Restriction
• Rotation Circuit Flow
Refer to "System Specifications," page 5-3 for specifications and tolerances.

Continued on next page...

5-30
D36x50 Series II Navigator HDD Service Pump Test Procedure

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

2. Turn ground disconnect switch to the DISABLE position.

6
7

4 8

Rotation
2

2
4

1
3

3. Remove motors from the circuit by installing a combination flow meter

(1), needle valve (2), and pressure gauge (3). Disconnect pressure line
from the B port of the flush valve manifold and attach to the needle valve
end of the test equipment. Disconnect other pressure line from the A port
of the flush valve manifold and attach to the outlet port of the flow meter.
4. Open needle valve (2) fully (turn counterclockwise). Install pressure
gauge (4) at diagnostic port (5).
5. Disconnect hose from case drain port (port L1) in the top of pump.

5-31
 Pump Test Procedure D36x50 Series II Navigator HDD Service

6. Install T-fitting (6), diagnostic fitting (7), and connect pressure gauge (8)
to indicate pump case drain pressure.
7. Turn the ground disconnect switch to the ENABLE position. Start
engine and inspect test equipment connections for leaks.
8. Enable Remote Lockout.
NOTE: If catastrophic failure is suspected, do not operate pump for any
longer than is absolutely necessary to determine its condition. If metal
fragments are found in the hydraulic lines, outlet port of pump, charge or
return filters, and/or tank, Do not operate pump. Filter system before testing
pump or motor.

9. Set engine speed to full throttle (2350 rpm). Verify engine speed at
tachometer. The engine must be able to maintain full throttle to achieve
desired pump flow.
Rotation

10. Allow hydraulic oil to warm up to approximately 130°F (54°C). If

needed, cycle a machine function to aid in warming the oil.
11. Observe and record the following:
• Engine RPM indicated on tachometer.
• charge pressure indicated at pressure gauge (4).
NOTE: If charge pressure is 350 psi ± 10 (24 bar ± .7), continue with test
procedure. If charge pressure is low, adjust charge pump relief setting.

12. Actuate the rotation control to full displacement position for clockwise
rotation and record.
• Flow indicated on flow meter (1).
• Charge pressure indicated on gauge (4).
• Pump case pressure indicated on gauge (5).
Continued on next page...

5-32
D36x50 Series II Navigator HDD Service Pump Test Procedure

NOTE: During test, do not allow case pressure to exceed 44 psi (3 bar). If it
reaches 44 psi (3 bar), discontinue test. During cold start the pressure is
allowed to reach 73 psi (5 bar) intermittent.

13. Gradually load pump by restricting the flow with needle valve (2) (turn
clockwise). Watch pressure gauge (3) and stop when pressure reaches
500 psi (34 bar). Inspect connections for leaks.
14. Continue increasing the pressure by increments of 500 psi (34 bar). Stop
the test procedure when 6000 psi (417 bar) is reached.
NOTE: If pressure limiters or relief valve pressure cannot be obtained, or is
not within design specification, refer to and check
multifunction valve components.

15. With engine operating at full load (full pump flow passing over relief
valve), record:

Rotation
• Engine speed
• Flow indicated on flow meter (1).
• Charge pressure indicated on gauge (4)
16. Open needle valve (2) fully (turn counterclockwise) to reduce artificial
load on pump.
17. Shut down engine and analyze test results.
18. At conclusion of test procedure, remove test equipment, reconnect
hydraulic lines and tighten connections.
19. Start engine and check connections for leaks.
Continued on next page...

5-33
 Pump Test Procedure D36x50 Series II Navigator HDD Service

Analyzing Test Results

Diagnostic Pump and motor wear is caused by hydraulic system contamination and
Observations Full degradation of the oil. Since the pump and motor in closed loop circuits
Load continuously cycle the same oil, the pump and motors will normally wear at
the same rate. If the test reveals that the pump is worn and should be
replaced, the motors may also be worn and need replacement.

The pump is considered worn beyond limits when the case drain flow
reaches or exceeds 30% of the no-load flow. Refer to "System Specifications,"
page 5-3 to determine minimum output flow requirements.

Possible Result #1:

• Flow meter (1) indicates a nominal flow decrease as circuit pressure

increases.
Rotation

• Pump charge pressure indicated on pressure gauge (4) remains within

design specification.
• Pump case pressure remains below 44 psi (3 bar).
• Engine speed indicated remains within design
specification.
Diagnosis - The pump appears to be in satisfactory operating condition.

Possible Results #2:

• Flow meter (1) indicates a moderate to high flow decrease as circuit

pressure increases. The flow decrease does not exceed 30% of the
theoretical or no-load flow.
• Engine speed remains within design specification.
Diagnosis - The condition of the pump may be marginal. If there is an
abnormal variation (reduction) in rotation speed, this could cause an
unacceptable loss and/or a marked increase in the operating temperature of
the fluid. The pump as well as the motor should be replaced.

Possible Result #3:

• Flow meter (1) indicates a progressive flow loss as circuit pressure

increases. The flow loss exceeds 30% of the
theoretical or (no-load) flow rating of pump.
• Engine speed remains within design
specification.
Diagnosis - There appears to be excessive leakage across ports of the pump.
The pump should be replaced.

5-34
D36x50 Series II Navigator HDD Service Pump Test Procedure

Inspect Electric Displacement Control (EDC)

Disconnect electrical cable from the connector on the pump and check for
neutral operation. Disconnecting the control handle should allow the pump
to return to neutral. If operation is satisfactory with the control
disconnected, inspect control handle at operator station for free movement.

If operation is not satisfactory with control handle disconnected, the pump

neutral setting may be out of adjustment.

NOTE: Before proceeding with pump control adjustment, inspect internal

linkage, torsion spring, and O-rings.

Remove cap screws while holding the control in place, and swing it away
from the housing and remove. Visually inspect for broken or missing
linkages, torsion spring, and O-rings. Inspect for missing, plugged, or

Rotation
damaged orifice.

5-35
 Pump Test Procedure D36x50 Series II Navigator HDD Service

Adjusting Pump Neutral Setting

WARNING: Entanglement in rotating drill chuck and drill rod can result
in death or serious injury. Stay away from rotating equipment. Do not
wear loose clothing that could catch on rotating equipment.

1. Install a 1000 psi (70 bar) gauge in each of the two

displacement control cylinder gauge ports (M4
and M5). Ensure rotation control is in NEUTRAL
position. Disconnect the manual displacement
control cable. Start engine and operate at high
idle speed.
Rotation

2. Loosen lock nut with a 13 mm wrench. Using a 4

mm Allen wrench, rotate clockwise until the 1
pressure increases in one of the pressure gauges.
Note the angular position of the wrench. Then
rotate the neutral adjusting screw
counterclockwise until the pressure increases by
an equal amount on the other gauge. Again note
the angular position of the wrench.

3. Rotate adjusting screw clockwise half the distance between the locations
noted above. The gauges should read the same pressure (case pressure),
indicating that the control is in its NEUTRAL position.
4. Hold the neutral adjusting screw stationary. Tighten neutral adjusting
screw lock nut to 120 in-lb (13.6 Nm). Do not overtorque the nut.
5. Once NEUTRAL position is set, stop engine, remove gauges, and install
gauge port plugs. Connect control cable from the joystick control at the
operator station.

5-36
D36x50 Series II Navigator HDD Service Pressure Checks and Adjustments

Inspect System Relief Valves

When the rotation motors are not functioning properly in one direction,
interchange multifunction valve cartridges to determine if the problem
changes to the other side of the circuit. If so, one cartridge is either
malfunctioning or does not have the proper setting. The first two digits of
the pressure setting are stamped on the end of the cartridge.

PRESSURE CHECKS AND ADJUSTMENTS

Charge Pressure - Check

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

NOTE: Cleanliness is extremely important when servicing hydrostatic

systems. Refer to “Returning Hydrostatic System to Service” section
whenever a hydrostatic component is replaced.

1. Remove cap and install a pressure

gauge at the diagnostic port (1). 1

2. Enable Remote Lockout.

3. Ensure rotation handle is in NEUTRAL.
4. Start engine and set engine throttle to full speed (2350 rpm).

5-37
 Pressure Checks and Adjustments D36x50 Series II Navigator HDD Service

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

6. Observe gauge in NEUTRAL.
Expected result: The diagnostic pressure gauge should read 350 psi ± 10
(24 bar ± .7).
7. If charge pressure is not within specification, replace charge filter. Refer
to the machine Maintenance Manual for instructions on replacing filters.
8. Recheck charge pressure. If pressure is still low, adjust charge pressure
while in NEUTRAL. See below. If charge pressure is correct, move
rotation control handle out of NEUTRAL and check FORWARD and
REVERSE pressure.
Expected result: Pressure should drop to 300 psi ± 20 (21 bar ± .6). If
charge pressure is OK in NEUTRAL but not in FORWARD or
REVERSE, most likely there is a problem in the rotation motors, or in
the 3-speed manifold valves. Check the rotation hydraulic circuit.
Rotation

If the rotation drive is sluggish or slow running and charge pressure is

OK in NEUTRAL, FORWARD, and REVERSE, check rotation gearbox
drain flow. Refer to "Rotation Motors Case Drain Flow Test," page 5-43 to
determine if the motors are worn and should be replaced.

5-38
D36x50 Series II Navigator HDD Service Pressure Checks and Adjustments

Pump Case Pressure Test

Test Objective To determine if pump case pressure exceeds specifications, indicating either
a restriction in case drain line or some condition causing excess flow to the
pump case.

Special Tools and • 1000 psi (70 bar) pressure gauge

Materials • diagnostic fitting with 1-1/16–12 thread to install in pump case pressure
port
Conditions Testing may be done initially with cold oil but must conclude with oil tank
temperature at normal working temperature, (at least 100°F (40°C). Verify
oil temperature with a non-contact thermometer.

IMPORTANT: This procedure requires specialized training. Do not perform

this test if you are not trained in the use of flow meters on high pressure
systems.

Rotation
IMPORTANT: Never test case pressure by removing the drain line and
plugging the case with a pressure gauge. This can lead to pump case failure
and does not provide an accurate test.

Procedure 1. Remove hose (1) from case drain

port (port ‘L2’) in the top side of
pump. 4
2. Install T-fitting (2), diagnostic
fitting (3), and connect pressure 2 3
gauge (4). 1

3. Load a drill rod into the machine

and clamp the front vise on it.
Operate machine at full throttle
with rotation joystick control in full
FORWARD; observe and record
pressure on the gauge and on the rotation gauge at the operators panel.
4. Ensure rotation pressure at operator station shows
approximately 4100 psi (forward torque limiter setting). If gauge
(4) shows pump case pressure above 40 psi (3 bar) continuous, or
75 psi (5 bar) intermittent, there is a restriction in the case drain
circuit or there is a condition causing excessive flow to the pump case.
Check case drain hose for restriction, if restriction is not found, check
case drain flow.

5-39
 Pump Multifunction Valve Inspection D36x50 Series II Navigator HDD Service

PUMP MULTIFUNCTION VALVE INSPECTION

The rotation pump has two multifunction valves. These cartridges
incorporate a check valve, pressure limiter valve, high pressure relief valve
and bypass valve. The cartridge is not repairable, but O-rings may be
replaced. Valves are adjustable.

1. Remove forward (1) or reverse (2)

multifunction valve. (both valves 2
are the same).
2. Inspect valve and mating seat in
the housing for damage or foreign Reverse
material. A damaged seat 1
(including its housing) or valve
must be replaced.
Rotation

Forward
NOTE: The pump reliefs are
adjustable. When contamination is the
cause of low system pressure and the
reliefs are removed from the pump,
many times the contamination is also removed. If relief components and
seals appear in good condition, flush it with clean oil to remove
contamination and reinstall.

NOTE: Several designs of high pressure relief valves have been used by the
pump manufacturer. Do not mix parts from different pumps.

3. Install valve cartridge with O-ring into the housing. Torque valve to 100–
170 ft-lb (136–230 Nm).

5-40
D36x50 Series II Navigator HDD Service Charge Pump Relief Valve Inspection

CHARGE PUMP RELIEF VALVE INSPECTION

The charge pump relief valve is located on the top side of the rotation pump.

1. To remove charge relief valve, mark

the lock nut and screw. Count the
number of turns to remove the
valve from the housing. Inspect
valve and mating seat in the
housing for damage or foreign
material. A damaged seat
(including its housing) or valve
must be replaced.
NOTE: Charge pump relief setting
may be adjusted by loosening the lock

Rotation
nut and turning the adjustment plug with a hex wrench. However, when
contamination is the cause of low charge pressure and the relief is removed
from the pump, many times the contamination is also removed. If the relief
seals and spool appear in good condition, flush valve with clean oil to remove
contamination and reinstall. Install so that the marks line up and proper
number of turns on the valve were made.

2. Torque valve to 38 ft-lb (52 Nm).

3. Verify charge pump pressure setting after installation.

5-41
 Charge Pump Relief Valve Inspection D36x50 Series II Navigator HDD Service

Charge Pressure - Adjust

1. Install pressure gauge at rotation
charge pressure diagnostic port (1).
2. Operate machine at full throttle
with rotation pump in NEUTRAL;
observe pressure reading.
3. Pressure gauge should read
approximately 350 psi.
1

4. Adjust by loosening the outer lock

3
nut (2) of pressure relief valve.
Rotation

Turn adjustment screw (3)

clockwise to increase pressure,
counterclockwise to decrease
pressure. 2

5. Shut down machine.

6. Remove pressure gauge.

5-42
D36x50 Series II Navigator HDD Service Rotation Motors Case Drain Flow Test

ROTATION MOTORS CASE DRAIN FLOW TEST

This test provides information on rotation motor condition by measuring the
case drain flow for excessive leakage.

IMPORTANT: Ensure any hoses or fittings that are added to the test
equipment are the same size and rating as hoses and fittings installed in the
hydraulic circuit. Mismatched hose or fitting sizes can result in erroneous
pressure indications. Mismatched pressure ratings can result in leakage or
personal injury.

The test procedure shown can be used to measure the case drain flow from
each motor.

Rotation
1

1. Disconnect case drain line (1) from the rotation motor being tested and
install it to the intlet of a 20 gpm flow meter. Ensure meter flow direction
arrow is pointing away from the gearbox.
2. Add a short hose (2) from the outlet of the flow meter to the drain lines
connecting the thrust motors and the other rotation motor.
Continued on next page...

5-43
 Rotation Motors Case Drain Flow Test D36x50 Series II Navigator HDD Service

3. Turn ground disconnect switch to the ENABLE position. Start engine

and inspect test equipment connections for leaks.
4. Allow system to warm up to approximately 130°F (54°C). If needed, cycle
a machine function to aid in warming the oil.
5. Set engine speed to full throttle (2350 rpm). Place rotation speed range
switch in LOW.
6. Actuate rotation control to full FORWARD and record case drain
measurement.

Analyzing Motor Test Results

Expected result: The case drain flow should measure between 1.5 gpm
(5.5 L/min) nominal, to 5.5 gpm (21 L/min) maximum. If the
measurement approaches or exceeds the maximum allowable leakage, it
is considered worn beyond its useful life.
Rotation

IMPORTANT: Motor wear is caused by contamination and degradation of

the oil. Since the pump and motor in the closed loop continuously recycle the
same oil, the pump and motor wear at the same rate. If leakage in a motor
approaches or exceeds the maximum, it is highly recommended that the
motor and pump be replaced.

Replace Drive Chuck

Special Tools and • torque wrench capable of producing 90 ft-lb (122 Nm)
Materials

1. Remove the six bolts and washers, and remove drive chuck (1). Remove
screen (2) if the rotation shaft is so equipped.
2. Cap or plug the end of the rotation shaft to keep the bore clean.
3. Always use a new O-ring (3) and rubber
washer (4) during re-assembly. Lightly lubricate 3
them before installation. Seat the O-ring in the
drive chuck groove and the rubber washer against
the screen lip.
4. Mount drive chuck on the rotation shaft. Use a
gradual cross pattern tightening sequence to
evenly seat drive chuck against the rotation shaft.
Torque bolts to 90 ft-lb (122 Nm) in a cross pattern
sequence.

5-44
D36x50 Series II Navigator HDD Service Drive Chuck Sub-Saver Installation/Removal

DRIVE CHUCK SUB-SAVER INSTALLATION/REMOVAL

Special Tools and Materials
• acetylene heating torch
• wire brush
• Formula “C” BAKERLOCK, or Plusco 170 Thread Locking Compound
(Vermeer P/N 235804-001)
Thread Locking Compound Considerations
Thread locking compound has a shelf life of three years as long as the
hermetically sealed containers are not opened. Prolonged storage at
temperatures above 100°F (38°C) may cause some settling of fillers and
require thorough mixing for best results. Freezing has no detrimental affects
on the components.

Rotation
The optimum drive chuck casing temperature for applying mixed compound
to threads is 70°–150°F (21°–66°C). The compound will not cure at
temperatures below 40°F (4°C).

Once the compound has been mixed, it has a limited usable life—apply as
soon as possible.
Temperature Usable Life Full Strength Cure Time
70°F (21°C) 90 minutes 48 hours
100°F (38°C) 40 minutes 17 hours
120°F (50°C) --- 6 hours
150°F (65°C) --- 2 hours

5-45
 Drive Chuck Sub-Saver Installation/Removal D36x50 Series II Navigator HDD Service

Install Sub-Saver 2

1. Clean all threads on sub-saver (1) and drive chuck (2) with solvent and
rinse with water. Remove all grease, moisture, and foreign matter.
Remove any rust with a wire brush.
2. Thoroughly mix the can of thread locking compound with the applicator.
Rotation

Shake the vial of hardener and add to the compound. Mix until
completely blended and no streaks are visible in the mixture.
3. Apply the compound to the entire circumference of the first 2/3 of the
drive chuck threads.
4. Clamp the sub-saver in the rear rod vise and make up the joint with
maximum torque (gearbox set to LOW).
IMPORTANT: Do not use put the sub-saver into use until the thread
locking compound has cured to full strength.

Remove Sub-Saver
To prevent damage to 1. Clamp sub-saver in the rear rod vise
the drive chuck, do not
apply heat directly to its 2. Using an acetylene heating torch, evenly and
surface. quickly apply heat to the threaded joint to the
loosen the threads. Apply heat only to the box end
of the sub-saver. The thread locking compound
will release at 500°–600°F (260°–315°C)
3. Quickly back the drive chuck out of the sub-saver
before the heat transfers to the drive chuck.

5-46
D36x50 Series II Navigator HDD Service Rear Seal Removal/Installation

REAR SEAL REMOVAL/INSTALLATION

3
4
5
8

Rotation
7 6

9
2

Special Tools and Materials

• torque wrench capable of producing 35 ft-lb (47 Nm)
• wire brush
• Loctite ODC-Free Cleaner and Degreaser
• Loctite Primer N 7649
• Loctite 515 Gasket Eliminator
• pipe sealant
Remove Seal
1. Remove water swivel (1) and clean old sealant from the threads.
2. Remove drain plug (2) and drain the oil. Remove old sealant from the
plug.
3. Remove four bolts (3) and washers (4) and pull rear seal gland (5) from
the gearbox.
4. Remove large O-ring (6) small O-ring (8) and 4 inch lip seal (7) from the
gland and discard.
5. Remove old sealant from the bolts, gland and gearbox machined surface.

5-47
 Gearbox Removal/Installation D36x50 Series II Navigator HDD Service

Install Seal
1. Clean the drain plug and bolts using Loctite ODC-Free Cleaner and
Degreaser, and then spray them with Loctite Primer N 7649. Follow the
manufacturer’s instructions to obtain the best results.
2. Apply a film of grease to the inner and outer diameters of the seal (7).
Orient seal as shown and fully seat it in the gland.
3. Lightly oil replacement O-rings and install them into seal gland.
4. Mount rear seal gland (3). Slide washers on the bolts; apply Loctite 515
to the bolt threads; and finger tighten them in the gearbox.
5. Use a gradual cross pattern tightening sequence to evenly seat rear seal
gland against the gearbox. Then, final torque bolts in a cross pattern
sequence to 35 ft-lb (47 Nm).
Rotation

6. Apply Loctite 515 to the drain plug threads and tighten it in the gearbox.
7. Apply pipe sealant to the threads of the water swivel (1). Thread swivel
into the rotation shaft and tighten it.
8. Fill gearbox with 80W-90 that conforms to API GL5 or MIL-L-2105D
specifications until it flows from the check plug on the gearbox.

GEARBOX REMOVAL/INSTALLATION
Special Tools and Materials
• torque wrench capable of producing 30 ft-lb (40 Nm) and 90 ft-lb
(122 Nm)
• wire brush
• pipe sealant

5-48
D36x50 Series II Navigator HDD Service Gearbox Removal/Installation

Remove Gearbox
1. Level drill rack and move gearbox to the rear of the rack.
2. Follow "Shutdown Procedure," page 2-1.
3. Since you will be opening the hydrostatic closed-loop system, thoroughly
clean gearbox and surrounding area.
4.Remove hose (1) from the water
1 swivel and clean residual sealant
from the threads. Cap or plug the
hose and swivel.
5.Label and disconnect any wire
connectors secured to hoses and
tubes. Remove ny-ties that secure
electrical harness to the gearbox.

Rotation
6. Label and remove ‘A’ port hose (2), ‘B’
2 4
port hose (3), 2-speed valve assembly 3
hoses (4) and (5). Cap or plug all
ports and fittings.

7. Remove bolts and washers (6) that

attach the cylinder (7) to the
carriage and move it to the side.

7
6

Continued on next page...

5-49
 Gearbox Removal/Installation D36x50 Series II Navigator HDD Service

8. Disconnect and cap case drain hose

(1).

9. Install a suitable lifting sling

beneath the hydraulic motors. Attach 4
an adequate lifting device to the
sling, and lift enough to remove the 2
Rotation

weight of the gearbox from the

floating head pins (2).
3

When removing the 10. Remove two retaining bolts (3) and caps (4).
floating head pins, be
careful not to damage 11. Carefully remove floating head pins.
the sliding surfaces.
12. Lift gearbox from the drill rack.

5-50
D36x50 Series II Navigator HDD Service
Install Gearbox
When installing the
floating head pins, be
careful not to damage
the sliding surfaces.
When connecting hoses
to ports, carefully oil the
threads and seats of the
hoses or fittings so that
correct torque values
can be achieved as
hoses are tightened.
Gearbox Removal/Installation
4 6 8
7
1 3
2
5
1. Install a suitable lifting sling beneath the hydraulic motors. Attach an
adequate lifting device to the sling, and lift the gearbox onto the gearbox
carriage.
Rotation
2. Align sliding bearings (1) on the gearbox with corresponding holes in the
carriage (2).
3. Install floating head pins (3), caps (4) and retaining bolts (5).
4. Install ‘A’ port hose (6)and ‘B’ port hose (7), torquing each hose to
87.5 ft-lb (118.7 Nm).
5. Install 2-speed valve assembly hoses (8) and (9), and torque them to 19
ft-lb (25.8 Nm).
6.Install case drain hose (10) and
torque it to 28.5 ft-lb (38.6 Nm).
7.Connect wire connectors and
secure harness to a hose or tube.
11 10 Replace all of the ny-ties.
8.Apply pipe sealant to the threads of
the hose (11). Thread hose into the
water swivel and tighten it.
9. Install carriage locking cylinder,
bolts, and washers.
10. Refer to "Returning System to
Service," page 5-60, before starting
the engine or running the machine.
12
13
5-51
 Motor Replacement D36x50 Series II Navigator HDD Service

MOTOR REPLACEMENT
Special Tools and Materials
• torque wrench capable of producing 180 ft-lb (244 Nm)
• tubing wrenches
• Loctite 515 or equivalent product

Removal
1. Level the rack and move the gearbox to the back of the rack.
2. Follow "Shutdown Procedure," page 2-1.
Rotation

3. Since you will be opening the hydrostatic closed-loop system, thoroughly

clean the gearbox and hoses.
4. Label and disconnect any wire connectors secured to hoses.
Because cleanliness is 5. Label, disconnect, and cap hoses attached to the motor to be removed.
extremely important
when working on the 6. Use suitable lifting device and lift strap to support motor.
gearbox, cap or plug all
of the hoses, tubes and
fittings during
disassembly.

Continued on next page...

5-52
D36x50 Series II Navigator HDD Service Motor Replacement

7. Remove bolts and washers (1).

1
8. Slide motor out of gearbox.

Install Motors
1. Thoroughly clean the machined motor mounting surface on the gearbox.
2.Apply a bead of 515 Loctite or

Rotation
2 equivalent product to gearbox
mating surface around each bolt hole
and around the center pilot hole.
3.Apply oil to splined motor shaft.
4.Lift motor into place. Support gear
(2) in gearbox and align splines on
motor shaft with drive gear and slide
into place.
5. Apply 515 Loctite or equivalent product to motor mounting bolts.
6. Use a cross pattern tightening sequence to evenly seat the motor against
the gearbox and final torque screws to 180 ft-lb (244 Nm).
Continued on next page...

5-53
 Motor Replacement D36x50 Series II Navigator HDD Service

When connecting hoses 7. Install hoses in the following suggested order for the particular motor
to ports, oil threads and being serviced:
seats of hoses or fittings
so that correct torque
values can be achieved. Rear Motor
Always lightly lubricate
fitting O-rings before Sequence Ports Torque
assembly.
(1) ‘B1’ (valve) to ‘A’ (motor) 87.0 ft-lb (118.7 Nm)
(2) ‘D2’ (valve) to ‘Y’ (motor) 19.0 ft-lb (25.8 Nm)
(3) ‘A1’ (valve) to ‘R’ (motor) 87.0 ft-lb (118.7 Nm)
(4) ‘C2’ (valve) to ‘F’ (motor) 28.5 ft-lb (38.7 Nm)

Front Motor

Sequence Ports Torque

Rotation

(5) ‘B2’ (valve) to ‘A’ (motor) 87.0 ft-lb (118.7 Nm)

(6) ‘A2’ (valve) to ‘R’ (motor) 87.0 ft-lb (118.7 Nm)
(7) ‘D1’ (valve) to ‘Y’ (motor) 19.0 ft-lb (25.8 Nm)
(8) ‘C1’ (valve) to ‘F’ (motor) 28.5 ft-lb (38.7 Nm)
Continued on next page...

5-54
D36x50 Series II Navigator HDD Service Rotation Shaft and Front Seal Removal/Installation

3
4 5

2
6

When connecting 8. Install the following hoses:

hydraulic hoses to ports,
oil threads and seats of
hoses or fittings so that
correct torque values
can be achieved as the
• 2-speed valve assembly hoses (1) and (2) and torque to 19 ft-lb
(25.8 Nm)
• A’ port hose (3) and ‘B’ port hose (4) and torque to 87.5 ft-lb (118.7 Nm)

Rotation
hoses are tightened. • case drain hose (5) and torque to 28.5 ft-lb (38.6 Nm)
• water hose (6) to water swivel using anaerobic pipe sealant on threads
9. Connect wire connectors and secure harness to a hose or tube. Replace
all of the ny-ties.
10. Refer to "Returning System to Service," page 5-60 before starting the
engine or running the machine.

ROTATION SHAFT AND FRONT SEAL REMOVAL/INSTALLATION

Special Tools and Materials
• torque wrenches capable of producing 5 ft-lb (7 Nm), 35 ft-lb (47 Nm) and
145 ft-lb (197 Nm)
• pry bar
• wire brush
• Loctite ODC-Free Cleaner and Degreaser
• Loctite Primer N 7649
• Loctite 515 Gasket Eliminator

5-55
 Rotation Shaft and Front Seal Removal/Installation D36x50 Series II Navigator HDD Service

Remove Rotation Shaft and Front Seal

1 15
3 7
6 14
8

13
2 12

4
5 9
16
10
11
21
Rotation

22
24
27
17
18
19
20
23

25 26

1. Remove drive chuck. Refer to "Replace Drive Chuck," page 5-44

2. Remove rear seal. Refer to "Rear Seal Removal/Installation," page 5-47
3. Remove plate (15). Remove sealant from the bolts, plate surface and
gearbox machined surface.
4. Remove four bolts and washers and pull front seal gland (24) from the
gearbox, allowing it to hang on the rotation shaft.
5. Loosen six screws in the flange of locking nut (13) and remove nut.
Remove sleeve (11) from the rotation shaft, and discard O-ring (12) from
the inner diameter. Remove cone bearing (10) and tube spacer (9).
6. Pull out rotation shaft (1), allowing gear (8) to remain in the gearbox.
Remove tube spacer (6), cone bearing (5) and front seal gland (2) from
the shaft.
7. Remove original high pressure seal (4) and O-ring (3) from the gland
and discard them. Remove old sealant from the bolts, gland and gearbox
machined surface.

5-56
D36x50 Series II Navigator HDD Service Rotation Shaft and Front Seal Removal/Installation

Install Rotation Shaft and Front Seal

1 3
6 14
15
7
8

13
12
2

4 5
16
9
10
11 21

Rotation
22
24
27
17
18
19
20
23
25 26
1. Clean the following parts with Loctite ODC-Free Cleaner and Degreaser,
following the manufacturer’s instructions to obtain the best results:
• bolts for plate (15) rear seal gland (3) and front seal gland (24)
• gearbox machined surfaces for the plate and seal glands
• surface of the plate and gland surfaces that contact the gearbox
2. Spray the above parts with Loctite Primer N 7649. Follow the
manufacturer’s instructions to obtain the best results.
3. Inspect rotation shaft (27) for visible wear in the areas where the seals
and bearings seat.
4. Inspect bearings (10) & (20) and bearing cups (11) & (19) for visible
wear, replacing them as needed. Seat the bearing cup against the
rotation gearbox shoulder.
Continued on next page...

5-57
 Rotation Shaft and Front Seal Removal/Installation D36x50 Series II Navigator HDD Service

5. Install seal (22) and O-ring (21)

into front gland (24).

SEAL

O-RING

6. Place rotation shaft (27) on bench SNAP

with threaded end up. Slide front RING
seal gland (24) (machined step up) BEARING
on the rotation shaft.
7. Place bearing (20) over shaft and
Rotation

seat against step on shaft. GLAND

8. Install snapring (18) on shaft into

groove at the base of the splines.

9. Place shaft into lower gearbox hole GEAR

while sliding 29 tooth gear (16) onto
splines.
10. Align sub-assembled rotation shaft
with the splines of gear (16) and
push it through the gearbox.

11. Install tube spacer (12) from the BEARING

SPACER
opposite side of the gearbox with the
machined step to the inside.
12. Slide bearing (10) on the rotation
shaft. Use bearing driver to drive
bearing in place until seated.

SHAFT

Continued on next page...

5-58
D36x50 Series II Navigator HDD Service Rotation Shaft and Front Seal Removal/Installation

13. Apply oil to groove and O-ring (7)

and install into seal sleeve (8). O-RING
GROOVE

14. Install seal sleeve (8) onto gearbox LOCK

driveshaft with chamfer toward the NUT
inside. Thread lock nut (1) on the
rotation shaft. Hold drive gear in
position with a pry bar and using a
three inch socket, torque nut to 142

Rotation
ft-lb (193 Nm). Rotate shaft two
revolutions and re-torque nut to 142
ft-lb (193 Nm). Repeat procedure SEAL
SET
SLEEVE
until the parts are seated and the SCREW
proper torque is achieved.
15. Use a gradual cross pattern tightening sequence to tighten the six set
screws in the flange of locking nut (1). Then, final torque screws in a
cross pattern sequence to 37 in-lb (4 Nm)

BOLTS 16.Mount front (24) and rear (3) seal

glands. Slide washers on bolts; apply
Loctite 515 to the bolt threads; and
GLAND finger tighten them in the gearbox.
Use a gradual cross pattern
tightening sequence to evenly seat
the front seal glands against the
gearbox. Then, final torque bolts in a
cross pattern sequence to 35 ft-lb (47
Nm).

5-59
 Returning System to Service D36x50 Series II Navigator HDD Service

RETURNING SYSTEM TO SERVICE

The hydrostatic systems can be easily damaged by contaminants or by lack
of oil. After repairing a hydrostatic system, use the following procedure to
assure an adequate supply of oil to each part of the system.

• Fill the tank with the recommended hydraulic fluid. Filter the oil with a
5-micron oil filter as it is added to the tank. Do not reuse hydraulic fluid.
• If replacing a hose, fill it with oil before starting the machine.
• If replacing a pump or motor, fill the case with oil before starting the
machine.

IMPORTANT: Hydrostatic components can be destroyed if not filled with

oil before the engine is started.
Rotation

5-60
D36x50 Series II Navigator HDD Service Filter Kit Parts

FILTER KIT PARTS

4
3

8
1
2 7
6
6
7 4
3

2
DIRECTION OF
OIL FLOW 1

Rotation
5

Filter Kit for Rotation and Thrust/Pullback Systems

Number Part Number Description Quantity

(1) 82923-001 Fitting-16M JIC x 16/62 90° SH Ref 2

(2) 72895-001 O-ring-Sq. #16 Flange 2
(3) 235718-001 Bolt-1/2”-13 x 2” GR8 Hex Zinc PLT 8
(4) 485-025 Washer-1/2” Flat Hardened Zinc 8
(5) 75351-001 Split Flange 2
(6) 75350-001 Spacer 2
(7) 72896-001 O-ring-Sq. #20 Flange 2
(8) 71927-001 Filter Assembly 1
71928-001 Element-Filter 1
75353-001 Seal Kit 1
71927-005 Indicator-Visual 1
71927-007 Glass-Visual Indicator 1

5-61
 Flushing the Rotation System D36x50 Series II Navigator HDD Service

FLUSHING THE ROTATION SYSTEM

FROM PUMP ‘A’ PORT
FROM PUMP ‘B’ PORT

DIRECTION OF
OIL FLOW
Rotation

Special Tools
• torque wrench capable of producing 90 ft-lb (122 Nm)
Procedure
IMPORTANT: Do not start the machine after installing a new pump, motor,
hose or tube until the filter kit is installed. If installing a new hydrostatic
pump or motor, fill the case with oil prior to starting the engine.

1. The drill rack should be level and the gearbox should be at the rear of the
rack.
2. Follow "Shutdown Procedure," page 2-1.
3. Thoroughly clean 3-speed loop flush valve and top of the gearbox.
4. Label and remove ‘A’ port hose and ‘B’ port hose, capping the fittings on
the 3-speed loop flush valve.
Oil the threads and IMPORTANT: Note orientation of the arrow showing oil flow direction, and
seats of the hoses or connect hoses to the filter kit. Torque hoses to 88 ft-lb (119 Nm).
fittings to achieve
correct torque values. 5. Install a 600 psi (40 bar) pressure gauge on the charge pressure
diagnostic port connected to the oil filter.
Continued on next page...

5-62
D36x50 Series II Navigator HDD Service Flushing the Rotation System

IMPORTANT: Push emergency stop button down to prevent the engine

from starting before charge pressure is established. Pump damage will
result if the engine starts before the hydrostatic system is properly filled
with oil.

NOTE: Do not crank engine for more than 30 seconds at a time to prevent
the starter from overheating. Allow starter to cool two minutes between
cranking attempts.

6. Crank engine until the charge pressure is 25-50 psi (1.7-3.4 bar).
7. Pull emergency stop button up. Start engine and run it at the lowest
possible RPM until charge pressure is at least 290 psi (20 bar).
IMPORTANT: To avoid internal damage to the pump, never attempt to
start the machine unless the pump is in neutral.

Rotation
8. Pull left joystick back and flush circuit for 10 minutes at half throttle.
IMPORTANT: To prevent reintroducing contaminants, do not push the
joystick forward while the flushing filter is installed.

Oil the threads and 9. Follow "Shutdown Procedure," page 2-1. Remove filter kit, and connect ‘A’
seats of the hoses or port hose and ‘B’ port hose to the three-speed loop flush valve, being
fittings to achieve careful not to get contaminants into the circuit. Torque hoses to 88 ft-lb
correct torque values. (119 Nm).
10. Take an oil sample. Ensure oil sample test results reflect IS0 18/16/13
cleanliness standard.

5-63
 Flushing the Rotation System D36x50 Series II Navigator HDD Service
Rotation

5-64
D36x50 Series II Navigator HDD Service Overview

Chapter 6: Thrust/Pullback

OVERVIEW
SYSTEM AND COMPONENT LOCATIONS
THRUST LIMITER VALVE
DV30, SOLENOID L29

FRONT VISE SWITCH

S34

MANIFOLD A11

RIGHT JOYSTICK

Thrust/Pullback
THRUST LIMITER RELIEF
VALVE PV6, SOLENOID L36

SHIFT CONTROL VALVE

DV4, SOLENOID L4

BRAKE CONTROL VALVE

DV3, SOLENOID L3
THRUST PULLBACK CIRCUIT BREAKERS
PUMP PMP2
VALVE MANIFOLD
A2

6-1
 System and Component Locations D36x50 Series II Navigator HDD Service

THRUST LIMIT
SELECTOR SWITCH
S23

THRUST LIMIT ADJUSTMENT

SWITCH S20
Thrust/Pullback

6-2
D36x50 Series II Navigator HDD Service Overview

OVERVIEW
Engine The engine drives the hydrostatic thrust/pullback pump which supplies oil
to the thrust/pullback motors. The motors are geared to a common pinion
rack and provide thrust and pullback force to the drill rod.

Thrust/Pullback The thrust/pullback pump PMP2 provides a variable output to drive the
Pump motors. The thrust/pullback motors are automatically shifted to half-
displacement high-speed mode whenever the front vise is ON.

Thrust/Pullback Thrust/pullback charge oil is supplied to the thrust/pullback closed loop to

Charge Pump replace internal leakage in components.

Rotation Charge Oil from the rotation charge pump provides oil pressure to shift the thrust/
Pump pullback motors displacement for 2-speed operation and release the brake
mechanism on motor MH2.

Thrust Limiter Components in thrust limiter manifold A11 limit thrust pressure whenever
(RockFire) the RockFire switch is ON. The RockFire control module energizes the
thrust limiter on/off solenoid valve whenever the RockFire switch is ON. The

Thrust/Pullback
control switch varies the actual pressure available by signalling the
RockFire control module to control the proportional solenoid within the
thrust limiter. The greater the output from the control module, the higher
the relief setting since the proportional solenoid acts to add pressure to the
relief valve base setting. Important: variable pressure relief PV6 must be
set at 350 psi /24 bar (=/< charge pressure) or the carriage may creep when
the control is not stroked, due to charge pressure going past the pressure
relief to the pump servo system.

Anti-Crash and The slowdown/anti-crash module affects the thrust/pullback EDC control
Slowdown Circuits circuit. Based on inputs from the front and rear slowdown and stop switches,
the module slows down the carriage at each end of its travel, then cuts the
circuit at the appropriate travel limit to prevent overtravel.

2-Speed Solenoid The 2-speed solenoid shifts both carriage motors into low displacement
(HIGH speed) whenever the front vise is on.

Operation Correct operation of the system requires that the engine is turning at rated
RPM, oil supply is unrestricted to the charge pump, and the charge filter is
not restricting flow.

6-3
 System Specifications D36x50 Series II Navigator HDD Service

SYSTEM SPECIFICATIONS
The following
specifications are for the Specification Value
thrust/pullback system
in general. For individual General
component governed engine RPM 2400 rpm
specifications, refer to
the appropriate section Thrust/Pullback Force at Maximum Pump Pressure
in this manual. maximum thrust 33,000 lb (14969 kg)
maximum pullback force 36,000 lb (16329 kg)
Pump
make/model Sundstrand 90 series
specification number .................... 90R055 KP1CD 80P3S1 C00GBA 424224
pressure limiter setting (multifunction valve) for 4900 psi (338 bar)
PULLBACK
multifunction valve pressure setting (THRUST) 3100 psi (214 bar)
thrust limiter setting (RockFire mode) for 400-3000 psi (28-207 bar)
THRUST
Thrust/Pullback

displacement per revolution 3.35 cid (55 cc)

nominal flow @ 2400 rpm 33 gpm (2.28 L/min)
maximum allowable case pressure (cold) 73 psi (5 bar)
maximum allowable case pressure (normal 44 psi (3 bar)
operating temperature)
Charge Pump (oil temperature must be 120°F (50°C) or more)
displacement per revolution 0.86 cid (14 cc)
relief pressure setting (check in NEUTRAL) 350 ± 25 psi (24 ± 1.7 bar)
@ 1750 rpm
nominal flow at 2400 rpm 7.6 gpm (.524 L/min)
maximum continuous inlet vacuum 9.8 in Hg (0.7 bar absolute)
maximum cold start inlet vacuum (at reduced maximum pump speed) 24.1 in
Hg (0.5 bar absolute)

6-4
D36x50 Series II Navigator HDD Service Hose Connections

HOSE CONNECTIONS

FRONT
MOTOR
MH1 SUCTION LINE
RETURN LINE
PRESSURE/RETURN LINE
PRESSURE LINE
CHARGE PRESSURE LINE
FLOW DIRECTION

REAR

Thrust/Pullback
MOTOR
MH2

RETURN
MANIFOLD
A12

PUMP PMP2

THRUST LIMITER
GAUGE SHUTTLE VALVE MANIFOLD
VALVE SV2 A11

6-5
 Hose Connections D36x50 Series II Navigator HDD Service

Hoses

Hose ID/ Circuit Function

Pressure Type

Thrust/Pullback ‘A’
pullback: high side pressure
thrust: low side pressure
Remote Gauge ‘A’ or ‘B’
‘A’ or ‘B’ side loop pressure
Remote Gauge GA2
‘A’ or ‘B’ side loop pressure
Thrust/Pullback ‘B’
thrust: high side pressure
pullback: low side pressure
Pump Case Drain
nominal pressure
Servo Limit B
Thrust/Pullback
closed Thrust/pullback pump closed loop ‘A’ circuit to thrust/
loop pullback motors ‘A’ ports
gauge Provides’A’ or ‘B’ side loop pressure signal to gauge
shuttle valve SV2.
gauge Provides loop pressure signal from gauge shuttle valve
SV2 to the thrust pressure gauge GA2 at the operator’s
station.
closed Thrust/pullback pump (PMP2) closed loop ‘B’ port to
loop thrust/pullback motors ‘R’ ports
return Drains thrust/pullback pump case drain from pump L1
port (including excess charge flow) to tank.
pilot Provides signal from thrust limiter pressure relief to

nominal pressure destroke pump (PMP2); limits ‘B’ side only.

Suction suction Supplies oil to charge pump inlet from tank (RES1)
whenever engine is turning.
Rotation ‘B’ Pilot pilot Provides rotation ‘B’ pressure signal to thrust limiter
forward: high side pressure manifold A11.
reverse: low side pressure
*NOTE: under “NORMAL operating conditions,” the following pressures will be found in the circuits indicate
“high side” pressures = 300–6090 psi (20–420 bar)
“low side” pressure = 300–500 psi (20–35 bar)
“nominal pressure” = 25–100 psi (1.7–6.9 bar)
“charge pressure” = 350 psi (24 bar)

6-6
D36x50 Series II Navigator HDD Service Hose Connections

Hoses

Hose ID/ Circuit Function

Pressure* Type

Thrust ‘A’
thrust: low side pressure
pullback: high side pressure
Thrust ‘B’
thrust: high side pressure
pullback: low side pressure
Pump Case Drain
nominal pressure
Thrust 2-Speed Solenoid
charge pressure
Thrust 2-Speed Control
apply: charge pressure
closed Thrust pump (PMP2) closed loop ‘A’ circuit.
loop
closed Thrust pump (PMP2) closed loop ‘B’ circuit.
loop
return Routes pump case drain oil to return manifold A12.
pilot Provides charge pressure from rotation pump PMP1 to
shift thrust motors into high speed when thrust 2-speed
solenoid L3 is energized. Common circuit with Thrust
2-Speed Control when solenoid is de-energized.
pilot Shifts 2-speed thrust motors into high-speed/low-
displacement. Receives oil from rotation charge pump

Thrust/Pullback
release: nominal pressure when solenoid valve is energized.
Thrust 2-Speed Drain return Drains thrust 2-speed shift and flush oil to reservoir.
nominal pressure
*NOTE: under “standard operating conditions,” the following pressures will normally be found in the circuits
indicated:
“high side” pressures = 300–6000 psi (20–415 bar)
“low side” pressure = 300–500 psi (20–35 bar)
“nominal pressure” = 25–100 psi (1.7–6.9 bar)
“charge pressure” = 300–500 psi (20–35 bar) (same as “low side” pressure)

NOTE: In thrust mode, the pump ‘B’ port sends oil to the thrust motors ‘R’ ports; in pullback mode pump ‘A’
port sends oil to the thrust motors ‘A’ ports.

6-7
 Electrical Diagram - Thrust/Pullback D36x50 Series II Navigator HDD Service

ELECTRICAL DIAGRAM - THRUST/PULLBACK

SLOWDOWN/ANTI-CRASH
MODULE A16 EDC CONTROLLER
A18 ROCKFIRE CONTROL
FRONT STOP MODULE A14
SWITCH S3

FRONT SLOWDOWN
SWITCH S4

LOADER CRASH
SWITCH S7

GROUND
BUS TB1
REAR SLOWDOWN
SWITCH S8
Thrust/Pullback

REAR STOP
SWITCH S9

FUSE F7

THRUST EDC FUSE F6

FRONT VISE
CLAMP SWITCH S34

THRUST
LIMIT
ADJUST
L44
NORMAL ROCKFIRE WATER
ROCKFIRE VALVE ON/OFF RELAY K5
THRUST THRUST BRAKE TRIHAWK
LIMITER SOLENOID L4 SWITCH S23
ON/OFF
L29
SEAT SWITCH
RELAY K7
SPEED
SOLENOID THRUST PRESSURE
L3 INCREASE/DECREASE
SWITCH S20

FUSE F4 SEAT SWITCH

S6 FUSE F3

FRONT VISE
CLAMP SOLENOID
L15

MO

6-8
D36x50 Series II Navigator HDD Service Hydrostatic Pump (PMP2)

HYDROSTATIC PUMP (PMP2)

A

Thrust/Pullback Pump
(second from engine)

Thrust/Pullback
Operation
The closed loop hydrostatic pump provides oil flow from either the ‘A’ or the
‘B’ port to the thrust/pullback motors to allow variable speed, bi-directional
operation.

When working on closed loop components, special procedures and extreme

cleanliness standards are required The hydrostatic drive components are
precision-built to very close tolerances and operate at high pressures.
Cleanliness is extremely important when servicing a hydrostatic system.

The thrust/pullback charge pump fills the loop hoses and provides control
pressure. The right joystick control lever provides an electrical signal to the
pump EDC, which provides a hydraulic pressure signal that operates a servo
piston to “stroke” the pump (change the swashplate angle). The angle of the
swashplate in either direction from zero (neutral) determines pump output
and flow direction. A combined pressure limiter and pressure relief limits
pump output by destroking the pump or relieving excess flow.

6-9
 Hydrostatic Pump (PMP2) D36x50 Series II Navigator HDD Service

Port Locations
Thrust/Pullback

Port Function Recommended Gauge Size Fitting

M1 system pressure port ‘A’ 10,000 psi or 1000 bar gauge 9/16”–18 O-ring fitting
M2 system pressure port ‘B’ 10,000 psi or 1000 bar gauge 9/16”–18 O-ring fitting
M3 charge pressure (after filter) 1000 psi or 50 bar gauge 9/16”–18 O-ring fitting
M6 charge pressure (before filter) 1000 psi or 50 bar gauge 9/16”–18 O-ring fitting
M4 servo pressure 500 psi or 50 bar gauge 9/16”–18 O-ring fitting
M5
L1 case pressure 100 psi or 10 bar gauge 1-1/16”–12 O-ring fitting
L2
X1 EDC pressure 1000 psi or 50 bar gauge 7/16”–20 O-ring fitting or
X2 9/16”–18 O-ring fitting
X3 external control pressure 1000 psi or 50 bar gauge 9/16”–18 O-ring fitting
S charge pump inlet vacuum gauge—tee into inlet line 1-5/8”–12 O-ring fitting

6-10
D36x50 Series II Navigator HDD Service Charge Pump

CHARGE PUMP

CHARGE RELIEF

CHARGE PUMP

Operation
Charging the Closed Loop: The charge pump fills the loop hoses and other
components with oil during initial start-up.

Thrust/Pullback
Replenishing oil lost to leakage: The charge pump replaces oil lost to
leakage past component clearances.

Provides cooling and filtering: The charge pump replaces oil lost to
component leakage with cooled and filtered oil from the tank.

Pilot pressure for pump control systems: The charge pump provides
pressurized oil to position the swashplate.

Pilot Pressure for external systems: Rotation charge pump pressure is

used to activate thrust/pullback brake and to shift the thrust/pullback
motors.

The charge pump is a positive displacement gerotor pump that is attached to

the thrust/pullback pump. Oil is forced by atmospheric pressure through the
suction strainer in the tank, into the charge pump, through the charge filter,
and through the charge check valves to both sides of the loop (in neutral) or
the low side of the loop (when the pump is stroked). The remainder of the oil
goes across the charge pressure relief, into the pump case, and into the drain
circuit to tank.

6-11
 Multifunction Valves D36x50 Series II Navigator HDD Service

MULTIFUNCTION VALVES
1 2

1 2

Operation
Thrust/Pullback

A multifunction valve is used in each closed loop port to limit the system
pressure and to allow charge oil to keep the closed loop filled. Three
functions of the multifunction valves are:

Pressure relief (1): If the closed loop oil pressure exceeds 6000 psi, it goes
over relief until the multifunction valve destrokes the rotation pump.

Pressure limiter (2): The multifunction valve pressure limiter sends a

pilot signal to destroke the pump (i.e. to reduce swashplate angle). The
pump maintains pressure but there is almost no flow.

Charge inlet (3): Each multifunction valve has a check valve inside which
allows charge pump oil to keep the low side of the loop filled and
pressurized.

6-12
D36x50 Series II Navigator HDD Service Thrust/Pullback Controls

THRUST/PULLBACK CONTROLS
ROCKFIRE DRILL PRESSURE TRIHAWK/ROCKFIRE DRILL SWITCH S23
SWITCH S20

FRONT VISE SWITCH S34

THRUST/PULLBACK JOYSTICK

Thrust/Pullback
Operation Overview
Control of the thrust/pullback function consists of four basic circuits:

1. The EDC controller circuit (thrust joystick) controls speed and

direction of the thrust/pullback motors.
2. The slowdown/anti-crash circuit varies the EDC control signal to
slow or stop carriage travel to prevent overtravel and to prevent rod
loader damage.
3. The thrust limiter circuit uses a hydraulic feedback loop to limit the
amount of pressure available to the thrust motors during RockFire drill
or Trihawk drill operation.
4. The 2-speed motor circuit shifts displacement of hydraulic motors
MH1 and MH2 to provide 2-speed operation of the thrust/pullback
carriage: low speed during thrust and pullback, high speed when
changing rods.

6-13
 Thrust/Pullback Joystick D36x50 Series II Navigator HDD Service

THRUST/PULLBACK JOYSTICK

keyway keyway

7 8 9 10 11 12

6 5 4 3 2 1

THRUST/PULLBACK JOYSTICK
Push - drillhead forward (thrust)
Pull - drillhead retract (pullback)
Thrust/Pullback

Controller Pin Identification

Pin Wire I.D. Type Function

1 344 GND Supplies ground from terminal buss TB1 pin ‘3’ through wire 344 to
EDC controller A18 terminal ‘1’.
2 852 control Carries EDC control current for forward thrust from/to EDC
controller A18 terminal ‘2’.
3 858 control Carries EDC control current for pullback from/to EDC controller A18
terminal ‘3’.
4 752B +12V +12V (from seat switch) to EDC controller A18 terminal ‘4’.
7 772 --- supplies signal from EDC controller A18 terminal ‘7’ to fleet
management connector

6-14
D36x50 Series II Navigator HDD Service Thrust/Pullback Joystick

keys

Harness Connector Pin Identification

Pin Wire I.D. Type Function

1 344 GND Supplies ground from terminal buss TB1 pin ‘3’ through wire 344 to
EDC controller A18 terminal ‘1’.
2 852 control Carries EDC control current for forward thrust from/to EDC
controller A18 terminal ‘2’.
3 858 control Carries EDC control current for pullback from/to EDC controller A18
terminal ‘3’.
4 752B +12V +12V (from seat switch) to EDC controller A18 terminal ‘4’.

Thrust/Pullback
7 772 --- supplies signal from EDC controller A18 terminal ‘7’ to fleet
management connector

6-15
 Thrust/Pullback Joystick D36x50 Series II Navigator HDD Service

EDC Control Circuit

SEAT SWITCH
S26

THRUST JOYSTICK A18

Thrust/Pullback

TO FLEET MANAGEMENT
CONNECTOR

SLOWDOWN/ANTI-CRASH
MODULE A16
TO
GROUND
THRUST PUMP
EDC

FUSE F6

The EDC control circuit uses the thrust/pullback joystick to control oil flow
and direction from the pump. Voltage from fuse F6 is sent through seat
switch S26 to pin 4 of the right joystick connector then to pin 4 of the EDC
controller in the joystick. The EDC controller sends a current signal on wire
852 and 858 through pin 2 and 3 of the joystick connector, through pin 9 and
10 of the slowdown/anti-crash module, through pin 12 and 13 of the 24 pin
connector to the AB coil of rotation pump EDC. This causes the pump to
stroke in forward or reverse.

6-16
D36x50 Series II Navigator HDD Service Thrust/Pullback Joystick

EDC Ground Circuit

EDC CONTROLLER
A18
THRUST PUMP EDC

GROUND BUSS

FROM
ROTATION
PUMP EDC

The EDC circuit ground path is from the EDC controller pin 1 to the console
ground buss.

Thrust/Pullback

6-17
 Slowdown/Anti-Crash Circuit D36x50 Series II Navigator HDD Service

SLOWDOWN/ANTI-CRASH CIRCUIT
SLOWDOWN/ANTI-CRASH
FRONT STOP MODULE A16
SWITCH S3

FRONT SLOWDOWN
SWITCH S4

LOADER CRASH
SWITCH S7
Thrust/Pullback

REAR SLOWDOWN
SWITCH S8 BUS TB1

FUSE F6

REAR STOP
SWITCH S9

THRUST EDC

6-18
D36x50 Series II Navigator HDD Service Slowdown/Anti-Crash Circuit

Operation
Slowdown The slowdown/anti-crash module slows or stops carriage travel by varying
EDC control current. The slowdown switches close whenever the carriage is
close to either end. The closed switch sends a +12V signal to the slowdown/
anti-crash module which then limits the current being sent through the
EDC circuit to the EDC on the thrust/pullback pump.

Stop When either the front or rear stop switch is closed by the carriage reaching
the end of its intended travel, the stop circuit prevents a signal to the pump
EDC. The closed switch sends a +12V signal to the slowdown/anti-crash
module which then stops the current being sent through the EDC circuit to
the EDC on the thrust/pullback pump. This prevents any further carriage
travel by cutting off current flow.

Anti-Crash If the slowdown/anti-crash module receives +12V signal from the magnet
switch indicating the rod loader arms are in the way of carriage travel, the
anti-crash circuit of the slowdown/anti-crash module shuts off current to the
thrust/pullback pump EDC.

Thrust/Pullback

6-19
 RockFire/Trihawk Pressure and Mode Switches D36x50 Series II Navigator HDD Service

ROCKFIRE/TRIHAWK PRESSURE AND MODE SWITCHES

ROCKFIRE CONTROL
MODULE A14

BUS TB1
GROUND

NORMAL ROCKFIRE
TRIHAWK SWITCH S23

ROCKFIRE WATER
VALVE ON/OFF RELAY K5
Thrust/Pullback

THRUST PRESSURE
INCREASE/DECREASE FUSE F4
SWITCH S20

PUMP PMP2

THRUST
LIMITER
ON/OFF
L29

THRUST LIMIT
ADJUST SOLENOID
L44

6-20
D36x50 Series II Navigator HDD Service RockFire/Trihawk Pressure and Mode Switches

ROCKFIRE/TRIHAWK PRESSURE AND MODE SWITCHES

TRIHAWK/ROCKFIRE DRILL SWITCH S23

Push Top - RockFire Drill
Centered - normal
Push Bottom - Trihawk Drill

ROCKFIRE DRILL PRESSURE SWITCH S20

Push Top - increase maximum thrust limiter pressure
Push Bottom - decrease maximum thrust limiter pressure

Thrust/Pullback
THRUST LIMITER
Operation The thrust limiter ON/OFF solenoid is energized by the drill mode switch in
either the ROCKFIRE or TRIHAWK mode. This applies ‘B’ side loop
pressure to the pump servo whenever the pressure exceeds the pressure
setting of the variable pressure relief. (Pressure is not limited when the drill
mode switch is in NORMAL mode.)

The variable pressure relief solenoid uses a pulse-width modulated (PWM)

signal from the RockFire module to increase the pressure relief setting. If no
current is applied by the RockFire module, the pressure relief remains at its
basic setting, which limits the thrust pressure to a very low level. If the
operator closes the INCREASE contact of the RockFire drill pressure switch,
the RockFire drill module responds by sending a PWM signal to raise the
pressure relief setting.

NOTE: See the following sections for circuit diagrams.

The thrust limiter is normally non-passing (closed). Under normal drilling

conditions the circuit is de-energized and the limiter is not applied. When
the drill mode switch is in ROCKFIRE or TRIHAWK mode, the circuit is
energized and the thrust limiter is applied.

6-21
 2-Speed Carriage Control Circuit D36x50 Series II Navigator HDD Service

2-SPEED CARRIAGE CONTROL CIRCUIT

FUSE F7

FRONT VISE
CLAMP SWITCH S34

GROUND BUS
TB1
2- SPEED
SOLENOID L3

Power from the vise fuse F7 is provided to 2-speed solenoid L3 from the front
vise switch S34 whenever the front vise is clamped. The 2-speed shift
Thrust/Pullback

solenoid applies shift oil (rotation charge pump pressure) to the shift ports of
2-speed motors MH1 and MH2.

6-22
D36x50 Series II Navigator HDD Service Troubleshooting the Hydrostatic Circuit

TROUBLESHOOTING THE HYDROSTATIC CIRCUIT

Pump PMP2 provides flow for the thrust/pullback loop, through ports A and
B.
IMPORTANT: Check fluid level in the tank. Low fluid can contribute to a
number of hydraulic problems. If it is low, add clean fluid that has been
pumped through a 5-micron filter to bring the fluid up to proper level. New
fluid, direct from the drum or bulk tank, has accumulated contaminants
while stored in the drum or bulk tank. Always filter new fluid before adding
it to any hydraulic system.

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

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

To replace the hot oil taken from the loop, the charge pump draws cool oil out
of the tank (through a suction filter), pushes it through the high pressure

Thrust/Pullback
filter and adds it to the low pressure side of the loop.

Any contamination in the oil will cause wear to both the pump and the
motors. As they wear, the clearances between moving parts in both pump
and motors increase, allowing more oil to pass out of the loop into the cases.
Monitoring component case drain flow will give a general indication of wear.

When troubleshooting any problem involving the thrust/pullback function be

aware that:
• If the Remote Lockout system is in LOCKOUT mode, drill functions are
disabled. Check lockout indicators on the console.
• If the seat is not occupied, seat switch S6 is open, the machine is not in
DRILL mode.
• If the front stop switch S3 or rear stop switch S9 is closed, the slowdown
and anti-crash module will not allow the gearbox carriage to travel any
farther toward that switch. It is however, allowed to move away from
that switch.
• If the front slow switch S4 or rear slow switch S8 is closed, the controller
will slow the movement of the gearbox in that direction.
If the gearbox will not move forward beyond the rear slow switch, the
controller may be receiving a signal from the loader anti-crash switch S7,
indicating that the rod loader arms are extended into the travel area of the
gearbox.

6-23
 Troubleshooting the Hydrostatic Circuit D36x50 Series II Navigator HDD Service

Indicators Used For Troubleshooting Closed Loops

Five primary clues combined with four measurements reveal most problems
found in closed loops hydraulic circuits.

The five clues are observed during normal operation of the machine. The five
clues are:

• noise
• temperature
• movement
• control
• torque

The four measurements can be taken when troubleshooting the thrust/

pullback hydraulic loop. The four measurements are:

• inlet restriction
• charge pressure
Thrust/Pullback

• system pressure
• case pressures

Pump Noise Shrieking noises from the pump or charge pump indicate cavitation or
pseudo-cavitation. Shut down until the situation is remedied.

Cavitation will be indicated by high inlet restriction.

Pseudo-cavitation will be indicated by foam in the oil tank, which is usually

caused by a hole or loose fitting in the suction line between the charge pump
inlet and the tank.

6-24
D36x50 Series II Navigator HDD Service Troubleshooting the Hydrostatic Circuit

Fluid Temperature The temperature of the hydraulic oil should not exceed 180°F (82°C) for an
extended length of time. High heat indicates a malfunctioning component in
a hydraulic system. Either the oil cooling circuit is not functioning efficiently
and the normal heat due to work is building up, or excess heat is being
generated by oil passing over a relief valve or excessive internal leakage in a
component.

Causes of high heat include:

• low oil level in the tank— add clean, filtered oil if needed
• clogged oil cooler—hot oil bypassing directly to the tank
• excessively dirty fins on the oil cooler—preventing heat exchange—clean
fins
• low charge pressure—charge pump pushing cool oil out over charge
pressure relief
• low setting on high pressure relief valves—heat is added to oil when
crossing relief valves and lower settings allow more oil to cross at a lower
pressure.
• high system pressure—increased workload due to failed mechanical

Thrust/Pullback
components such as bearings or linkages increase the working pressure
of the circuit.
• excessive internal leakage in pump and motors

Movement—One Inspect the electrical circuits that apply, and troubleshoot circuits involved
Direction Only directly with operating the malfunctioning motors.

Possible causes include:

• faulty EDC module— If voltage output to the EDC changes in response

to joystick movement, the joystick is supplying voltage but the EDC is
not responding.
• failed charge and high pressure relief
valve—on the pump are two valves
called the “charge check and high
pressure relief valve” or multifunction 2
valves. Valve (1) controls thrust, and
valve (2) controls pullback.
1
Shut down the machine and swap the
two and see if the non-functioning
direction changes. If so, remove and clean the malfunctioning valve or
replace it.

6-25
 Troubleshooting the Hydrostatic Circuit D36x50 Series II Navigator HDD Service

Movement—Neither Determine if only the thrust/pullback motors are affected. If they are,
Direction suspect the pump and continue below. Otherwise, review interlocks that
apply, and troubleshoot circuits involved directly with operating the
malfunctioning motor(s).

Possible causes include:

• Joystick output not reaching the EDC—verify output from joystick.

• faulty pump EDC module
• insufficient charge pressure—check in neutral, forward, and reverse. See
"Charge Pressure Measurement," page 6-33. If low only in neutral (or
neutral and forward/reverse), replace charge pressure relief valve in the
pump. If charge pressure remains low, replace charge pump.
• Faulty multifunction valves not allowing sufficient pressure to build to
operate the motors. Observe pressure gauge for thrust/pullback on the
console. Maximum pressure indicated should be 3100 psi (213 bar) in
thrust mode and 4900 psi (337 bar) in pullback. Otherwise, replace
multifunction valves.
• internal leakage in pump and motor not allowing sufficient circuit
Thrust/Pullback

pressure to build to do the work. Conduct case pressure tests ("Case

Pressure Measurement," page 6-35) and replace pump and motor if
needed.

6-26
D36x50 Series II Navigator HDD Service Troubleshooting the Hydrostatic Circuit

Movement— If a motor continues to move slowly when the control handles are centered:
Gearbox Creeps in
Stop 1. Follow "Shutdown Procedure," page 2-1 and unplug EDC at harness
connection from the pump.
2. Restart engine and use the
manual controller on the
EDC (1) and attempt to find
neutral.
NOTE: The center pump PMP2 1
controls thrust and pullback.

If you can start and stop the

motors with the manual control
lever, the pump is OK and the
problem lies in the EDC or the
signal from the joystick to the
EDC. Null the EDC (see the
following steps).

Thrust/Pullback
If you cannot stop the creep with
the manual control lever, the
pump needs to be replaced.

6-27
 Troubleshooting the Hydrostatic Circuit D36x50 Series II Navigator HDD Service

Nulling the Pump

WARNING: Pressurized fluid can penetrate body tissue and result in

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

1. Install a 500 psi test gauge at the servo port.

2. Install another 500 psi test gauge in other servo
port, directly opposite from the first gauge.
3. Loosen lock nut on the null adjustment screw (2).
Thrust/Pullback

4. Unplug EDC from the harness.

5. Start machine and run it at low idle. Allow
system to warm up for a few minutes. Slowly
speed up engine to maximum 2350 rpm.
6. Using an Allen wrench, rotate null adjustment
screw until both gauges show the same pressre.
7. Rotate adjustment screw one way or the other
until gauge shows an increase in pressure. Note
location of the Allen wrench handle in relation to
the adjusting nut. (Example: Handle is at the
“1:00 clock” position.)
8. Rotate adjustment screw the opposite way until
the other gauge shows an equal increase in pressure. Count the turns
and note location of the Allen wrench handle in relation to the adjusting
nut. (Example: Handle is at the “7:00 clock” position.)
9. Turn Allen wrench back the other way one half distance. (Example: Turn
it 3/4 turn if distance from first to second mark was 1-1/2 turns.)
10. Tighten locking nut and reconnect EDC to the harness. Remove gauges
and replace cap screws.

6-28
D36x50 Series II Navigator HDD Service Troubleshooting the Hydrostatic Circuit

Control—Response If the motors react slowly to control inputs:

is Sluggish
1. Follow "Shutdown Procedure," page 2-1 and unplug the EDC on PMP2.
2. Restart engine, and have an operator sit in the seat to put machine in
DRILL mode.
3. Use lever (1) to adjust pump
output.
4. Operate the thrust/pullback
motors.
If the motors’ speed and
direction react normally to 1
inputs from the manual control,
the problem lies in the joystick
controller, or the EDC. Check
joystick output to the EDC
controller on the pump.

If the motors react sluggishly to

Thrust/Pullback
the manual control, the problem
is hydraulic.

6-29
 Troubleshooting the Hydrostatic Circuit D36x50 Series II Navigator HDD Service

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

• partially open bypass valve—verify it is turned in.

Checking Bypass Valves
The bypass function is performed by the
multifunction valve cartridges (1) on the
hydrostatic pump.

Pressurized oil is allowed is to escape the

high pressure side of the circuit if the bypass
valve is open. Ensure both bypass valves are
closed.
Thrust/Pullback

1. Place a 5/8″ wrench on the center hex (2)

on the bypass valve.
2. With moderate hand pressure on the
wrench, attempt to tighten the hex
(rotate clockwise). 2

If it tightens, it was partially open. If it will

not tighten, it was closed.

• insufficient charge pressure—check in neutral and forward and reverse.

See "Charge Pressure Measurement," page 6-33. Then note the following:
• If low ONLY in neutral, replace charge pressure relief valve in the
pump. If charge pressure remains low, replace pump.
• If low in neutral AND forward/reverse, remove and check charge
pressure relief valve in the pump. If charge pressure remains low,
replace the pump.
• internal leakage in pump and motor—perform case pressure test on the
pump. See "Case Pressure Measurement," page 6-35.

6-30
D36x50 Series II Navigator HDD Service Troubleshooting the Hydrostatic Circuit

Motor Torque
Motor torque is a function of pressure in the high side of the loop less the
pressure in the low side of the loop.

Pressure on the high side of the loop is a result of resistance provided by the
work being done. For this function the work is moving the gearbox carriage
back and forth.

The pressure on the low side of the loop is the charge pump pressure setting,
350 psi (24 bar). Check charge pressure (see "Charge Pressure
Measurement," page 6-33).

If torque is suspected to be less than acceptable, visually inspect to find a

reason. Is there leakage at shaft seals? Also ensure check bypass valve is
closed ("Checking Bypass Valves," page 6-30).

If no visual reason is apparent, it may be that the moving parts in the pump
and motors are worn to the point that there is excessive internal leakage.
Internal leakage in a pump or motor can be assessed with a case drain test
on that component when circuit is at maximum pressure.

Thrust/Pullback

6-31
 Troubleshooting the Hydrostatic Circuit D36x50 Series II Navigator HDD Service

Charge Pump Inlet Restriction Measurement

1. Disconnect charge pump
inlet hose (1). Plumb in a
T-fitting and connect a 30″ 1
Hg vacuum gauge to the
fitting.
2. Refill charge pump inlet
hose with hydraulic fluid
and reconnect charge pump
inlet hose to the fitting and
pump.
3. Connect a 600 psi test gauge
to the thrust/pullback charge
pressure diagnostic port (2).
4. Disconnect fuel solenoid and use the
key switch to turn the engine until
the charge pressure begins to rise.
2
Thrust/Pullback

5. Start engine and run it at the lowest

possible speed until charge pressure
reaches 300 psi or more. Then run
engine at 2350 rpm.
6. Have an assistant run the controls to move gearbox carriage forward and
back as you observe vacuum gauge in forward (thrust), in reverse
(pullback) and in neutral (stopped).
Expected result: When the oil is warm (100°F/38°C or greater) the gauge
should not indicate more than 5″ Hg. When the oil is cold, it should not
indicate more than 10″ Hg. If it does, check sump strainer for
contaminate buildup.
NOTE: To remove vacuum gauge at the conclusion of the test, follow steps 1
through 6 again, but remove the T-fitting and vacuum gauge in step 1. Steps
4 and 5 are required to safely start up the pump whenever any of its hoses
have been disconnected and reconnected. To remove charge pressure gauge,
shut down, disconnect gauge and replace dust cap on the diagnostic port.

6-32
D36x50 Series II Navigator HDD Service Troubleshooting the Hydrostatic Circuit

Charge Pressure Measurement

Charge pressure should be 350 psi, ± 10 psi (23 bar, ± 0.5 bar). If higher,
change charge filter and check pressure relief valve (see "Charge Pump Relief
Valve Inspection," page 5-41. If lower, review reasons below.

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

inlet restriction, or wear in the pump.
• The charge pressure relief valve may be opening at a lower pressure.
• There may be cross port leakage in the valves in assembly A2, allowing
charge pump flow to drain to tank.

The following procedure measures the charge pressure and helps determine
possible cause of low pressure.

1. With the machine shut down, attach

a 600 psi test gauge to the diagnostic
port (1).
2. Have an assistant sit in the

Thrust/Pullback
operator’s seat and start the
machine, following the normal
starting procedure and run the 1
engine at idle while you inspect and
verify that there are no leaks where
the test gauge is connected to the
diagnostic port.
3. Run engine at 2350 rpm. Charge pressure should read 350 psi, ± 10 psi
(23 bar, ± 0.5 bar). Needle may drop briefly, but it must recover to this
range.

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

("Charge Pump Inlet Restriction Measurement," page 6-32). If the inlet
restriction is within limits, replace pump.

6-33
 Troubleshooting the Hydrostatic Circuit D36x50 Series II Navigator HDD Service

Function Pressure Measurement

A gauge is provided on the machine to
measure system pressure for the 1
hydraulic circuit. The thrust/pullback
pressure gauge (1) is mounted on the
drill operator’s control console.

If pressure exceeds 3100 psi (213 bar)

during thrust—remove, inspect, and
clean or replace multifunction valve at
port A.

If pressure exceeds 4900 psi (337 bar) during pullback—remove, inspect, and
clean or replace multifunction valve at port B.

WARNING: Pressurized fluid can penetrate body tissue and result in

serious injury or death. Leaks can be invisible. Keep away from any
suspected leaks. Relieve pressure in the hydraulic system before searching
for leaks, disconnecting hoses, or performing any other work on the system.
Thrust/Pullback

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.

For information on multifunction valve removal and installation, see

"Multifunction Valves," page 6-40.

6-34
D36x50 Series II Navigator HDD Service Troubleshooting the Hydrostatic Circuit

Case Pressure Measurement

Some fluid leaks through the clearances between the moving parts of the
pump. When the pump is working against greater pressure, leakage
increases. Leakage collects in the case and is drained away through a case
drain line that connects port L1 of pump PMP2 to return manifold A12.

If leakage becomes so great that the continuous case pressure exceeds 40 psi
(3 bar), replace pump PMP2. See "Pump PMP2," page 6-43.

Pressure in the case is allowed to

momentarily spike up to 75 psi (5.2 bar)
during cold starts, but must fall back
within the 40 psi (3 bar) limit after the
system has warmed to operating
temperature.

1. With the machine shut down,

remove plug (1) and attach a 160
psi pressure test gauge to the case.

Thrust/Pullback
2. Start machine, and run it at idle as
you check the connection for leaks. 1
Tighten if needed.
3. Run engine at normal operating speed and operate the thrust/pullback
function while watching the gauge. Record the highest reading.
4. Shut down, remove gauge and reinstall plug.

6-35
 Troubleshooting the Hydrostatic Circuit D36x50 Series II Navigator HDD Service

Case Drain Flow Measurement

This test requires a 10 gpm flow meter
1
and a calculator. Conduct this test with
a rod loaded in the machine.

1. With the machine shut down,

disconnect case drain line hose at
port D of return manifold A12.
2. Connect a 10 gpm flow meter to the
case drain line and the tank.
Ensure flow arrow on the meter is
pointing to the tank.

3. Ensure pump is at full displacement (joystick fully back), and note

carefully the engine speed at the moment you note the indicated flow.
Have the assistant start and operate the machine while you observe the
flow meter.
Thrust/Pullback

4. Observe and record the highest flow shown on the flow meter, and engine
speed on the tachometer when the thrust/pullback motors are moving at
highest speed (mid rack), under as great a load as conditions allow, with
the thrust/pullback joystick fully forward or fully back.
5. Shut down machine, remove flow meter and reconnect case drain line to
manifold A12. Analyze results.

6-36
D36x50 Series II Navigator HDD Service Troubleshooting the Hydrostatic Circuit

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

This is a piston pump, with an expected volumetric efficiency of 97–98%

when new—meaning they internally leak 2–3% of flow at working pressure.
Pumps are considered worn beyond useful life when their volumetric
efficiency declines to 70% (30% internal leakage).

This pump is 3.35 in3 displacement. The engine will pull down as a load is
placed on the system, so it is important to use the actual speed at the time
the flow was noted.

• Multiply the speed (RPM) noted in the test times 3.35 to obtain
theoretical flow from the pump, in cubic inches per minute.
• Divide this by 231 to express this volume in gallons per minute (gpm).
• Multiply this by 0.30 to see the maximum allowable leakage for this
engine speed.
• Example: If the speed was 2350 rpm at the highest flow...

Thrust/Pullback
3.35 in3 x 2350 rpm = 7872.5 in3/min
7872.5 in3/min ÷ 231 = 34 gpm
34 gpm x 0.30 = 10 gpm max allowable case drain flow at 2350 rpm

If actual case drain flow is greater than the maximum allowed at that
engine speed, replace pump PMP2 (see "Pump PMP2," page 6-43).

6-37
 Troubleshooting the Hydrostatic Circuit D36x50 Series II Navigator HDD Service

Testing Joysticks
The joysticks are potentiometers sending analog information (varying
voltage) to the pump EDC.

1. Disconnect 12-pin connector at the base of the joystick. Attach 12-pin

connectors of the breakout box to the joystick plug and the harness jack.
2. Turn key switch on and sit in the seat.
3. Measure voltage from 1 to 2 on the breakout box while moving the
joystick slowly forward, and slowly back.
Expected result: 2.5 volts DC when the joystick is centered (NEUTRAL),
zero volts DC when fully back and 5 volts DC when fully forward. If so,
joystick appears to be operating normally.

If there is no voltage, go to step 4.

If there is voltage, but it does not vary with stick position as described,
replace joystick.
Thrust/Pullback

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

6-38
D36x50 Series II Navigator HDD Service Troubleshooting the Hydrostatic Circuit

Testing Proximity Switches

1. Position gearbox midway on the rack so the faces of all four proximity
switches are visible.
2. Disconnect switch from the harness, and measure voltage from pin 4 to
pin 3 in the harness jack.
Expected result: 12 volts DC, ± 1.2 vDC. If so, continue below. If not, test
continuity on harness segments from pin to the ground and pin 4 to fuse
F6. Repair or replace faulty harness segment.

3. Test continuity on the switch plug from pin 4 to pin 3 while closing the
switch.
Expected result: Continuity when switch closes. Open when switch is
released. If so, continue below.

If not, replace defective switch.

4. The fault appears to be in the harness from the switch connection to the
slow down anti-crash module. Consult diagram and test harness

Thrust/Pullback
segments for the wire leading from pin 3 of the switch jack. Repair or
replace the defective harness segment.

Adjusting Proximity The switch body is attached to the rack by bolts and kept secure with
Switch retaining nuts. To adjust a proximity switch, do the following:

1. Loosen the retaining bolts.

2. Move target surface used by this switch (gearbox carriage) over the
switch.
3. While testing continuity across the switch, adjust retaining bolts to move
the face of the switch close enough the carriage to close the switch.

6-39
 Multifunction Valves D36x50 Series II Navigator HDD Service

MULTIFUNCTION VALVES
Thrust/Pullback

WARNING: Pressurized fluid can penetrate body tissue and result in

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

Continued on next page...

6-40
D36x50 Series II Navigator HDD Service Charge Pressure Relief Valve PRL1

1. Use wrench to hold outer cartridge.

2. Turn bypass actuator out of outer cartridge.
3. Remove bypass actuator (1), spring (2), spring
seat (3), and check poppet (4) from the pressure
limiter housing (5). Inspect valve and mating seat
in the housing for damage or foreign materials. It
will be necessary to replace housing if the seat is
damaged.

5 4 6
3

2 1

Thrust/Pullback
4. Apply oil to O-ring (6) and install poppet, valve cartridge, spring, and
bypass actuator with O-ring into the housing. Torque the actuator to 20
ft-lb (95 Nm).

CHARGE PRESSURE RELIEF VALVE PRL1

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

6-41
 Adjusting Charge Pressure Relief Setting D36x50 Series II Navigator HDD Service

ADJUSTING CHARGE PRESSURE RELIEF SETTING

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

CHARGE PUMP REPLACEMENT

The charge pump on this model of drill cannot be purchased as a separate
unit. If charge pump fails, the pump and the charge pump must be replaced
as a unit.
Thrust/Pullback

6-42
D36x50 Series II Navigator HDD Service Pump PMP2

PUMP PMP2
1. Label and mark hoses prior to disassembly.
2. Drain the hydraulic tank.
3. Disconnect hoses from the implement pump. Plug or cap all open hose
ends and ports.

Thrust/Pullback
1

4. Remove four bolts (1) that attach manifold A9 to the implement pump.
Remove O-ring (2) and cap the pump port and the manifold port to
prevent system contamination.
5. Support implement pump PMP3 as you loosen and remove the two bolts
holding the pump support bracket to the pump support.
6. Remove the four bolts holding the implement pump to PMP2.
7. Remove implement pump and the O-ring between it and PMP2.
8. Support pump PMP2 as you loosen and remove the four bolts holding
PMP2 to PMP1. Remove PMP2. Also, locate and remove the O-ring
between PMP1 and PMP2. Plug or cap all open hose ends and ports.
Continued on next page...

6-43
 Pump PMP2 D36x50 Series II Navigator HDD Service

9. Disconnect hoses from the fittings on the pump. Plug or cap all open hose
ends and ports.
10. Support tandem pump as you loosen and remove the four bolts holding
the face of PMP2 to pump PMP1. Remove pump and O-ring between the
two pumps.
Thrust/Pullback

11. Transfer fittings from the old pump to the new pump. Cap all fittings as
they are installed to minimize contamination. Torque bolt for pump
support bracket to 20 ft-lb (27 Nm).
12. Apply grease to the splines on the pump drive shaft. Coat O-ring with oil
and install between pumps. Take care when bringing the mating
surfaces together to avoid pinching the O-ring. Align splines and slide
into coupling. Support tandem pump and install mounting bolts. Torque
mounting bolts to 90 ft-lb (122 Nm).
13. Connect hoses, snug connection with a wrench, but do not overtighten.
14. Attach charge filter assembly to PMP2. Do not overtighten the
connection.
15. Inspect O-ring removed between implement pump and thrust/pullback
pump. Coat new O-ring with clean oil or vaseline and install it.
Continued on next page...

6-44
D36x50 Series II Navigator HDD Service Pump PMP2

16. Apply grease to the splines on the implement pump driveshaft. Carefully
support implement pump and slide it into thrust/pullback pump so the
splines align. Be careful when bringing the mating surfaces together to
avoid pinching the O-ring.
17. Torque mounting bolts to 90 ft-lb (122 Nm). Install pump support
bracket with lower pump mounting bolts.
18. Install pump support bracket to pump support. Torque bolts to 90 ft-lb
(122 Nm).
19. Reconnect hoses to implement pump. Do not overtighten.
20. Coat O-ring with clean oil or vaseline and install it. Be careful when
bringing the mating surfaces together to avoid pinching the O-ring.
Install proportional dump valve manifold onto implement pump. Torque
mounting bolts to 35 ft-lb (48 Nm).

Returning System to 1. Refill tank to proper level with new fluid that has been filtered through a

Thrust/Pullback
Service 5-micron absolute filter.
2. Disconnect engine fuel solenoid L7.
3. Attach a 600 psi test gauge to the
test port on manifold A8.
4. Have an assistant crank the engine
while you watch the test gauge. Do
not crank longer than 30 seconds and
wait at least one minute before
cranking again.
5. When gauge indicates 350 psi, ± 10
psi (23 bar ± 2 bar), charge pressure
is restored. Reconnect solenoid L7
and remove test gauge.

If pressure indicated is not 350 psi, ± 10 psi (23 bar ± 2 bar), inspect for
any leakage. Repair leaks if found. Otherwise, correct size or number of
charge pressure adjustment shims may not have been installed at pump
manufacturer. Contact Vermeer Service department for advice.
6. Start engine and run it at idle while inspecting hose connections and the
mating surfaces between PMP1 and PMP3 for leaks. Repair leaks if
found.

6-45
 Motor Removal/Installation D36x50 Series II Navigator HDD Service

MOTOR REMOVAL/INSTALLATION
Special Tools and Materials
• torque wrenches capable of producing 30 ft-lb (40 Nm) and 100 ft-lb (135
Nm)
Remove Motors

3
2
Thrust/Pullback

1. Level the rack and if possible, move the thrust/pullback carriage to the
back of the rack.
2. Follow "Shutdown Procedure," page 2-1.
3. Since you will be opening the hydrostatic closed-loop system, thoroughly
clean motors (1) and (2), as well as the rotation gearbox assembly (3).
Continued on next page...

6-46
D36x50 Series II Navigator HDD Service Motor Removal/Installation

Because cleanliness is 4. Label, remove and cap hoses and tube fittings.
extremely important,
cap or plug all of the
hoses, tubes and fittings

Thrust/Pullback
during disassembly.

6 5
1

2 3

Because cleanliness is 5. Label, cap, and remove hoses attached to the motor and brake assembly.
extremely important,
cap or plug all of the
hoses, tubes and fittings
during disassembly.
Continued on next page...

6-47
 Motor Removal/Installation D36x50 Series II Navigator HDD Service

4 2

WARNING: Clamp or block the thrust/pullback carriage to lock it in place, preventing the
carriage from moving if the rack is inclined. Serious crushing injuries may occur if struck
by moving carriage.

6. Remove ten bolts (1) for the motor being serviced. Lift motor from the
Thrust/Pullback

carriage.
7. Remove gear (2) by removing two screws (3), washers (not shown), and
plate (4).

6-48
D36x50 Series II Navigator HDD Service Motor Removal/Installation

Install Motors
1. Lift motors on the carriage. Gradually tighten ten bolts on each motor,
using a cross-pattern tightening sequence to evenly seat the motors.
Final torque the bolts to 180 ft-lb (244 Nm).

When connecting hoses 2. Install hoses in the following suggested order for the particular motor
and tubes to fittings,
carefully oil the threads
and seats so that
correct torque values
can be achieved as the
nuts are tightened.
Always use lightly
lubricated new O-rings
during assembly.
being serviced:
Hose Connections
Sequence Ports Torque
(4) ‘A’ (motor 1) to fitting 92 ft-lb (124.7 Nm)
(5) ‘R’ (motor 1) to fitting 92 ft-lb (124.7 Nm)
(6) ‘Y’ (motor 1) to ‘Y’ (motor 2) 19 ft-lb (25.8 Nm)
(7) ‘1’ (motor 1) to fitting 28.5 ft-lb (38.6 Nm)
(8) ‘T2’ (valve) to ‘1’ (motor 1) 19 ft-lb (25.8 Nm)
(9) ‘A’ (motor 2) to fitting 92 ft-lb (124.7 Nm)

Thrust/Pullback
(10) ‘R’ (motor 2) to fitting 92 ft-lb (124.7 Nm)
(11) ‘1’ (motor 2) to fitting 28.5 ft-lb (38.6 Nm)
(12) ‘B’ (valve) to ‘B’ (motor 2) 19 ft-lb (25.8 Nm)
(13) ‘Y’ (valve) to ‘Y’ (motor 2) 19 ft-lb (25.8 Nm)
(14) case drain (rotation gearbox) 28.5 ft-lb (38.6 Nm)
(15) ‘A’ (3-speed/loop flush valve) 87.5 ft-lb (118.7 Nm)
(16) ‘B’ (3-speed/loop flush valve) 87.5 ft-lb (118.7 Nm)

3. Remove clamps and blocks securing thrust/pullback carriage.

6-49
 Returning System to Service D36x50 Series II Navigator HDD Service

RETURNING SYSTEM TO SERVICE

The hydrostatic systems can be easily damaged by contaminants or by lack
of oil. After repairing a hydrostatic system, use the following procedure to
assure an adequate supply of oil to each part of the system.

• Fill tank with the recommended hydraulic fluid. Filter oil with a 5-micron
oil filter as it is added to the tank. Do not reuse hydraulic fluid.
• If replacing a hose, if possible, fill it with filtered oil before starting the
machine.
• Fill motor or pump case with oil before starting the machine.

IMPORTANT: Hydrostatic components can be destroyed if not filled with

oil before the engine is started.

Remove Trapped Air From Hydraulic Circuit

1. Start engine.
Thrust/Pullback

1
2. Locate four small Allen head screws
(1) on the brake of the thrust/
pullback motor.
3. Open screws several turns one at a
time to remove trapped air in the
circuit.
4. Tighten screw when oil is seen
seeping from around the screw head.

6-50
D36x50 Series II Navigator HDD Service Carriage Removal/Installation

CARRIAGE REMOVAL/INSTALLATION
Special Tools and Materials
• torque wrenches capable of producing range of 30 ft-lb (40 Nm) and 300
ft-lb (407 Nm)
• four 1/2" x 10" NC bolts
Remove Carriage

4 6

5
3
2 1

Thrust/Pullback
1. Remove thrust/pullback motors. Refer to "Motor Removal/Installation,"
page 6-46
2. Remove rotation gearbox. Refer to "Carriage Removal/Installation," page 6-
51
3. Disconnect and cap hoses (1) and (2). Remove four nuts (3), washers and
bolts, and remove hose carrier (4).
4. Attach lifting device to carriage at gearbox mounting tubes.
5. Remove bolts, washers (5) and end stop (6).
Continued on next page...

6-51
 Carriage Removal/Installation D36x50 Series II Navigator HDD Service

6 4

6. Loosen lock nut (1). Loosen lock nut (2) and back out bolt (3) to relieve
guide roller pressure on each side of the rack. Loosen four nuts (4)
(bottom rollers only) on each side of the rack.
7. Remove limit switch (5) by removing two mounting screws, four washers
Thrust/Pullback

(not shown) and two nuts (not shown).

8. Install a suitable lifting sling onto carriage (6) so it will be balanced
when slid off the rack. Attach an adequate lifting device to the sling, and
lift enough to remove the weight of the carriage from the rack.

WARNING: Clamp or block the thrust/pullback carriage to lock it in place, preventing the
carriage from moving if the rack is inclined. Serious injury may occur if struck by moving
carriage.

Continued on next page...

6-52
D36x50 Series II Navigator HDD Service Carriage Removal/Installation

1 1

1 1
2

9. Remove four bolts (1) and washers on the underside of mount (2),
replacing them with four 1/2 x 10” NC bolts (not shown) and washers.
Remove remaining bolts and washers, allowing the mount to rest on the
four 1/2 x 10” NC bolts.
10. Slide carriage from the rack.

Thrust/Pullback

6-53
 Carriage Removal/Installation D36x50 Series II Navigator HDD Service

Install Carriage

7 3

2
4 4
8

1 6 6
9

1. Install a suitable lifting sling onto carriage (1) so it will be balanced.

Attach an adequate lifting device to the sling, and slide the carriage onto
the rack.
Thrust/Pullback

WARNING: Clamp or block the thrust/pullback carriage to lock it in place, preventing the
carriage from moving if the rack is inclined. Serious crushing injuries may occur if struck
by moving carriage.

2. Torque four nuts (2) (bottom rollers only) on each side of the rack to 125
ft-lb (170 Nm).
3. Use bolt (3) on each side of the rack to adjust equal gaps (4) between the
carriage and rack plate. Then, set a clearance of 1/16" (2 mm) between
guide rollers (5) and rack edges (6). Tighten nut (7) and torque nut (8) to
300 ft-lb (407 Nm) on each side.
4. Install limit switch (9), using two mounting screws, four washers (not
shown) and two nuts (not shown). Tighten switch at the extreme top end
of the slot on the mounting bracket.
Continued on next page...

6-54
D36x50 Series II Navigator HDD Service Carriage Removal/Installation

5. Lift transport valve mount (1) up against the underside of the rack.
Remove 10 inch bolts and install eight bolts (2) and washers. Remove
clamps and blocks used to prevent the carriage from moving on the rack.

Thrust/Pullback
2 3
4

5 6

6. Lift hose carrier (1) into place. Apply Loctite 277 or similar product to
bolt threads and install four bolts, and washers (2). Torque bolts to 180
ft-lb (244 Nm). Install stop (3) using bolts and washers (4).
7. Install hoses (5) and (6), torquing them to 87.5 ft-lb (118.7 Nm).
8. Install rotation gearbox. Refer to "Install Carriage," page 6-54
9. Install thrust/pullback motors. Refer to "Install Motors," page 6-49
Continued on next page...

6-55
 Carriage Removal/Installation D36x50 Series II Navigator HDD Service

4
5

6 6 3

10. Clamp a rod in the rear vise. Verify that drive chuck (1) correctly
engages the rod end. If adjustment is required, loosen nuts (2) and (3) on
each side of the rack. Use adjustment bolts (4) to shift the carriage side
to side, centering the drive chuck to the rod end.
Thrust/Pullback

11. Once the drive chuck is centered, set a clearance of 1/16" (2 mm) between
guide roller (5) and rack plate edge (6) on each side. Tighten nuts (2)
and torque nuts (3) to 300 ft-lb (407 Nm).

6-56
D36x50 Series II Navigator HDD Service Overview

Chapter 7: Ground Drive

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

Circuit Components
The following components are used in the ground drive circuits.

Seat Switch S26

Seat Switch Relay K7
Drill/Track Solenoid L24
Drill/Track Valve DV27
Fuse F6
Left Brake Manifold A28
Right Brake Manifold A29
PFC Pump PMP3

Ground Drive
Pressure Relief Valve PV5
Right Track Control Valve DV11
Right Track Brake Valve DV32
Right Track Motor MH6
Left Track Control Valve DV10
Left Track Brake Valve DV31
Left Track Motor MH5

7-1
 Overview D36x50 Series II Navigator HDD Service

Circuit Schematic
LEFT TRACK RIGHT TRACK
TERIMINAL
BUS TB1 MOTOR MH5 MOTOR MH6

SEAT SWITCH
RELAY K7
LEFT TRACK RIGHT TRACK BRAKE
BRAKE VALVE VALVE DV32
DV31

SEAT SWITCH S26 A5

LEFT TRACK
VALVE
FUSE F6 DV10

RIGHT TRACK
VALVE
DV11
Ground Drive

RELIEF
PV5

VALVE
RELIEF VALVE MANIFOLD
SOLENOID L24 PV4
A9

DRILL/
TRACK
VALVE
DV27, TO WATER
PUMP MOTOR
PUMP PMP3
HYD. ENABLE
VALVE DV29,
SOLENOID L26

TO TANK FROM TANK

TO VISE, STAKEDOWN, TO TANK
GREASER, STABILIZER,
RODLOADER, WATER
FUNCTIONS

7-2
D36x50 Series II Navigator HDD Service Overview

Component Locations
LEFT GROUND DRIVE
CONTROL VALVE DV10

RIGHT GROUND DRIVE

CONTROL VALVE DV11

SEAT SWITCH S26

PFC PUMP
PMP3

LEFT TRACK
MOTOR MH6

Ground Drive
LEFT BRAKE RIGHT TRACK
VALVE DV31 MOTOR MH5

RIGHT BRAKE
VALVE MANIFOLD
A29
CHECK
VALVE CV7

LEFT BRAKE DRILL/TRACK VALVE

VALVE MANIFOLD A28
DV27, SOLENOID L24

RIGHT BRAKE
VALVE DV32 RELIEF VALVE
LOAD SENSE VALVE PV4
DV28, SOLENOID L25
VALVE FV9

Continued on next page...

7-3
 Overview D36x50 Series II Navigator HDD Service

PUMP PMP3
Ground Drive

7-4
D36x50 Series II Navigator HDD Service Overview

Hydraulic Connections
TO WATER
PUMP MOTOR

TO OIL TANK

VALVE PUMP
MANIFOLD PMP3
A9

FROM OIL TANK

CONTROL VALVE TO OIL TANK
A5

TO OTHER FUNCTION
VALVES

DIAGNOSTIC
PORT
TO MANIFOLD A12

RIGHT MOTOR
MH6

Ground Drive
LEFT MANIFOLD
MOTOR A28
MH5
MANIFOLD
A29

7-5
 Overview D36x50 Series II Navigator HDD Service

Circuit Operation
PFC Pump The Eaton PFC pump PMP3 supplies
1
pressurized oil to operate the ground
drive motors as well as the rod loader,
stabilizer, vises, stakedowns, and water
pump.
2

Pump PMP3 receives its load sense

signal at port S. The load sensing
function is triggered by metered oil flow
to the pressure/flow compensator (1)
from the ground drive valve manifold.

When the hydraulic system is not

actuated, the pump will remain in low
pressure standby mode which is set at 250 psi (17 bar).

When a hydraulic function is actuated, the pump receives pressure

information from the load sense lines coming from valve manifold A5. Pump
displacement changes to increase/decrease flow at the pressure required to
operate the circuit, plus 250 psi (17 bar) to operate the compensator.

The pump will respond to the highest pressure of all the functions and
provide the total flow required to operate multiple circuits. If demand
Ground Drive

requires the pump to produce a hydraulic pressure that is equal to the

pressure setting of the high pressure compensator (2), the pump will go into
high pressure standby mode and stay on full stroke until the load is
overcome or the control valve is returned to NEUTRAL.

7-6
D36x50 Series II Navigator HDD Service Overview

Ground Drive Valve The ground drive control valve assembly

A5
Assembly A4 A5 consists of two manually controlled
spool sections. Each section is
responsible for the control of a specific DV10
function. Valve DV10 controls the left
track function, and right track function
is controlled by DV11. When none of the DV11
functions are actuated, all valve sections
are held centered by springs.

Each valve section incorporates a load

sense ‘LS’ port which provides circuit
pressure to the ‘LS’ port on the PFC PV5
pump.

The valve assembly incorporates a pressure relief valve PV5 designed to

protect the hydraulic circuit components from excessive pressure. The valve
is set for a maximum 3500 psi (243 bar) system pressure. If a pressure spike
were to occur in the track hydraulic circuit during operation, the normally
closed valve will open, relieving the excess pressure to the tank and reducing
circuit pressure until it drops below 3500 psi (243 bar).

TB1

Ground Drive
TRACK/DRILL SOLENOID
L24

SEAT SWITCH RELAY K7

FUSE F8
SEAT SWITCH S26

Drill/Track Valve Drill/track solenoid L24 is located in manifold A9. It controls normally open
DV27, Seat Switch valve DV27 that allows PFC pump flow to ground drive valve manifold A5
Relay K7, Seat unless the seat switch S26 is closed. If an operator is on the seat, switch S26
Switch S26, closes which supplies voltage to track/drill solenoid L24. This energizes the
Solenoid L24 solenoid and closes valve DV27, which does not allow oil flow to ground
drive/rack valve A5.

7-7
 Overview D36x50 Series II Navigator HDD Service

Brake Valves DV31

and DV32 LEFT RIGHT
MOTOR MH5 MOTOR MH6

BRAKE BRAKE
CYLINDER CYLINDER

DV31 2 DV32 2

1 1
FROM DV10 FROM DV11

TO TANK

Whenever transport valve A5 shifts to send flow for track movement, supply
pressure is also applied to release brake units on the ground drive motors.
Circuit pressure in pilot passages (1) overcomes spring pressure (2) in brake
valves DV31 and DV32. When either valve that controls track function is
Ground Drive

moved to the forward or reverse direction, circuit pressure is applied to the

rod end of the brake cylinder. This retracts the brake cylinder, releasing the
brake. In the event of engine or rotation pump failure, the park brakes may
be released by applying pressure from a portable power source at
approximately 300 psi (20 bar), directly to the track brake at the brake hose
inlet.

The left and right track drive motors MH5 & MH6 receive oil flow from
transport valves DV10 & DV11. The motors provide rotational force to the
track drive sprockets through a planetary gear reduction. The spring-
applied, pressure release brakes hold the planetary stationary when the
machine is not being transported.

7-8
D36x50 Series II Navigator HDD Service Troubleshooting

TROUBLESHOOTING
Check Out Related Circuits and Components
• Always look for problems in common and related systems before doing
any difficult test procedures.
• Check hydraulic and electrical overall schematics and verify that fluid
conditioning components and engine/power components are OK.
• Operate electrical circuits that recieve power from the same circuit
breaker or switch; check the function of hydraulic circuits relying on the
same pump or control valve for hydraulic power.
• If a related function is not operating properly, repair those components
first, then proceed with troubleshooting if necessary.

Basic Troubleshooting Questions

1. Is there a mechanical problem? Check for bent, broken, or misadjusted
components. Is the track tension adjusted properly?
2. Are the machine common systems operating correctly? Are the related
circuits working correctly?

Ground Drive
3. PFC pump flow is shared with the vise, rod loader, stabilizer, stakedown
functions and water pump drive circuit. A malfunction in one circuit
could affect the other.
4. Ensure load sense pressure signal is getting back to the pump at port S
from the LS port of valve A5.
5. Are the controls working correctly? Are the hydraulic components
functioning correctly? Valve manifold A5 is supplied PFC pump pressure
from hydraulic drill/track valve DV27 in valve manifold A9. The PFC
pump and load sense functions must be working correctly.

7-9
 Troubleshooting D36x50 Series II Navigator HDD Service

Troubleshooting Electrical Circuits

Unless the problem is obvious, investigate these fundamental electrical-
related questions:

1. Is the power source (thermal fuse F6) OK? Electrical actuators such
as relays and coils may operate correctly down to as low as 10.8V, but
any system voltage measuring below 12.5V can be suspect, especially if
grounds are faulty.
2. Are the grounds OK? The circuit must be complete to ground (terminal
bus TB1), and the voltage drop in the ground circuit must be no higher
than 0.5V.
3. Is the current path complete? Many problems can be traced to a
broken wire or faulty pin connection in a plug.
4. Are all the switches OK? Seat switch S26 supplies power to activate
the drill/track solenoid L24.
5. Are all electrical actuators OK? Test the coil either in relay K7 or
drill/track solenoid L24; ensure the current path is complete and the
resistance is within tolerance.
6. Is the mechanical output OK? Even if all electrical components are
functioning properly, a valve may leak or fail to move, or relay contacts
may stick or not conduct current.
Ground Drive

7-10
D36x50 Series II Navigator HDD Service Troubleshooting

Troubleshooting the Hydraulic Circuit

Unless the problem is obvious, investigate these fundamental hydraulic-
related questions:

1. Can the pump deliver correct FLOW? Is the inlet restricted? Is the
pump worn out? Is the compensator correctly controlling pump stroke?
2. Is the system PRESSURE correct? Is the compensator set correctly? Is
the relief set correctly? Is load sense pressure reaching the pump from
valve A5?
3. Is the circuit delivering correct pressure to the actuator? Is a
variable signal based on function demand being delivered to the
compensator, either from a variable control such as the transport or
water control or from a solenoid valve through the load sense solenoid?
Are the actuators original equipment or correct replacements?
4. Are the motors functioning? Correct pressure and flow at the motor
ports will make the motors function properly unless the motors are worn,
defective, incorrect replacements, or otherwise defective.
5. Are the directional control valves operable? Flow must be applied
correctly to any actuator for it to function as designed.
6. Is there an abnormal resistance to work? Pressure in a hydraulic
circuit comes only from “line” (“circuit”) resistance or from “load”

Ground Drive
(“actuator”) resistance. Any change from normal will result in changed
performance.
NOTE: A dramatic change in operation between cold conditions and
warmed up conditions point toward pump or motor wear, since hot oil leaks
more quickly through loose clearances. Some electrically controlled circuits
using variable current proportional solenoids might also change with
temperature since current and temperature can be closely related.

Mechanical Components
Always check for mechanical malfunctions—such as defective bearings,
binding linkages, and loose fasteners.

7-11
 Troubleshooting D36x50 Series II Navigator HDD Service

O-Ring Installation

- - - -
Ground Drive

The diagram shows O-ring position information for most of the types of
cartridges used on the D36x50. Refer to the component sections in the
component chapters for O-ring positions for individual valve cartridges. The
diagram above shows the classification of positions for 2-way through 5-way
valves.

NOTE: Black elastomer backup rings are serviced in the field with single-
turn (white) Teflon (TFE) backup rings, since special tools are required to
install the black backup rings.

7-12
D36x50 Series II Navigator HDD Service Troubleshooting

Flow Test for PMP3

This test determines pump condition by measuring internal leakage when
the pump is under load.

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.

Set Up You will need a pressure flow test device, equipped with a 0–6000 psi
pressure test gauge, a flowmeter capable of reading 45 gpm in the middle of
its flow range, a needle valve and a handheld pyrometer.

Ground Drive
3

6
5 1

1. Disconnect and cap hoses at port TM and port LS1 of valve manifold (A9)
(1).
Continued on next page...

7-13
 Troubleshooting D36x50 Series II Navigator HDD Service

2. Install a T-fitting (2) at port TM of manifold (1). Attach one end of a 1-

inch diameter 3000 psi rated hose (3) to the fitting and the other end to
the inlet side of the flow meter (4). Ensure flow arrow is pointing away
from valve manifold A9.
3. Disconnect and cap hose attached to return manifold A12 at port B.
4. Install a 1'' hose (5) with a 3000 psi pressure rating between the outlet
port of the flowmeter and port B of return manifold A12.
5. Ensure needle valve on the flowmeter is fully open.
6. Connect a 3000 psi rated 3/8'' hose (6) to the fitting at manifold port TM.
Connect the other end of the hose to manifold port LS1.

Conducting the Test 1. Start engine and check all connections for leaks. Shut down and tighten
connections as needed to stop leaks.
2. Increase engine speed to 2400 rpm.
3. Use the pyrometer to ensure temperature of the fluid in the tank is at
least 100°F (38°C). If not, run gearbox forward and back to warm the
fluid.
4. Observe tachometer and record the engine RPM, flow indicated on the
Ground Drive

meter, and the pressure gauge at the beginning of the test.

5. Slowly turn in the needle valve on the pressure flow test device until the
pressure reaches 3000 psi (207 bar), then record the amount of flow
indicated.
6. Observe tachometer and record the engine speed while the pressure flow
test device is indicating 3000 psi (207 bar).
7. Shut down machine, remove equipment and review results. Reconnect
load sense lines and other hoses.

A: Beginning B: Ending (at 3000 psi or 207 bar)

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

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

A3: indicated pressure: _________________ psi (bar) B3: indicated pressure: ______3000 psi 207 bar____

7-14
D36x50 Series II Navigator HDD Service Troubleshooting

Understanding the The theoretical flow from this 4.52 cid (75 cc) pump, if run at 2400 rpm, is 47
Results gpm. This figure does not allow for any internal leakage. All pumps have
some internal leakage between the moving parts of the pump. Leakage
drains into the case of the pump. The case drain line carries this back to the
tank.

This is a piston pump. New piston pumps are expected to be about 97%
efficient, so expected flow at 2400 rpm at 3000 psi is 45.5 gpm for this pump
when new, and 33 gpm for a pump at the end of its useful life.

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

Calculating 1. Multiply value in B1 (ending engine speed) times 4.52 (displacement of

Theoretical Flow the pump). This is the theoretical flow in cubic inches per minute for this
and Acceptable engine speed.
Flow
2. Divide this amount by 231 to convert the cubic inches per minute to
gallons per minute.
3. Multiply this value by 0.70. The result is the minimum acceptable flow
from this pump at this engine speed.
Compare minimum acceptable flow value with the value recorded in B2. If
B2 is lower, the pump is worn beyond its useful life and should be replaced.

Ground Drive
See "PFC Pump PMP3," page 8-9.

7-15
 Troubleshooting D36x50 Series II Navigator HDD Service

SYMPTOM: Some Hydraulic Power but Machine Will Not Move

1. Are the Fluid Conditioning and Engine circuits operating correctly? Oil level,
temperature, and condition, oil cooler problems, or engine speed and power outside of specifications can
cause or contribute to faulty operation.

Possible Problem Possible Effect What to do

hydraulic oil Low hydraulic oil level can cause a Fill hydraulic oil to correct level.
level low variety of problems.
A plugged suction screen will cause Clean suction screen.
plugged suction ground drive performance problems
screen and eventually will cause extensive
hydraulic component damage.
Hydraulic functions that rely on Check engine RPM while operating
maximum pump flow will have slow under load.
engine RPM too operation since maximum flow is
low reduced when RPM is reduced. Low
RPM also causes reduced pump and
motor efficiency.
A blocked oil cooler or other conditions Check hydraulic oil cooler.
overheating causing overheating of hydraulic oil
can cause various problems.

G
Ground Drive

3. Is the track lockout system working? The track lockout system is intended to prevent the
tracks from being operated when there is an operator present in the seat.

Possible Problem Possible Effect What to do

The drill/track solenoid L24 receives Ensure seat switch does not apply
current from relay K7 through seat current to drill/track solenoid L24.
switch S26. If the seat switch is closed,
power at
the track lockout solenoid is
drill/track solenoid
energized. This means that the tracks
WILL be enabled even if an operator is
not present on the seat.
Continued on next page...

7-16
D36x50 Series II Navigator HDD Service Troubleshooting

4. Are the hydraulic components functioning correctly? Operation of a hydraulic system

requires the correct function of pump, flow and direction controls, and actuators.

Possible Problem Possible Effect What to do

PFC pump flow

Refer to pump flow test.
problem
If PFC pump pressure is misadjusted, Check system relief pressure and
system pressure there might not be sufficient pressure pump compensator pressure.
misadjusted to track the machine under some
conditions.
The ‘T’ line from the brake manifold Check that the ‘T’ line is unrestricted.
vents the piloted valves used to
brake valve not release the park brakes. If the ‘T’ line
vented from the brake manifold is not vented,
the brakes may not release completely
if at all.
The ground drive motors use Check for evidence of tampering with
ground drive counterbalance valves to prevent counterbalance valves. If they have
motor runaway of the motors. If the valves been adjusted, they must be returned
counterbalance have been misadjusted, motors may for new ones since there is not
valve be hard to turn or could run away down currently a procedure to reset the
hills. valves.
If the ground drive motors are worn After verifying no other system

Ground Drive
and inefficient, ground drive function problems, perform a pump flow test. If
ground drive will be impaired. pump flow is good, all controls are
motor condition good, and performance is still
unsatisfactory, the motor should be
replaced.

5. Is the track too tight? If the track is too tight, it could lead to excessive effort to move the
machine, especially if pump or motor condition is not good.

Possible Problem Possible Effect What to do

If the track is too tight, it could lead to Check and adjust track tension if
excessive effort to move the machine, needed.
track tension
especially if pump or motor condition is
not good.

7-17
 Troubleshooting D36x50 Series II Navigator HDD Service

Towing the Machine

Conditions If the engine cannot be started, disengaging the sun gear in each track
planetary gearbox removes all motor and brake control, allowing the
machine to be towed.

WARNING: Machine can move suddenly when planetary gearboxes are disengaged.
Serious injury or death is possible if struck by or run over by the machine. Always block
both tracks securely before disengaging the planetary sun gears. Securely attach the
machine to a towing machine with sufficient capacity to safely move the machine.

Procedure

3 4

1
Ground Drive

1. Thoroughly clean faces of left and right track planetary gearboxes (1).
Remove two bolts (2) and cover (3) on each gearbox.
2. Reverse covers so projections (4) are facing inward and bolt the covers in
place. The sun gears are now disengaged.
3. Tow machine to the new location.
4. Remove covers (3); reverse covers so projections (4) are facing outward
as shown; and bolt covers in place. The sun gears will engage as soon as
the teeth are aligned when the motors are powered. Operate motors
slowly in forward and reverse directions to ensure gears are fully
engaged.

7-18
D36x50 Series II Navigator HDD Service Valve Service

VALVE SERVICE

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.

Ground Drive
WARNING: Before performing any maintenance on the machine, follow the Shutdown
Procedure unless instructed differently by the manual.

Always depressurize and verify before removing any solenoid valve. Certain
cartridge valves may function as check valves and could trap and retain
pressure in a system indefinitely. It may be possible in some cases to relieve
pressure by shutting off the machine, turning the key back on (leave the
engine off) and cycling the function switch for the circuit you are servicing.
However, some valves may require pilot pressure from the PFC pump or one
of the charge pumps to open the valve and relieve trapped pressure. Never
assume that because the engine is not running or a function control
has been cycled that there is no pressure present in the system!
Continued on next page...

7-19
 Valve Service D36x50 Series II Navigator HDD Service

Cartridges Inspect cartridge to ensure no external contaminant is present. Ensure O-

rings and backups are intact and correctly positioned. The O-ring should
always be toward the higher pressure port or between double backups on bi-
directional valves.

Coils Tighten the coil retaining nut to the following specifications:

• ‘08’ size: 5–7 ft-lb (6.75–9.5 Nm) maximum
• all other sizes: 7–10 ft-lb (9.5–13.5 Nm) maximum

Housings Inspect cavity for burrs or other machining irregularities which could
damage O-rings during installation.

Assembly Dip cartridge in clean oil. Screw the cartridge in by hand until the top O-ring
makes contact, then wrench tighten to the following torque specifications:
• ‘08’ size: 20 ft-lb (27 Nm)
• ‘58’ size: 20 ft-lb (27 Nm)
• ‘10’ size: 25 ft-lb (33.4 Nm)
• ‘12’ size spool type: 35 ft-lb (46.5 Nm)
• ‘12’ size poppet type: 60 ft-lb (80 Nm)
• ‘16’ size 50 ft-lb (67 Nm)
Ground Drive

7-20
D36x50 Series II Navigator HDD Service Solenoid Coils

SOLENOID COILS
Three types of solenoid coils are used on the D36x50II. The following chart
lists features and torques. For correct operation of solenoid valves it is very
important to torque the coils correctly.

Coil Specifications NOTE: Ohms and Watts are at 70°F (20°C). The drop-out voltage for ‘08’
and ‘10’ size coils is 10.2V. Coils are rated to operate continuously at up to
212°F (100°C). For accurate testing, be sure to check voltage, resistance, and
current at normal coil operating temperatures. Regardless of voltage and
temperature conditions, pull-in current must be at least 0.840A for size ‘08’
coils and 1.18A for size ‘10’ coils.

Coil Type Vermeer P/N Amps Ohms Watts Installation Torque

‘08’ 251117-009 1.2 9.8 14.7 5–7 ft-lb (6.75–9.5 Nm)

‘10’ 251112-005 1.67 7.2 20 7–10 ft-lb (9.5–13.5 Nm)
EHPR 251108-003 1.2 5.4 NA 7–10 ft-lb (9.5–13.5 Nm)
proportional (max)

The solenoid coils external O-rings seal the coils against moisture. Ensure
whenever a coil is replaced, the appropriate O-ring seals are correctly
positioned to prevent the coils from being damaged by water. Consult the

Ground Drive
following chart and compare with the specification number in the component
section to determine the correct positioning of waterproofing O-rings and
seals.

7-21
 Solenoid Coils D36x50 Series II Navigator HDD Service

Coil Waterproofing
Ground Drive

The solenoid coils use external O-rings to seal the coils against moisture.
Ensure that, whenever a coil is replaced, the appropriate O-ring seals are
correctly positioned to prevent the coils from being damaged by water.
Compare the configurations shown above with the specification number in
the component section to determine the correct positioning of waterproofing
O-rings and seals.

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D36x50 Series II Navigator HDD Service Troubleshooting

TROUBLESHOOTING
Troubleshooting procedures are given for each operating mode of the
different functions of this chapter. Start each procedure by performing a
pretest inspection of the machine. See "Pretest Inspection," page 7-23.

Often problems can be solved by simply doing a walk-around inspection of

the machine and looking for obvious problems.

If nothing obvious is found during the inspection, operate the other actuator
functions of the machine to help further isolate a problem. See
"Troubleshooting Machine Performance," page 7-25.

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

Mechanical

Inspect mechanical valve control handles and linkages for damage,

misalignment, or improper adjustment.

Ground Drive
Electrical

Always check the following items before turning on switches or running the
unit.

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

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

Continued on next page...

7-23
 Troubleshooting D36x50 Series II Navigator HDD Service

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

Hydraulic

Check hydraulic circuits for any failures.

• Look for broken, kinked, loose, or leaking hoses and fittings on hydraulic
components.
• Check level of hydraulic oil in hydraulic tank. Low fluid can cause erratic
behavior in hydraulic circuits. Correct level is between the two lines on
dipstick. Ensure fluid being added has been filtered through a 5-micron
filter.
Ground Drive

Also review information in the General Information chapter under

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

7-24
D36x50 Series II Navigator HDD Service Troubleshooting

Troubleshooting Machine Performance

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

Therefore, because of the various interdependences of the different

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

Make note of any functions not operating normally based on the theory
given in each chapter for that function. Comparing the results with the
normal operation given for each mode of a particular function will help to
isolate the fault(s) to one or more function or component.

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

Possible Results The possible results listed are meant to guide the service technician in a
logical manner to isolate a fault as quickly as possible.

Ground Drive
1. If faults are noted when operating all the machine actuators, it would
indicate a circuit or component that is common to all the actuators is
most likely faulty. The following common functions and components
should be investigated:
• Engine. See "Engine Troubleshooting," page 3-21.
• Remote Lockout. See Chapter 15.
• Shared hydraulic components. See Chapter 4.

2. If faults are noted in the ground drive and stabilizer functions, as well as
the rod loader, auto greaser, stakedown, drilling fluid, and vise functions
and all other functions of the machine are OK, the hydraulic components
common to just these functions should be investigated, including:
• Combination Valve Assembly A9.

7-25
 Troubleshooting D36x50 Series II Navigator HDD Service

Testing Ground Drive Performance

This check is based on the assumption that the common hydraulic
components, pump PMP3 and combination valve assembly A9 are operating
normally. Because of this assumption, it is required that all functions
supplied by this pump be evaluated.

1. Ensure "Machine Performance," page 2-8 and engine starting and warm-
up procedures have been performed.
2. With engine running, use phototach to verify engine speed of 2,400 ± 100
rpm.
3. Enable Remote Lockout.
4. Press hydraulic enable push button S30 to enable rod loader, vise, and
water valve circuits.
5. Lower the stabilizer all the way down using the control switches (1) at
the rear control panel.
6. At rear control panel, operate rack angle control lever, to lower the rack
until both tracks are completely clear of ground/floor.
7. Simultaneously start stopwatch and move track control handle (left or
right track) to maximum FORWARD position. Count revolutions of track
for 60 seconds, then release control handle. Track should rotate at
Ground Drive

approximately 8 rpm.
8. Repeat step 6 for REVERSE direction of track. Track should rotate at
approximately 8 rpm.
9. Return tracks to ground/floor by decreasing rack angle and raising the
stabilizer.

7-26
D36x50 Series II Navigator HDD Service Troubleshooting

Troubleshooting/Testing Ground Drive Function

Before beginning any troubleshooting or testing procedures, perform the
"Pretest Inspection," page 7-23. If nothing obvious is found continue.

1. In order to ensure the fault is isolated to just the ground drive and rack
angle functions, the technician should operate all the machine functions
and observe the actuators as discussed in "Troubleshooting Machine
Performance," page 7-25.
If any functions other than the ground drive and rack angle functions are
faulty, continue troubleshooting based on the possible results given. If all
other machine functions are operating normally, continue with step 3.
2. If the problem is isolated to both the ground drive and rack angle
functions, the diverter valve manifold A9 and transport/rack valve
manifold A8 should be investigated. Refer to "Transport/RackValve
Assembly A8," page 7-30. If the problem is isolated to only the ground
drive function, continue with step 3.
3. If the ground drive is operating abnormally, either the motor, brake,
brake shuttle valve, or transport control valve has most likely
malfunctioned. See the common symptoms of faulty hydraulic
components under "Hydraulic Troubleshooting," page 1-12 then proceed
with step 4.

Ground Drive
NOTE: Hydraulic component testing is based on volumetric efficiency. Test
the components for excessive internal leakage to determine if they are worn
beyond design specification. Refer to the Vermeer Industrial Dealerships
Technician’s Shop Manual (Vermeer P/N 105400V80), for information on how
to test these components.

4. Test efficiency of motor with track removed. Excessive cross-port leakage

can be caused by damage or wear to internal components.
Connect a pressure gauge to the case drain of the motor and compare the
no-load motor shaft speed against the full load speed. If volumetric
efficiency is below 80%, refer to component repair section and repair or
replace motor. For efficiency specifications, refer to "Specifications," page
7-29. If motor is OK, continue with step 5.
NOTE: The track motors are bi-directional. To accurately determine their
condition, motors should be tested in both directions.

5. Test and inspect the brake and brake valve circuit. Test whether the
brakes are engaged by applying pressure from a portable power source at
approximately 350 psi (24 bar), directly to the track brake case at the
hose inlet. If brakes were not applied, continue to step 8. If so, continue.
Continued on next page...

7-27
 Troubleshooting D36x50 Series II Navigator HDD Service

6. Disassemble and inspect brake, in planetary gear assembly, for signs of

seizure of mechanical parts. Refer to component repair section.
7. Disassemble and inspect brake shuttle valve. Excessive leakage across
the blocked-flow ports can be caused by contamination, damage, or wear
to internal components. If so, replace valve. Refer to component repair
section. If valve is OK, continue with step 6.
8. Disassemble control valve assembly A8 and inspect for contamination or
damage to internal seals, O-rings, and internal components. Refer to
"Troubleshooting Transport/Rack Valve Manifold A8," page 7-28 and
component repair section.

Troubleshooting Transport/Rack Valve Manifold A8

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

1. Test solenoid L14 in combination valve manifold A9.

2. Inspect valves DV15 and DV16 in combination valve manifold A9.
3. Inspect the cartridge valves in valve assembly A8 for damage or
contamination. Refer to "Transport/RackValve Assembly A8," page 7-30 for
Ground Drive

instructions on removing and disassembly.

Test Equipment Needed

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

• Multimeter for continuity tests, voltage measurements, resistance

measurements in the various electrical circuits
• Pressure gauge
• Various hydraulic testing tools

NOTE: The hydraulic component test procedures discussed in this chapter

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

7-28
D36x50 Series II Navigator HDD Service Troubleshooting

Specifications
Listed below are the electrical and hydraulic specifications for the ground
drive function.

Electrical:

• Nominal circuit voltage - 12 volts DC

• Solenoid L14 resistance - 9.8 ohms at 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)
• Control valve assembly A8 relief valve PV9 pressure setting - 3500 psi
(241 bar)
• Motor MH5 and MH6 max ground speed 1.5 mph (2.4 km/h)
• Motor MH5 and MH6 maximum output @ 614 rpm / 254 ft-lb

Ground Drive
Component Repair/Replace
If troubleshooting procedures determine a component is in need of repair or
replacement, refer to the appropriate procedures at the back of the chapter
or other chapters where instructed. After repairs have been made, refer
to"Hydraulic Fluid Sampling," page 4-20 and follow instructions.

7-29
 Component Repair D36x50 Series II Navigator HDD Service

COMPONENT REPAIR
Transport/RackValve Assembly A8

4
5

7
2

1
6

3
Ground Drive

Remove 1. Label, disconnect, cap and plug hydraulic hoses going to control valve.
2. Remove bolts (1), washers (2) and shield (3) from machine.
3. Remove bolts (4), washers (5) and nuts (6) and remove valve (7) from
machine
Install When installing control valve, reverse removal procedures.

NOTE: Torque bolts (1) to 22 ft-lb (30 Nm).

7-30
D36x50 Series II Navigator HDD Service Component Repair

Directional Valves DV10, DV11 and DV12

4
5
6

5
4
3
6

1. Remove control lever (1) and bracket (2).

NOTE: Do not remove spool from valve.

2. Remove positioner (3).

Ground Drive
3. Remove seal retainer (4), backup washer (5), and O-ring (6) on each end
of valve housing.
4. Apply a light coat of petroleum jelly to O-ring and install with backup
washer, and seal retainer.
5. Install positioner, lever bracket, and control lever.
6. Install control valve, connect hydraulic hoses, and install console cover.

7-31
 Component Repair D36x50 Series II Navigator HDD Service

Load Check Plug

8
7
6
5

1 4

1. Unscrew and remove load check plug (8).

NOTE: Document orientation of O-rings and backup washers (for
installation purposes).

2. Remove O-rings (4, 5 and 7) and backup washers (6). Inspect check
spring (2) and poppet 1). Ensure they are clean and free of dirt.
Ground Drive

3. Apply a light coat of petroleum jelly to new O-rings and install with
backup washers.
4. Install load check plug. Torque plug to 20 ft-lb (27 Nm).
5. Install control valve to machine. Connect hydraulic hoses. Install console
cover.

7-32
D36x50 Series II Navigator HDD Service Component Repair

Relief Valve PV9

1

3
5 2
4
1. Remove tie rod (1) and nut (2) holding valve section (4) to valve
manifold.
2. Remove O-rings (5).

Ground Drive
3. Remove relief valve (3).
NOTE: Before installing components, apply a light coat of petroleum jelly to
O-rings.

4. Install O-rings and backup washer with relief. Torque relief to 20 ft-lb
(27 Nm). Torque tie rod to 12.5 ft-lb (17 Nm).
5. Install control valve. Connect hydraulic hoses, and install console cover.

7-33
 Component Repair D36x50 Series II Navigator HDD Service

Brake Valves DV31 and DV32

4

4
4

1. Label, disconnect, cap and plug hydraulic hoses going to valve.

2. Remove bolts (1), washers (2), and nuts (3) mounting valve to under side
of transport control panel.
Ground Drive

3. Remove fittings (4) from valve body.

NOTE: Inspect cavity for contaminants.

Reverse removal procedure to install valve.

Torque mounting bolts to 10 ft-lb (13 Nm).

7-34
D36x50 Series II Navigator HDD Service Component Repair

Track Motors MH5 and MH6

1
3
2

Ground Drive
Remove 1. Label, disconnect and cap all hydraulic hoses to motor.
2. Disconnect track chain. See "Track Chain," page 7-45.
3. Remove bolt (2) holding motor (1) to brake assembly.
4. Remove retaining plate (3).
Special Tools NOTE: Special tools available from Eaton are needed to perform these
procedures. They are included during the repair procedures.

• Torque wrenches capable of producing 50 in-lb (5.5 Nm), 30 ft-lb (40 Nm),
and 50 ft-lb (68 Nm)
• Press
• Plastic or rubber hammer
• Eaton seal installation tube
• Eaton seal driver
• Eaton tool for protective sleeve on motor shaft

7-35
 Component Repair D36x50 Series II Navigator HDD Service

Disassembly

29 28 22 23
11 14
10
26 8
17
7
27 6
25 17
24 2
21
30
16
13 1 17
12 5
15 3
9 20
18

19
4
IMPORTANT: Cleanliness is extremely important when repairing
hydraulic motors. Work in a clean area. Clean port areas of motor
thoroughly.
Ground Drive

IMPORTANT: Inspect all parts for damage (scratches or burrs) or unusual

wear during each step of disassembly. Check condition of all mating
surfaces. Do not re-use O-rings or seals.

1. Drain oil from the motor and thoroughly clean the exterior.
2. Place motor in a soft-jawed vise with output shaft down. If possible, keep
the motor in a vise during disassembly and assembly.
Continued on next page...

7-36
D36x50 Series II Navigator HDD Service Component Repair

3. Remove four tie bolts from the motor. Lift valve housing straight up. If
done carefully, the springs and balance ring will remain on the valve.

Ground Drive
4. Carefully remove seals, plug assembly and check plug assembly from the
valve housing.

5. Remove balance ring subassembly, and balance ring’s inner and outer
face seals. Remove valve.
Continued on next page...

7-37
 Component Repair D36x50 Series II Navigator HDD Service

6. Remove valve plate and its seal. Remove the valve drive.

7. Remove Geroler, being sure to retain the rollers in the outer ring if they
are loose. Remove two seals from each side of the Geroler.
Ground Drive

8. Remove drive and 3-1/2" seal from bearing housing.

9. Clamp bearing housing in a vise, loosen eight cap screws, and place
housing on a clean, flat surface.
Continued on next page...

7-38
D36x50 Series II Navigator HDD Service Component Repair

10. Remove cap screws and mounting flange.

11. Remove shaft seal and pry dust seal loose, using a small screwdriver. Do
not damage the mounting flange bore.

Ground Drive
12. Remove 3-1/2" seal from bearing housing, followed by the shaft and
bearing assembly. A press may be necessary.
13. Remove shaft face seal from bearing housing bore. Be careful not to
damage the bore.
14. Clean all metal parts in clean solvent and blow dry with air. Do not wipe
with cloth or paper towels because lint or other matter could get into the
hydraulic system and cause damage. Do not use abrasives or try to file or
grind motor parts.
15. Check around the keyway and chamfered area of the shaft for burrs,
nicks or sharp edges that can damage seals during assembly.
• Shaft seal installation tool (Eaton P/N 600496)
• Bullet (Eaton P/N 600465)

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 Component Repair D36x50 Series II Navigator HDD Service

Assembly

NOTE: Use all new O-rings and seals. Coat with petroleum jelly to help
position them during installation.

1. Place bearing housing on a smooth, flat surface with largest open end of
housing up. Align Eaton seal installation tube with seal seat. Apply
petroleum jelly to shaft face seal. Install seal in bore of tube as shown.
Then, insert Eaton seal driver in the tube. Push face seal into seal seat
with rotating action. Seat seal properly in the groove.

2. Install shaft and bearing assembly in bearing housing. A press may be

necessary. Do not distort shaft seal.
Ground Drive

3. Apply petroleum jelly to the 3-1/2" seal. Install seal in outer seal groove
of bearing housing.
4. Install dust seal in flange (metal side of seal facing flange as shown),
using a press. If a press is not available, use a plastic or rubber hammer.
Be careful not to damage or cock the seal in the bore.
5. Install shaft seal in flange (flat, smooth side facing flange as shown).
Then, apply petroleum jelly to the inner diameter of shaft seal and dust
seal.
Continued on next page...

7-40
D36x50 Series II Navigator HDD Service Component Repair

6. Tape or apply a protective sleeve (Eaton tool) to the shaft to prevent

cutting or distorting seals. Install flange, lubricate threads of eight
flange cap screws with oil, and finger tighten screws.

7. Clamp bearing housing in a vise. Gradually torque cap screws to 20 ft-lb

(20 Nm), using sequence shown.

Ground Drive
8. Reposition motor in a vise with output shaft down, clamping the motor
across the flange edge. Pour a small amount of light oil inside the shaft.
.

9. Apply petroleum jelly to 3-1/2” seal, and install seal in groove of the
bearing housing. Install drive in output shaft, inserting the longer
splined end first. Install two alignment studs in bolt holes (diagonal
corners) of bearing housing.
10. Install two small seals in the case drain grooves of the Geroler,
lubricating them with petroleum jelly.
Continued on next page...

7-41
 Component Repair D36x50 Series II Navigator HDD Service

Timing

NOTE: There are three steps involved in timing the motor. Timing
determines the shaft rotation direction. Timing parts include Geroler, valve
drive, valve plate and valve.

11. Timing step #1:

• Locate largest open pocket in Geroler, and mark it on outside edge.
• Align case drain hole and pressure relief hole in Geroler with case
Ground Drive

drain and pressure relief hole in bearing housing; install Geroler on

bearing housing; and retain rollers in outer Geroler ring if loose.
• Install valve drive in Geroler.
• Apply petroleum jelly to 3-1/2" seal and install in valve plate.
• Align case drain hole in valve plate with case drain hole in Geroler; and
install valve plate (seal side toward Geroler).
12. Timing step #2:
• Locate slot opening in valve plate which is in line with largest open
pocket of Geroler.
13. Timing step #3:
• Locate any one of the valve side openings that goes through to the face
of the valve.
• Align selected side opening with open slot of valve plate that is in line
with largest open pocket of the Geroler.
• Install valve by rotating clockwise 1/2 spline tooth until spline teeth
engage, providing correct rotation.
Continued on next page...

7-42
D36x50 Series II Navigator HDD Service Component Repair

14. Apply clean grease to balance ring assembly springs. Install two springs
and two pins in holes of valve housing bore.
15. Apply petroleum jelly to both seals and install them in valve housing.

IMPORTANT: Inner and outer face seals must be installed correctly for

Ground Drive
motor to operate properly. Damaged seals, resulting from forcing or bending,
will adversely affect motor operation.

16. Apply petroleum jelly to inner and outer face seals. Install seals on the
balance ring as shown.

BALANCE RING

17. Align two pins of balance ring with two spring holes in the valve housing.
Install balance ring in housing.
Continued on next page...

7-43
 Component Repair D36x50 Series II Navigator HDD Service

18. Insert a finger through the port. Apply pressure to side of balance ring,
holding it in position until the valve housing is in place. Align case drain
hole (refer to steps 11–13 for case drain hole location) in valve housing
with case drain hole in valve plate. Install valve housing against valve
plate. Check between body parts of motor for unseated seals.
Ground Drive

19. Gradually torque bolts to 50 ft-lb (68 Nm), using sequence shown.
20. Install plug assembly and check plug assembly.

7-44
D36x50 Series II Navigator HDD Service Component Repair

Install 1. Apply a light coat of oil to O-ring. Align motor mounting holes and
planetary assembly (brake) holes. Ensure port holes are facing down, as
shown.
2. Install bolts and washers to motor, mounting it to brake and planetary
gearbox.
NOTE: Torque bolts to 90 ft-lb (120 Nm).

3. Connect hydraulic hoses.

4. Install track chain. Refer to "Track Chain," page 7-45.

Track Chain
Remove 1. Locate track chain master
connecting pin (1). Position it on top
of track drive sprocket.

Ground Drive
2. Release track chain tension by
turning relief fitting (2) in tension 2
cylinder one or two turns. Drain oil
from fitting until tension is
adjusted.
3. Drive out track chain connection
pin. Lay ends of track on the
ground.
4. With a suitable lifting device, jack track frame up until the rollers and
track drive sprocket are clear of track chain. Support frame with
jackstand.
NOTE: Note orientation of track for installation purposes.

5. Slide track out from under track frame.

Continued on next page...

7-45
 Component Repair D36x50 Series II Navigator HDD Service

Install 1. Slide track under track frame. Lay track out as noted when removed.
Track should extend past the idler roller. Approximately 1-1/2 ft (0.5
meter) should extend past track drive sprocket.
2. Raise machine frame and remove jackstand. Lower frame onto track.
3. Wrap track chain around track frame. Install track chain connecting pin.
4. Fill cylinder with grease until
spring (1) is compressed. 1

NOTE: Correct spring tension is

acheived when distance between
cylinder barrel and rod cap (2)
measures 4.25'' (10.7 cm).

2
Ground Drive

7-46
D36x50 Series II Navigator HDD Service Component Repair

Track Tension Tightener

5
1

7
8
11 6 4

9
10
Remove 1. Remove track chain. See "Track Chain," page 7-45.
2. Loosen setscrew (1). Remove nut
(2), washer (3), and bolt (4).
3. Remove idler roller (5).

Ground Drive
4. Remove front idler bracket (6),
spring (7), and rod cap (8). Cover
Front Idler
5. Remove bolts holding cover on side
of track assembly.
6. Remove bolts (9) and washers (10) holding grease cylinder (11) in place.
Install Reverse removal procedures to install.

Torque nut (2) to 210 ft-lb (285 Nm). Apply Loctite 515 or equivalent to
setscrew (1) and tighten.

Torque bolts (9) to 35 ft-lb (48 Nm).

Refer to next page for tension adjustment.

7-47
 Component Repair D36x50 Series II Navigator HDD Service

Track Tension NOTE: Before starting adjustment procedures, ensure tracks are clean and
Adjustment free of dirt and mud.

1. Turn relief fitting on cylinder

(1) one or two turns to drain 1
grease to decrease tension.
Remove fitting cover and insert
grease to increase tension.
2. Measure distance between rod
cap (2) and cylinder barrel (3). 3
NOTE: Measurement should read 2
4.25'' (10.7 cm).

3. Replace cover on fitting.

4. Drive machine forward approximately 3 ft (1 m) and reverse 3 ft (1 m).
Check tension and adjust if necessary.
Ground Drive

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D36x50 Series II Navigator HDD Service Component Repair

Planetary Gears
Remove

2
2

1
1

5 3

11
6
12
7
5

Ground Drive
9
4
10
8

1. Remove track chain. Refer to "Track Chain," page 7-45.

2. Remove bolts (8) and washers (4) mounting track drive sprocket on
planetary gearbox.
NOTE: The planetary assembly consists of planetary, brake and motor.

3. Disconnect and cap hydraulic hoses on motor (1) and brake (6).
4. Remove bolts (10) and washers (9) mounting planetary to the planetary
adapter.
5. Carefully slide planetary assembly out from adapter.
NOTE: A fitting on the rear side of planetary will need to be aligned with
notch in adapter to successfully remove planetary assembly from adapter.

6. Remove bolts (3) and washers (4) mounting brake and motor to
planetary gearbox. Carefully slide brake and motor out of coupling from
gearbox.
Continued on next page...

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 Component Repair D36x50 Series II Navigator HDD Service

NOTE: Special tools are required when repairing planetary. Contact factory
service department for procurement of these tools. During the following
procedures these tools will be noted with Auburn Gear part numbers.

Disassembly

16
26 18 17
24 27
28 10 5
25 21

6
3
13

10
7

8
17

1 9
Ground Drive

19
33

11
2
15 13 12 19
22 14
23 20

1. Slide coupling (1) from splines on input shaft (2).

2. Position assembly upright on the face of spindle (3).
3. Remove disengage cover (4).
4. Remove bolts (5) and large cover (6) from the unit.
Continued on next page...

7-50
D36x50 Series II Navigator HDD Service Component Repair

NOTE: Thrust washer (7) and the disengage plunger (8) usually remain
attached to large cover when it is removed.

5. Remove thrust washer, disengage plunger and O-ring (9) from the large
cover.
6. Remove primary sun gear (10) from end of output shaft.
7. Remove primary carrier assembly (11).
8. Remove secondary carrier assembly (12).
9. Remove input shaft from spindle.
10. Remove retaining rings (13), washers (14), and disengage spring (15)
from input shaft.
11. One tab of lock washer (16) will be engaged in slot of bearing nut (17),
lock washer and thrust washer (18).
NOTE: A special lock nut wrench 596Z is required for the removal of the
bearing lock nut.

12. Bolt spindle drive tool 598FF to ring gear (19). Grade 8 bolts should be
used. Carefully drive spindle (3) from hub (20) by turning center bolt of
spindle drive tool. Care should be taken to avoid damaging splines and
threads on spindle.

Ground Drive
NOTE: Bearing cone (21) has been designed with a press fit with respect to
spindle. Considerable force will be required to remove cone from spindle.

13. Remove spindle drive tool from ring gear.

14. Remove bolts (22), and washers (23) from hub to remove ring gear. It
may be necessary to strike ring gear with a rubber mallet to loosen from
hub.
15. Remove boot seal (24), oil seal (25), and bearing cones (26) and (21)
from hub. Inspect bearing cups (27) and (28) in position and remove only
if replacement is required.

Assemble 1. Press bearing cups (27) and (28) in each side of hub (20). It is
recommended that bearing cups and cones be replaced in sets.
2. Assemble bearing cone (26) into cup (27) at seal end of hub (20). Press
seal (25) into hub. Install boot seal (24) on hub.
3. Position spindle (3) upright on bench. Lubricate lips of seal (25) and
lower hub (20) onto spindle (3). Center hub as it is lowered over spindle
to prevent seal damage.
Continued on next page...

7-51
 Component Repair D36x50 Series II Navigator HDD Service

4. Assemble bearing cone (21) over spindle (3). Press bearing cone over
spindle bearing journal using press and cylindrical bearing cone driver
598E. Press bearing cone (21) down until rollers just touch cup (28).
Take care to avoid pressing cone too far.
NOTE: If press is not available, place tool 598E over splined end of
spindle (3) on the edge of bearing cone and drive into place with hammer or
mallet. If this method is used, care must be taken to avoid damage to
bearing cone and spindle.

5. Install thrust washer (18) with tab in keyway of spindle and bearing nut
(17).
IMPORTANT: Do not install lock washer (16) at this time.

6. Clean mating surfaces and apply a bead of silicone sealant to face of hub
(20) that mates with ring gear (19). Hub is attached to ring gear with
3/8-24 grade 8 hex head cap screws (22) and flat washers (23). Torque
cap screws to 52–60 ft-lb (70–81 Nm).
7. Place spindle drive tool 598FF over spindle (3) and bolt or pin to ring
gear (19). Ensure center bolt of drive tool is not touching spindle and is
prevented from rotating by jam nuts provided on tool.
8. Check initial rolling torque by installing a torque wrench on center nut
of spindle drive tool and turning hub (20) slowly and steadily with the
Ground Drive

torque wrench. Note mean torque. An initial bearing torque of greater

than 4.3 ft-lb (5.8 Nm), with boot seal installed or 3.8 ft-lb (5.2 Nm)
without boot seal means cone (21) was pressed on too tightly in step 4. In
this case back off bearing cone (21) by pressing spindle (3) out of cone
(21) until initial preload is relieved. Refer to step 10 of disassembly
procedure.
9. Torque bearing nut (17) with bearing nut wrench 596Z until a bearing
torque of 3.8–4.2 ft-lb (5.2–5.7 Nm), with a boot seal installed, or 3.2–3.8
ft-lb (4.3–5.2 Nm), without a boot seal, is reached. This may require
several trials of pressing the cone (21), torquing the nut (17), and then
checking the rolling torque. Rotate hub (20) by hand as nut is being
tightened in order to seat bearings. Up to 250 ft-lb (339 Nm) of torque
may have to be applied to bearing nut (17) in order to press cone (13)
into position.
10. Remove bearing nut (17) and install lock washer (16). Replace bearing
nut.
11. Torque bearing nut (17) to 60–70 ft-lb (80-94 Nm).
Continued on next page...

7-52
D36x50 Series II Navigator HDD Service Component Repair

12. Secure bearing nut (17) by bending a lock washer (16) tab into one of the
four bearing nut slots. If no tab aligns with the slot, nut may be
tightened until one of the slots aligns with a lock washer tab.
13. Assemble washer (18), spring (15), a second washer (18), and retaining
ring (13) in the middle grooves of input shaft (2). Install a second
retaining ring in groove near small end of input shaft.
14. Assemble splined end of the input shaft (2) down into spindle (3).
15. Assemble secondary carrier assembly (12) to spindle (3) at splines.
16. Assemble primary carrier assembly (11) into ring gear (19). It will be
necessary to rotate carrier to align secondary carrier assembly (11).
Assemble primary sun gear (10) over input shaft (2). Rotate primary sun
gear (10) to align input shaft (2) to gear splines and gear teeth in
primary carrier assembly (11).
17. Lubricate O-ring (9) and assemble in groove inside cover hole, push
disengage plunger (8) into cover (6) with pointed end facing inside of
unit.
18. Assemble thrust washer (7) with tangs engaged with cover (6). A small
amount of grease applied to the back side of thrust washer (7) will hold
washer in place.
19. Apply a bead of silicone sealant to the end of face of ring gear (19).

Ground Drive
Assemble cover (6) aligning holes of cover and ring gear. Assemble hex
head bolts (5). Torque bolts to 20–25 ft-lb (27–34 Nm).
20. Assemble disengage cover (17) with dimpled center protruding out.
Assemble and torque bolts (19) Torque bolts to 10–20 ft-lb (13–27 Nm).
21. Invert power wheel assembly and assemble coupling (1), with
counterbore out, to input shaft (2).
22. Assemble hydraulic motor to planetary drive, fill with lubricant to proper
level and replace all plugs.
NOTE: Install O-ring between the motor and planetary drive.

7-53
 Component Repair D36x50 Series II Navigator HDD Service

Install 1. Apply a light coat of oil to O-ring. Install O-ring over brake flange.
2. Align splines on brake assembly into coupling inside planetary gearbox.
3. Apply a light coat of oil to O-ring. Install on motor flange. Install motor
splines into brake assembly coupling and install bolts with washers.
Torque bolts to 90 ft-lb (120 Nm).
NOTE: Ensure hydraulic hose ports on motor are facing down.

4. Install planetary assembly to planetary adapter (main frame) with bolts

and washers. Torque bolts to 180 ft-lb (245 Nm).
5. Install track drive sprocket with bolts and washers. Torque bolts to
95 ft-lb (130 Nm).
6. Install hydraulic hoses on motor and brake assemblies.
7. Install track chain. Refer to "Track Chain," page 7-45.
Ground Drive

7-54
D36x50 Series II Navigator HDD Service Overview

Chapter 8: Rod Loader

OVERVIEW
The rod loader circuits control loading and unloading drill rod from the drill
string. Pressure flow compensated (PFC) pump PMP3 supplies oil to the rod
loader hydraulic components. Load sense feedback to the pump is controlled
by solenoid activated valve DV28 from load sense relay K4. The hydraulic
enable switch S30 allows oil to the rod loader hydraulic circuits by
controlling solenoid activated valve DV29.

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

• Rod Loader Motor MH7

• Rod Loader Valve A6 including:
• Rod Loader Motor Control Valve DV13
• Rod Loader Motor Control Valve Solenoid L33
• Rod Loader Motor Control Valve Solenoid L32

Rod Loader
• Rod Loader Lift Control Valve DV12
• Rod Loader Lift Control Valve Solenoid L5
• Rod Loader Power Valve DV9
• Rod Loader Power Valve Solenoid L6
• Rod Loader Flow Divider Valve FV10
• Rod Lift Cylinders CY1 and CY2
• Right Joystick Control A15, including:
• Rod Selector Retract Switch S39
• Rod Selector Extend Switch S38
• Rod Lift Switch S37
• Rear Loader Presence Switch S6
• Loader Anti-Crash Switch S7

8-1
 Overview D36x50 Series II Navigator HDD Service

Rod Handling Terms

‘Adding’ - The action of taking drill rod from the rod box and adding it to the
drill string.

‘Removing’ - The action of removing drill rod from the drill string and
returning it to the rod box.

Overview
Theory information contained within this chapter describes rod loader
operation. Review this material to gain a working understanding of rod
loader operation.

Performance Checks
The performance checks for rod loader actuators are found on page "Rod
Loader Performance," page 2-20. The performance checks are to be performed
before any rod loader troubleshooting procedures.

Troubleshooting
Troubleshooting information for the rod loader is located "Troubleshooting,"
page 8-14. These should be performed after verification of a malfunction by a
performance check. Further fault isolation is accomplished using the
Rod Loader

appropriate troubleshooting procedures.

8-2
D36x50 Series II Navigator HDD Service Electrical Diagram

ELECTRICAL DIAGRAM
ANTI-CRASH MODULE A16

THERMAL BREAKER F3

TO LOAD SENSE
DIODE D4

FRONT LOADER
ARM PRESENCE TO LOAD SENSE
SWITCH S5 DIODE D4

TERMINAL BUS TB1

REAR LOADER
ARM PRESENCE
SWITCH S6

Rod Loader
FROM HYDRAULIC ENABLE
SWITCH S30
LOADER ARM
ANTI-CRASH S7

RIGHT
LOADER LIFT JOYSTICK A15
SOLENOID L5
LOADER
LIFT S37
LOADER ARMS
IN SOL. L33
LOADER ARMS
IN SWITCH S38
LOADER ARMS
OUT SOL. L32

ROD LOADER ROD LOADER

POWER SOL. L6 REVERSE SWITCH
S39

THERMAL
BREAKER F2

8-3
 Electrical Diagram D36x50 Series II Navigator HDD Service

HYDRAULIC DIAGRAM
ROD LOADER MOTOR
MH7

SOLENOID L33
LOADER MOTOR
CONTROL VALVE
DV13
FRONT ROD LIFT
CYLINDER CY2
SOLENOID L32

SOLENOID L5

LIFT FLOW
VALVE REAR ROD LIFT
ORIFICE VALVE
DV12 CYLINDER CY1
FV10
FV7

ROD
LOADER
POWER
VALVE DV9 SOLENOID L6
Rod Loader

TO TANK

DRILL/ PRESSURE RELIEF

TRACK PV7
VALVE
LOAD
SENSE
VALVE
DV28,
PUMP PMP3

SOLENOID
L26

HYDRAULIC ENABLE
VALVE DV29,
SOLENOID L26

TANK

8-4
D36x50 Series II Navigator HDD Service Component Locations

COMPONENT LOCATIONS
ROD
TRANSFER
EXTEND
SWITCH S38

LOADER LIFT
SWITCH S37

ROD
TRANSFER
RETRACT
SWITCH S39

Rod Loader
HYDRAULIC ENABLE THERMAL BREAKER F2
RELAY K6

LOAD SENSE
RELAY K4

8-5
 Component Locations D36x50 Series II Navigator HDD Service

Rod Handling Component Identification

Arm
Adding* - Extends a drill rod out to
the drill string.
Removing** - Retracts a drill rod in
from the drill string.

REAR LIFT CYLINDER CY1

FRONT LIFT CYLINDER CY2
Adding* - Lowers drill rod from rod box down
to selector plate.
Rod Loader

Removing** - Raises drill rod from selector

plate up to rod box.

ROD LOADER MOTOR MH7

REAR LOADER ARM

PRESENCE SWITCH S6 FRONT LOADER
ARM PRESENCE
SWITCH S5

8-6
D36x50 Series II Navigator HDD Service Component Locations

CCW MOTOR
ROTATE SOLENOID L32
ROD LOADER
POWER VALVE DV9, CW MOTOR ROTATE
SOLENOID L6 SOLENOID L33
LOADER LIFT VALVE
DV12, SOLENOID L5

ROD LOADER
CONTROL MANIFOLD
A6

ROD LOADER MOTOR

FLOW CONTROL CONTROL VALVE MH7
VALVE FV1

Rod Loader

8-7
 Hydraulic Connections D36x50 Series II Navigator HDD Service

HYDRAULIC CONNECTIONS

ROD LOADER
MOTOR MH7
REAR ROD
FRONT ROD BLOCKER CYLINDER (CY9)
BLOCKER CYLINDER (CY9)

REAR ROD TRANSFER

CYLINDER (CY10)
FRONT ROD TRANSFER
CYLINDER (CY10)
REAR ROD
LOADER LIFT REAR ROD
CYLINDER CY2 ROD LIFT
CYLINDER (CY12)
FRONT ROD FLOW ROD LOADER
ROD LIFT MANIFOLD A6
DIVIDER FV1
CYLINDER (CY12)
Rod Loader

FRONT
ROD SELECT
CYLINDER (CY10)
FRONT REAR ROD
ROD LOADER SELECT CYLINDER
CYLINDER CY1 DIAGNOSTIC (CY)
PORT
DIAGNOSTIC ROD LOADER VALVE (A4)
PORT (B4)
TANK

PUMP PMP3

FROM HYDRAULIC
RESERVOIR
VALVE A9
PUMP PMP3

LOAD SENSE
MANIFOLD A9

8-8
D36x50 Series II Navigator HDD Service Operation

OPERATION
PFC Pump PMP3 The PFC pump supplies hydraulic flow at pressure according to demand.
Refer to "Circuit Operation," page 7-6.

Hydraulic Enable The hydraulic enable valve TO ROD LOADER TO GROUND DRIVE
Valve DV29 and DV29 located in the MANIFOLD A6 VALVE A5
Solenoid L26 proportional dump valve A9
allows pressurized oil from LOAD SENSE
PRESSURE FROM
pump PMP3 to reach the rod
VALVES
loader valve manifold A6. This
valve also allows oil flow to the
A9
vise, stakedown, stabilizer,
rack angle, and water shutoff
circuits. The valve spool
movement in DV29 is
controlled by electric solenoid
L26.
L26

DV29

Rod Loader
PMP3

OIL
TANK

8-9
 Operation D36x50 Series II Navigator HDD Service

Hydraulic Enable Circuit

TERMINAL BUSS TB1

HYDRAULIC
ENABLE
SWITCH
ROD LOADER POWER
S30
SOLENOID L6
Rod Loader

HYDRAULIC ENABLE BREAKER

RELAY K6 F9

TO REAR
STABILIZER
DIODE D3 SWITCH
TO TERMINAL
SEAT SWITCH RELAY 30 RELAY K11
DRILL/TRACK K7
SOLENOID L24
SEAT SWITCH BREAKER
S26 F6
HYDRAULIC
ENABLE
SOLENOID
L26

TRACK BRAKE SOLENOID L4

Continued on next page...

8-10
D36x50 Series II Navigator HDD Service Operation

A series of relays and switches control the function of hydraulic enable

solenoid L26 which supplies oil to rod loader, vise, stakedown, stabilizer,
greaser and drilling fluid hydraulic circuits.

Breaker F6 supplies power to pin 1 of seat switch S26 and to pin 30 of seat
switch relay K7. When the seat switch is pressed, power is provided to
terminal 86 of seat switch relay K7. This energizes relay K7 connecting
terminals 30 and 87 which provides voltage to drill/track solenoid L24, track
brake solenoid L4, and hydraulic enable switch S30.

When hydraulic enable switch S30 is closed, voltage is provided to terminal

86 of hydraulic enable relay K6 by wire 718. This energizes relay K6,
connecting terminals 30 and 87. Terminal 87 is connected to wire 718 by
wire 718A. Voltage is supplied back through wire 718 to rod loader power
solenoid L6, drill/track solenoid L24, and hydraulic enable solenoid L26.
Relay K6 and solenoids L6, L24, and L26 remain energized until voltage at
terminal 30 (from circuit breaker F9) is interrupted.

Rod Loader

8-11
 Operation D36x50 Series II Navigator HDD Service

Rod Loader The rod loader manifold A6 contains four solenoid valves, flow divider valve
Manifold A6 FV10, and orifice FV7 to control rod loader operation. There is no hydraulic
load sense line from the rod loader manifold to PFC pump pmp3.
ROD LOADER SOLENOID
MOTOR A6
L33
CONTROL
VALVE DV13

LOADER LIFT
CONTROL
VALVE DV12,
SOLENOID L5 SOLENOID
L32

ORIFICE FV7

FLOW
CONTROL
ROD LOADER VALVE
POWER VALVE FV10
DV9, SOLENOID
L6
Rod Loader

Pressurized oil flows into the valve at port P and return oil flows out at port
T. Orifice FV7 reduces the flow of incoming oil to reduce actuator speed.

Relief valve PV4 in valve manifold A9 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.

8-12
D36x50 Series II Navigator HDD Service Function Operation

FUNCTION OPERATION
Each individual function of the rod loader is controlled by switches S37, S38,
and S39. Anti-crash switch S7 protects the carriage from colliding into rod
loader. It is still possible to crash the rod loader into the carriage. It is also
possible to crash parts of the rod loader into drill rods or other parts of the
rod loader if the proper operation sequence is not followed.

There are two functions of the rod loader:

• Extend or Retract Arms
• Raise or Lower Rod Lifters
Extend or Retract The loader arms perform the basic function of the rod loader. They reach out
Arms to the drill string to both deliver and remove drill rod. Magnets on the ends
of the arms hold the drill rod while it is being moved to or from the drill
string. The sequence of adding drill rod to the drill string requires the arms
to extend out to the drill string with drill rod, and retract after the joint is
made up. In order to remove a rod from the drill string, the arms extend to
the drill string, after the joint is broken and the rod is free, the magnets hold
the rod while the arms retract. The movement of the arms takes place in two
distinct steps.

Raise or Lower Lifts The rod lift cylinders raise the drill rod in the rod box up and out of the way
so the loader arms can be positioned. When adding drill rod to the drill

Rod Loader
string the lifts are lowered to allow drill rod into the arms.

ROD LOADER CONTROLS

The following three rod loader switches are used to control the rod loader
functions:

• Arm Extend Switch S38

• Arm Retract Switch S39
• Rod Lift Switch S37

ROD LOADER ADD SEQUENCE

NOTE: ‘Add’ sequence or ‘adding’ is the action of taking drill rod from the
rod box and adding it to the drill string.

8-13
 Troubleshooting D36x50 Series II Navigator HDD Service

TROUBLESHOOTING

Check Out Related Circuits and Components

• Always look for problems in common and related functions before doing
any difficult test procedures.
• Check hydraulic and electrical overall schematics and verify that the
common systems and related circuits are OK.
• Look for electrical functions operating on the same circuit breaker or
switch; look for hydraulic systems relying on the same pump or control
valve.
• If a related function is not working properly, repair those components
first, then proceed with troubleshooting if necessary.

Basic Troubleshooting Questions

1. Is there a mechanical problem? 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
Rod Loader

system could cause problems 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? The rod loader circuits are powered
by the rod loader circuit breaker and include the limit switches and two
operator control switches (rod transfer and rod lift). 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 manifold A9. Flow control valve
FV10 must be functioning properly or loader lift cylinders CY1 and CY2
might not synchronize at the end of their cycle. Orifice FV7 controls oil
flow into manifold A6. If the orifice becomes blocked or is removed,
operation will be affected.

8-14
D36x50 Series II Navigator HDD Service Troubleshooting

Troubleshooting Electrical Circuits

Unless the problem is obvious, investigate these fundamental electrical-
related questions:

1. Is the power source (battery, ignition switch, and rod loader OK?
Electrical actuators such as relays and coils may operate correctly down
to as low as 10.8V, but any system voltage measuring below 12.5V can be
suspect, especially if grounds are faulty.
2. Are the grounds OK? The circuit must be complete to ground, and the
voltage drop in the ground circuit must be no higher than 0.5V.
3. Is the current path complete? Many problems can be traced to a
broken wire or faulty pin connection in a plug.
4. Are all the switches OK? Refer to the rod loader schematics to
determine what switches are contained within the circuit.
5. Are all electrical actuators OK? A coil in a relay or a solenoid may
have failed. Ensure current path is complete and resistance is within
tolerance.
6. Is the mechanical output OK? Even if all electrical components are
functioning properly, a valve may leak or fail to move, or relay contacts
may stick or not conduct current.

Rod Loader

8-15
 Troubleshooting D36x50 Series II Navigator HDD Service

Troubleshooting the Hydraulic Circuit

Unless the problem is obvious, investigate these fundamental hydraulic-
related questions:

1. Can the pump deliver correct FLOW? Is the inlet restricted? Is the
pump worn out? Is the compensator correctly controlling pump stroke?
2. Is the system PRESSURE correct? Is the compensator set correctly? Is
the relief set correctly?
3. Is the circuit delivering correct pressure to the actuator? Is the
load sense circuit functioning correctly? Is a variable signal based on
function demand being delivered to the compensator, either from a
variable control such as the transport or water control or from a solenoid
valve through the load sense solenoid? Are the actuators original
equipment or correct replacements?
4. Are the motors or cylinders functioning? Correct pressure and flow
at the motor ports will make the motors function properly unless the
motors are worn, defective, or incorrect replacements.
5. Are the directional control valves operable? Flow must be applied
correctly to any actuator for it to function as designed.
6. Is there an abnormal resistance to work? Pressure in a hydraulic
circuit comes only from “line” (“circuit”) resistance or from “load”
Rod Loader

(“actuator”) resistance. Any change from normal may result in changed

performance.
NOTE: A dramatic change in operation between cold conditions and
warmed up conditions suggests pump or motor wear, since hot oil leaks
more quickly through loose clearances. Some electrically controlled circuits
using variable current proportional solenoids might also change with
temperature since current and temperature can be closely related.

Mechanical Components
Always check for mechanical malfunctions—such as defective bearings,
binding linkages, and loose fasteners.

8-16
D36x50 Series II Navigator HDD Service Troubleshooting

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

Operate the machine functions and document performance of working

actuators.

Note functions not operating normally based on the theory given in that
function chapter. Comparing results with normal operation given for each
mode of a particular function will help to isolate the fault(s) to one or more
functions or components.

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

Possible Results 1. If faults are noted when operating all the machine actuators, it would
indicate a function or component that is common to all the actuators is
most likely faulty. The following common functions and components
should be investigated:
• Engine. See "Engine Troubleshooting," page 3-21.

Rod Loader
• Shared hydraulic components. See Chapter 4.
• Remote Lockout. See Chapter 15.
2. If faults are noted in the rod loader, stakedown, vises, greaser, and
drilling fluid functions, as well as the stabilizer and ground drive
functions and all other functions are OK, the following components
should be investigated:
• PFC pump PMP3
• Combination Valve Assembly A9.
• Return Manifold A22. See "Oil Filtering Function," page 4-12.
3. If problems are noted only in the rod loader function, and all other
functions are OK, troubleshoot the rod loader electrical circuit first.

8-17
 Troubleshooting D36x50 Series II Navigator HDD Service

Testing Rod Loader Performance

Before beginning any troubleshooting or testing procedures, perform the
"Pretest Inspection," page 4-17. If nothing obvious is found, continue.

1. Ensure switches listed in "Checking Machine Performance," page 2-9, are

in correct positions.
2. If pretest inspection has not been performed, conduct inspection before
proceeding.
3. Start the engine.
4. Enable Remote Lockout.
5. Press hydraulic enable switch S30 to
enable rod loader circuits.
NOTE: The performance values listed for S30
the rod loader circuit are for reference
purposes only. All functions should require
about 2 seconds for completion. Due to these
short time frames, operational conditions of
these circuits should not be determined by
the results of these tests alone. If circuit
operation is in question, refer to
troubleshooting the rod loader function section.
Rod Loader

6. Push rod lift switch S37. Rod lift cylinders

will extend in approximately 2 seconds.
The LED above the switch will light while
the rod is in the lowered position.
7. Push rod lift switch again. Rod lift
cylinders will retract in approximately 2
seconds.

S37

Continued on next page...

8-18
D36x50 Series II Navigator HDD Service Troubleshooting

8. Push loader arm extend switch S38. Loader

arms will move to the drill string in
approximately 2 seconds. The LED will
remain lit while the button is being pressed.

S38

9. Push loader arm retract switch S39 to

RETRACT position. Loader arms will move
toward the rod box in approximately 2
seconds.

S39

Rod Loader

8-19
 Troubleshooting D36x50 Series II Navigator HDD Service

Troubleshooting the Rod Loader Load Function

The rod load function contains both electrical and hydraulic components. If
the steps in "Troubleshooting Guidelines," page 1-8 indicate the circuit is not
operating properly, begin troubleshooting by following the general
guidelines below.

1. If the loader arms will not extend, remove rod loader valve manifold
cover.
2. With engine running, seat switch closed, and Remote Lockout enabled.
Push hydraulic enable button S30. Ensure gearbox carriage is fully
retracted (rear stop switch S9 is closed).
3. Disconnect wire 718B from rod loader power solenoid L6. Use
multimeter to check for voltage.
Expected result: When switch is pushed, 12 volts will be present at wire
718B of solenoid L6.

If not, check components in circuit for voltage. If voltage is found at

hydraulic enable switch S30, check continuity of wire 718B to solenoid
L6. Replace wire section if faulty. If so, continue.
4. Check wire 322 at solenoid L6 for continuity to ground. If continuity is
found, go on to the next step. If not, repair wire segment.
Rod Loader

5. Push loader arms extend switch S38. Use multimeter to check for voltage
at wire 702 of solenoid L32.
Expected result: When switch is pushed, 12 volts will be present at wire
702.

If not, check components in circuit for voltage. If voltage is found at pin

5, wire 702 of right joystick 12 pin connector, check continuity of wire 702
to solenoid L32. Replace wire section if faulty. If so, continue.
6. Disconnect wire harness from solenoid L32. Use multimeter to check
resistance of coil L32.
Expected result: Coil resistance should measure 7.2 ohms @ 68°F (20°C).
If not replace coil. If so, troubleshoot the hydraulic circuit.
Continued on next page...

8-20
D36x50 Series II Navigator HDD Service Troubleshooting

7. Push loader arms retract switch S39. Use

multimeter to check for voltage at wire
816.
Expected result: When switch is pushed,
12 volts will be present at wire 816. 1

If not, check components in circuit for

voltage. If voltage is found at switch S39,
check continuity of wire 816 to solenoid
L33 (1). Replace wire section if faulty. If
so, continue.
8. Test the solenoid coil for magnetism
when switch is activated. If so, also test
coil resistance. It should have a
resistance of 7.2 ohms @ 68°F (20°C). If
so, troubleshoot hydraulic circuit.
9. Inspect rod loader valve A6. If OK,
continue.

Rod Loader

8-21
 Troubleshooting D36x50 Series II Navigator HDD Service

Troubleshooting Rod Lift Function

The rod loader select function contains both electrical and hydraulic
components. If the steps in "Checking Machine Performance," page 2-9
indicate the circuit is not operating properly, begin troubleshooting by
following the general guidelines below.

1. If the rod loader lift cylinders will not extend, and other rod loader
functions are working correctly, remove rod loader valve manifold cover.
2. With the engine running, and the operator seat switch closed, ensure
Remote Lockout is functioning properly and that the rotation gearbox is
in the retracted position. Push hydraulic enable button S30. This
activates rod loader power valve solenoid L6, supplying hydraulic oil to
rod loader valve A6.
3. Disconnect wire 704 from solenoid L5.
4. Push rod lift switch S37. Use
L5
multimeter to check for voltage at wire
704.
L6
Expected result: When switch is
pushed, 12 volts will be present.
If not, check components in the
electrical circuit for voltage. If voltage
Rod Loader

is not found at switch, check continuity

of wire 704 at the right joystick 12-pin
connector to solenoid L5. Replace wire
section if faulty. If so, continue.
5. 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.
6. Inspect rod loader valve A6. If OK,
continue.
7. Test cylinders CY3 and CY4 for cross piston leakage. Refer to the
Vermeer Industrial Dealerships Technician’s Shop Manual.

8-22
D36x50 Series II Navigator HDD Service Troubleshooting

Test Equipment Needed

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

• Multimeter for continuity tests, voltage measurements, resistance

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

NOTE: Hydraulic component test procedures discussed in this chapter will

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

Specifications
Listed below are electrical and hydraulic specifications for rod loader
functions.

Electrical:

Rod Loader
• Nominal circuit voltage - 12 volts DC
• Rod loader valve solenoid coils L16, L17, L18, and L19 - 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 maximum output @ 37 rpm - 562 ft-lb (762 Nm)

Component Repair/Replace
If troubleshooting procedures determine a component is in need of repair or
replacement, refer to the appropriate procedures at the back of the chapter
or other chapters where instructed. After repairs have been made, refer
to"Hydraulic Fluid Sampling," page 4-20 and follow instructions.

8-23
 Component Repair D36x50 Series II Navigator HDD Service

COMPONENT REPAIR
Rod Loader Valve Manifold A6

2 3

1
2

Remove 1. Label, disconnect, cap and plug hydraulic hoses connected to valve
manifold.
Rod Loader

2. Disconnect wire harness from solenoid coils.

3. Remove screws (1), washers (2), and nuts (3) mounting valve to frame.
4. Remove valve from side of rod box.
5. Remove fittings.
Inspect valve openings for contamination or burrs.

Reverse removal procedure to install valve. Torque screws to 20 ft-lb (27

Nm).

8-24
D36x50 Series II Navigator HDD Service Component Repair

Directional Valves DV13, DV12, and DV9

Remove 1. Disconnect electrical connection
from solenoid coils. 2 3
2. Remove nut and solenoid coil L33
and L32 (3), L5 (2), or L6 (1).
3. Unscrew and remove valve from
valve manifold. 1

NOTE: Make note of O-ring and backup

washer orientation.

4. Inspect valve and O-rings for

damage and ensure no external
contaminants are present.
5. Inspect valve body cavity for burrs or other irregularities which could
damage O-rings during installation.
6. Replace O-rings and backup washers if needed.
7. Dip valve in clean filtered oil.
8. Screw valve in by hand until O-ring contacts valve body. Torque valve to
25 ft-lb (33.9 Nm).

Rod Loader
9. Install solenoid coil. Torque nut to 5 ft-lb (6.8 Nm).

8-25
 Component Repair D36x50 Series II Navigator HDD Service

Rod Lift Cylinders CY1 and CY2

3
7
2

6
4
8

9
Remove 1. Ensure no rods are in rod lift arm (1).
Rod Loader

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

3. Label, disconnect and cap hoses attached to cylinder (4).
4. Remove bolts (5), washers (6), and nuts (7) holding cylinder to
undercarriage.
5. Remove cotter pin (3) and pin (2) that attaches cylinder to base of rod lift
arm (1).

8-26
D36x50 Series II Navigator HDD Service Component Repair

Disassemble

6 6
4

5 6
6 6 2 1 6
1. Use spanner wrench to remove square keystock wire (1) from gland (2).
Wire should be removed in counterclockwise (CCW) motion.
2. Remove gland (2).
3. Pull rod assembly (3) out of cylinder body. Ensure ports are open and

Rod Loader
positioned to direct oil into a suitable container.
4. Remove nut (4) from rod assembly.
IMPORTANT: Do not clamp onto unpainted portion of the rod. Scarring rod
can cause premature seal failure.

5. Slide piston (5) off rod.

6. Remove and replace seals and rings (6). Refer to the Parts Manual for
seal repair kit components. Apply a light coat of petroleum jelly to seals
before installation.
Assemble 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 head gland into cylinder body and secure.
4. Install cylinder by reversing removal steps. Torque mounting bolts to 35
ft-lb (47 Nm).

8-27
 Component Repair D36x50 Series II Navigator HDD Service

Rod Loader Motor MH7

1
Rod Loader

Remove 1. Label, disconnect and plug hoses to motor.

2. Remove screws (1) holding motor to underside of rod box.
3. Disengage splined shaft.

8-28
D36x50 Series II Navigator HDD Service Component Repair

Disassemble

Valve Plate
Splined Drive Seal
Wear Plate
Seal
Shaft Face Seal
Bearing and
Shaft Assembly
Valve Drive
Shaft Seal Geroler
Bearing
Housing Tie Bolt (4)
Outer Face Spring
Seal
Inner Face
Seal

Backup Balance
Washer Ring Valve Housing

Seal Valve O-ring

Exclusion Seal

Plug
Pin
Seal Speed Sensor

Rod Loader
Continued on next page...

8-29
 Component Repair D36x50 Series II Navigator HDD Service

Because cleanliness is IMPORTANT: Inspect all parts for damage (scratches or burrs) or unusual
extremely important, wear during each step of disassembly. Check condition of all mating
cap or plug all of the surfaces. Do not re-use O-rings or seals.
hoses and fittings during
disassembly. 1. Drain oil from the motor and thoroughly clean the exterior.
2. Place motor (1) in a soft-jawed vise with the output shaft down. If
possible, keep motor in a vise during disassembly and assembly.
Rod Loader

3. Remove four tie bolts from the motor.

Continued on next page...

8-30
D36x50 Series II Navigator HDD Service Component Repair

4. Lift valve housing (1) straight up.

NOTE: If done carefully, the springs and balance ring will remain on the
valve (2).

Rod Loader
6

5. Carefully remove seal (3) from valve housing (4).

6. Remove case drain plug (5) with O-ring seal (6).
Continued on next page...

8-31
 Component Repair D36x50 Series II Navigator HDD Service

2 3

7. Remove two pins and two springs (4) from balance ring subassembly (2).
8. Remove balance ring subassembly from motor housing (1).
9. Remove balance ring’s inner (5) and outer (3) face seals.
10. Remove valve (6).

9
Rod Loader

10

11. Remove valve plate (7) and its seal (8) from the motor housing (9).
12. Remove valve drive (10).
Continued on next page...

8-32
D36x50 Series II Navigator HDD Service Component Repair

13. Remove geroler (1) from motor housing (2), being sure to retain rollers in
the outer ring if they are loose.
14. Remove drive (3).
15. Remove seal (4) from bearing housing.

8
6

Rod Loader
5

16. Remove wear plate (5) from bearing housing (6).

17. Remove shaft face seal (7) from wear plate.
18. Remove seal (8) from bearing housing.
Continued on next page...

8-33
 Component Repair D36x50 Series II Navigator HDD Service

19. Remove shaft and bearing assembly (1) from bearing housing (2).
NOTE: A press may be needed to remove bearing assembly from bearing
housing.

5
3
Rod Loader

20. Remove shaft seal (3), backup washer (4), and exclusion seal (5) from
bearing housing (6).
NOTE: Ensure bore of housing is not damaged.

21. Clean all metal parts in clean solvent and blow dry with air. Do not wipe
with cloth or paper towels because lint or other matter could get into the
hydraulic system and cause damage. Do not use abrasives or try to file or
grind motor parts.
22. Check all mating surfaces.
23. Check around the chamfered area of the shaft for burrs, nicks or sharp
edges that can damage seals during assembly.

8-34
D36x50 Series II Navigator HDD Service Component Repair

Assemble

3
5
1
6

NOTE: Use all new O-rings and seals. Coat with petroleum jelly to help
position them during installation.

1. Install exclusion seal (1) in outer seal groove of bearing housing (2),
using a press.

Rod Loader
NOTE: If a press is not available, use a plastic or rubber hammer. Be
careful not to damage or cock the seal in the bore.

2. Place backup washer (3) into seal bore.

3. Place shaft seal (4) onto installation tool and press seal into seal bore of
bearing housing.
4. Clamp bearing housing (2) in a vise across the flange edge.
5. Tape or apply a protective sleeve (Eaton tool) to the shaft to prevent
cutting or distorting the seals.
6. Install shaft and bearing assembly (6) into bearing housing.
7. Apply a light film of petroleum jelly to the 3″ seal (5) and install into
bearing housing.
Continued on next page...

8-35
 Component Repair D36x50 Series II Navigator HDD Service

2
1 2

8. Using two 8″ alignment studs (not shown) will aid in assembly of motor.
Install alignment studs diagonally opposed in bearing housing (1).
9. Apply a light film of petroleum jelly to inner face seal (2) and install in
wear plate (3).
IMPORTANT: Do not distort seal.

10. Install wear plate (3) against the bearing housing.

2
Rod Loader

11. Apply a light film of petroleum jelly to the 3″ seal (2), and install seal in
the groove of the wear plate (1).
12. Install splined drive (4) in bearing and shaft assembly, inserting longer
splined end first.
13. Align notch on the outside of geroler (3) with notch on the wear plate (1).
Ensure rollers are retained in the outer ring if they are loose.
Continued on next page...

8-36
D36x50 Series II Navigator HDD Service Component Repair

14. Install valve drive (2) in geroler (1).

Continued on next page...

Rod Loader

8-37
 Component Repair D36x50 Series II Navigator HDD Service

2 3 Rotate valve
1 clockwise 1/2
tooth max. to
engage spline

Any one of 6
ports open to
5 outside of valve
4
Largest open
pocket

NOTE: There are three steps involved in timing the motor. Timing
determines the shaft rotation direction. Timing parts include geroler (1),
valve drive (5), valve plate (4), and valve (3).

15. Timing step #1:

• Locate largest open pocket in geroler (1) and mark it on outside edge.
• Apply a light film of petroleum jelly to 3″ seal (2) and install in valve
plate (4).
• Align notch on outside of valve plate with notch on geroler.
Rod Loader

16. Timing step #2:

• Locate slot opening in valve plate which is in-line with largest open
pocket of geroler.
17. Timing step #3:
• Locate any one of the side openings of the valve (3) that goes through
to the face of the valve.
• Align selected side opening with open slot of valve plate that is in-line
with largest open pocket of the geroler.
• Install valve by rotating clockwise 1/2 spline tooth until spline teeth
engage, providing correct rotation.
Continued on next page...

8-38
D36x50 Series II Navigator HDD Service Component Repair

Clockwise
Rotation

Counterclockwise
Rotation
18. Proper rotation is when pressurized as follows:
• pressure in port (1) clockwise rotation.
• pressure in port (2) counterclockwise rotation.

3
5 4

Rod Loader
6

19. Apply clean grease to the balance ring assembly springs (3). Install two
springs and two pins (4) in the holes of the valve housing bore.
20. Apply a light film of petroleum jelly to 3″ seal (5) and install in valve
housing (6).
Continued on next page...

8-39
 Component Repair D36x50 Series II Navigator HDD Service

Outer Seal

2
1

Inner Seal
3

IMPORTANT: The inner and outer face seals (2) must be installed correctly
for the motor to operate properly. Damaged seals, resulting from forcing or
bending, will adversely affect motor operation.

21. Apply petroleum jelly to the inner and outer face seals (2). Install seals
on the balance ring (1) exactly as shown.
22. Align pin notches in balance ring with two pins in valve housing (3).
Install balance ring assembly in housing.
Rod Loader

Balance
Ring Assembly
3

23. Insert a finger through the port of the valve housing (3).
24. Apply pressure to the side of the balance ring, holding it in position until
the valve housing is in place.
25. Install valve housing against valve plate.
NOTE: 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.
Continued on next page...

8-40
D36x50 Series II Navigator HDD Service Component Repair

26. Install tie bolts (2) in the motor housing (1). If alignment studs were
used, install two bolts opposite the studs.
27. Finger tighten bolts.
28. Remove alignment studs and replace with the two remaining bolts.
29. Gradually torque the bolts to 50 ft-lb (68 Nm), using sequence shown

Rod Loader
above.
30. Install case drain plug (3) assembly.

8-41
 Component Repair D36x50 Series II Navigator HDD Service

Rod Box
Remove

WARNING: Falling load can crush. Never lift rod box over people.

Do not stand or work under raised rod box.

WARNING: Pinch points can result in serious crushing injuries. Keep

hands and feet away from pinch points of rod loader. Keep shields in
place and properly secured.

1. Move column selector bar fully in towards rack.

2. Fully retract rod selector.
3. Raise rod lifter arm to push rods into box.
4. Install front and rear rod keeper pins
Rod Loader

(1) and hairpins. Lower rods and 1

shut off engine.

5. Connect hoist chain to four rod box

lift rings (2).
6. Turn four rod box adjusting screws
(3) outward. 2

7. Remove rod box keeper bars (4).

8. Remove rod box.
4

8-42
D36x50 Series II Navigator HDD Service Flow Test for PMP3

Install 1. Connect hoist chain to lift rings.

IMPORTANT: Lift rod box by top lift rings only.

2. Carefully lower rod box between guide plates.

NOTE: Install rod box with male threads to front.

3. Install rod box keeper bars.

4. Remove hoist chain.
5. Adjust four screws back in until rod box lines up with selector plate.
6. Start engine.
7. Raise rod lifter arm to push rod into rod box.
8. Shut off engine.
9. Remove both bottom rod keeper pins before drilling. Store pins in holders
on top of rod box.

FLOW TEST FOR PMP3

Rod Loader
This test determines pump condition by measuring internal leakage when
the pump is under load.

WARNING: Pressurized fluid can penetrate body tissue and result in

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

Continued on next page...

8-43
 Flow Test for PMP3 D36x50 Series II Navigator HDD Service

Setting Up
You will need a flow meter capable of handling 45 gpm at the midpoint of its
flow range, equipped with a 0–6000 psi pressure gauge and needle valve.
2
3

6
5 1

1. Disconnect and cap hoses at port TM and port LS1 of the combination
valve manifold A9 (1).
Rod Loader

2. Install a T-fitting (2) at port TM of manifold (1). Attach one end of an

inch diameter 3000 psi rated hose (3) to the fitting and the other end to
the inlet side of the flow meter (4). Ensure flow arrow is pointing away
from proportional dump valve A9.
3. Disconnect and cap hose attached to return manifold A12 at port B.
4. Install a 1'' hose (5) with a 3000 psi pressure rating between the outlet
port of the flow meter and port B of return manifold A12.
5. Ensure needle valve on the flow meter is fully open.
6. Connect a 3000 psi rated 3/8'' hose (6) to the fitting at manifold port TM.
Connect the other end of the hose to manifold port LS1.
7. Ensure needle valve on the flow test device is fully open.

8-44
D36x50 Series II Navigator HDD Service Flow Test for PMP3

Conducting the Test

1. Start machine and check all connections for leaks. Shut down and
tighten connections as needed to stop leaks.
2. Increase engine speed to 2400 rpm.
3. Use pyrometer to ensure hydraulic fluid in the tank is at least 100°F
(38°C). If not, run gearbox forward and back to warm the fluid.
4. Observe tachometer and record the engine RPM, flow indicated on the
meter, and the pressure gauge at the beginning of the test.
5. Slowly turn in the needle valve on the pressure flow test device until the
pressure reaches 3000 psi (207 bar), then record amount of flow
indicated.
6. Carefully observe tachometer and record engine speed while the
pressure flow test device is indicating 3000 psi (207 bar).
7. Shut down machine, remove equipment and review results. Reconnect
load sense lines and other hoses.

A: Beginning B: Ending (at 3000 psi or 207 bar)

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

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

A3: indicated pressure: _________________ psi (bar) B3: indicated pressure: ______3000 psi 207 bar____

8-45
 Flow Test for PMP3 D36x50 Series II Navigator HDD Service

Understanding the Results

The theoretical flow from this 4.52 cid (75 cc) pump, if run at 2400 rpm, is 47
gpm. This figure does not allow for any internal leakage. In reality, all
pumps have some internal leakage. This leaks between the moving parts of
the pump, into the case of the pump. The case drain carries this back to the
tank.

This is a piston pump. New piston pumps are expected to be about 97%
efficient, so expected flow is 45.5 gpm (172 L/min) at 2400 rpm for this pump
when new, and 32 gpm (121 L/min) for a pump at the end of its useful life.

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

Calculating 1. Multiply the value in B1 (ending engine speed) times 4.52 (displacement
Theoretical Flow of the pump). This is the theoretical flow in cubic inches per minute for
and Acceptable this engine speed. (Metric users, multiply times 25 for cc/min.)
Flow
2. Divide this amount by 231 to convert the cubic inches per minute to
gallons per minute. (Metric users, divide by 1000 for L/min).
3. Multiply this value by 0.70. The result is the minimum acceptable flow
from this pump at this engine speed.
Rod Loader

Compare the minimum acceptable flow value with the value recorded in B2.
If B2 is lower, this pump is worn beyond its useful life and should be
replaced. See "PFC Pump PMP3," page 4-26.

8-46
D36x50 Series II Navigator HDD Service Rod Transfer Arm Barrier Limit Switch

ROD TRANSFER ARM BARRIER LIMIT SWITCH

4
1

Limit switches are 1. Loosen two screws (1). With bar (2) locking the barrier arm (3) in the
located on the front and position shown, slide limit switch (4) on the mounting bracket slightly
rear rod loaders. past the point where an audible click is heard as switch actuator (5) is
deflected. Tighten two screws (1).
2. Verify correct switch operation by raising and lowering barrier arm(3).
With barrier arm raised, rotation and thrust/pullback must be disabled.
Latch the barrier arm in place with bar (2).

Rod Loader
ANTI-CRASH SWITCH

5 6

4
3
1

This anti-crash switch is 1. Fully retract rod loader arms (1) so they are under first row of rod (2).
only on the rear rod
loader.

Two bolts (6) allow the 2. Position switch (3) so the following conditions exist:
switch to be positioned
vertically and • Roller (4) makes firm contact with plate (5).
horizontally. • Manually pulling back on the roller results in an audible click.
• Roller ramps smoothly (without binding switch) onto the surface of the
plate as the rod loader arms move forward.

8-47
 Alignment of Rod Loader Arms to Rod Row D36x50 Series II Navigator HDD Service

ALIGNMENT OF ROD LOADER ARMS TO ROD ROW

3
2 4

1 5 6

1. Arms (1) on front and rear rod loaders are designed to be correctly
centered to rod row (2) when the following conditions exist:
• Rod loaders are fully retracted.
• Bars (3) are fully back against plate cover stop surfaces (4).
2. To reposition arms (1) forward relative to the rod row, adjustments are
as follows:
• Fully extend front and rear rod loaders to relieve pressure on bars (3).
• Loosen lock nuts (5).
The holes for pins (7) • Advance screws (6) from being fully flush with plate cover stop
Rod Loader

are oversized to permit surfaces (4) to reposition arms forward.

a small amount of
adjustment using
• Tighten lock nuts (5).
screws (6).

8-48
D36x50 Series II Navigator HDD Service Rod Alignment to Drive Chuck

ROD ALIGNMENT TO DRIVE CHUCK

Special Tools
• torque wrench capable of producing 180 ft-lb (244 Nm)

4
5
1 3
2

Procedure
1. Load a rod on the rod loader arms and fully extend the arms. Visually
check rod alignment to the rear vise and drive chuck. Then, verify
alignment further by clamping the rod in the upper vise and slowly
engaging the drive chuck with the rod.
2. Adjustments are as follows:
• The front and rear rod loaders are centered horizontally using screws

Two of four bolts (5) on
each rod loader are
located behind hoses.
Rod Loader
(1). Loosen lock nuts (2) and advance the screws to decrease the
extension of the arms. Tighten the lock nuts.
• The front and rear rod loaders are centered vertically using screws (3).
Loosen lock nuts (4), as well as bolts (5) and nuts (not shown). Advance
screws (3) to raise the arms. Torque bolts (5) and nuts to 180 ft-lb
(244 Nm). Tighten lock nuts (4).

8-49
This page intentionally left blank.
D36x50 Series II Navigator HDD Service Overview

Chapter 9: Stabilizer

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

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

• Stabilizer Valve Assembly A25 including:

• Valve DV24
• Extend Solenoid L18 and Retract Solenoid L19
• Combination Valve Assembly A9, including:
• Hydraulic Enable Valve DV29 and Solenoid L26
• Stabilizer Cylinder CY11, including:

Stabilizer
• Lock Valve CV15
• Pilot-operated Check Valve CV14

9-1
 Theory D36x50 Series II Navigator HDD Service

Component Locations
STABILIZER SWITCH S24

STABILIZER SWITCH S27

PILOT OPERATED
STABILIZER VALVE A20
CHECK VALVE CV10

ORIFICE FV1, FV2

STABILIZER EXTEND
SOLENOID L18
CHECK
STABILIZER RETRACT VALVE CV1
Stabilizer

SOLENOID L19
CYLINDER CY11

9-2
D36x50 Series II Navigator HDD Service Theory

COMBINATION
VALVE
MANIFOLD
A9

Stabilizer
HYDRAULIC
ENABLE VALVE
DV29, SOLENOID
DV26

9-3
 Theory D36x50 Series II Navigator HDD Service

Hose Connections

STABILIZER CYLINDER CY11

RETURN
MANIFOLD

STABILIZER VALVE
MANIFOLD A25
Stabilizer

HYDRAULIC
TANK RES1

PFC PUMP PMP3

PROPORTIONAL
DUMP VALVE A9

9-4
D36x50 Series II Navigator HDD Service Theory

Electrical Schematic

CIRCUIT TERMINAL BUS TB1

BREAKER
CB5

FRONT STABILIZER
SWITCH S24
SEAT SWITCH RELAY K7

DIODE D2

DIODE D1

Stabilizer
SEAT SWITCH S26

HYDRAULIC ENABLE CIRCUIT

SOLENOID L26 BREAKER
CB6

STABILIZER EXTEND
SOLENOID L18

STABILIZER RETRACT
SOLENOID L19
REAR STABILIZER
SWITCH S27

9-5
 Theory D36x50 Series II Navigator HDD Service

Hydraulic Schematic
CHECK VALVE CV14 RETRACT SOLENOID
STABILIZER L19
CYLINDER CY11 VALVE DV24

FROM SWITCH S27

OR S24

FROM SWITCH S27

OR S24
EXTEND
CHECK
VALVE CV15 SOLENOID
L18
COMBINATION
VALVE A9
Stabilizer

PUMP PMP3

HYDRAULIC ENABLE
VALVE DV29
HYDRAULIC
TANK RES1

9-6
D36x50 Series II Navigator HDD Service Theory

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

• Hydraulic Oil Tank RES1

• Return Filters FL3 and FL4
• Oil Cooler HE1
• PFC Pump PMP3
For more information on these hydraulic components, refer to Chapter 4.

Stabilizer

9-7
 Theory D36x50 Series II Navigator HDD Service

Combination Valve Assembly A9

TO GROUND DRIVE LOAD SENSE VALVE DV28,
SOLENOID L25

FROM PUMP PMP3

SOLENOID
L26
HYDRAULIC
ENABLE VALVE
DV29
TO STABILIZER TO TANK
Stabilizer

MANIFOLD A25
Operation The combination valve assembly A9 controls all flow from pump PMP3. It
contains hydraulic enable valve DV29 which allows pump flow out of port B
to the stabilizer, vise, rod loader, stakedown, drilling fluid, and auto greaser
functions.

When the ignition switch is in RUN position, with operator seat switch
closed (seat occupied) and the hydraulic enable button pushed:

• Solenoid L26 of DV29 is energized.

• Oil flow will be directed to the stabilizer, vise, rod loader, stakedown,
drilling fluid, and auto greaser control valve assemblies.
• Drill/track solenoid L24 is activated, shifting valve DV27 which stops oil
flow to the ground drive function.

NOTE: If function does not operate normally, see troubleshooting section in

this chapter.

9-8
D36x50 Series II Navigator HDD Service Stabilizer Function

STABILIZER FUNCTION
Stabilizer LOWER Mode
STABILIZER VALVE DV24 SOLENOID L19

LOCK
CYLINDER CY11
CHECK
CV14

TO RETURN
MANIFOLD A22

FROM COMBINATION
VALVE
SOLENOID L18 VALVE A9
CHECK VALVE CV15 MANIFOLD A25
Operation For the stabilizer to lower:

• Operator seat switch S26 must be open (seat unoccupied) if using rear
stabilizer switch.
• Operator seat switch S26 must be closed (seat occupied) if using front
stabilizer switch.

Stabilizer
• Hydraulic enable switch S30 must be pressed (closed).
• Engine running at full throttle.
• Stabilizer switch on either transport control panel or operator control
panel must be pushed at top.
The stabilizer circuit controls the stabilizer cylinder at the rear of the
machine. It is comprised of hydraulic components that raise and lower an
arm that stabilizes the machine during operation.

When required operating conditions are met:

• Oil flows from combination valve manifold A9 (port B) to stabilizer valve

manifold A25.
• Oil flows from stabilizer manifold A25 to cylinder CY11.
• Cylinder CY11 extends to lower stabilizer.
• Lock check valves CV14 and CV15 keep the cylinder from retracting
when there is no circuit pressure by locking oil in the cylinder. This
ensures the cylinder will remain in the same position when the control is
released and solenoids L18 and L19 are not powered.

NOTE: If stabilizer lower mode does not operate as expected, see

"Troubleshooting Stabilizer Function," page 9-15.

9-9
 Stabilizer Function D36x50 Series II Navigator HDD Service

Stabilizer RAISE Mode

CYLINDER CY11 STABILIZER VALVE DV24

LOCK CHECK SOLENOID L19

VALVE CV14

TO RETURN
MANIFOLD A22
FROM COMBINATION
MANIFOLD A9

CHECK VALVE CV15 SOLENOID L18

Operation For stabilizer to raise:

• Operator seat switch S26 must be open (unoccupied) if using switch on

transport control panel OR operator seat switch must be closed (seat
occupied) if using switch on operator control panel.
• Engine must be running at full throttle.
• Hydraulic enable switch S30 must be pressed (closed).
• Stabilizer switch on either transport control panel or operator control
Stabilizer

panel must be pushed at bottom.

When required operating conditions are met:

• Oil flows from combination manifold A9 (port B) to stabilizer valve A20.

• Oil flows from stabilizer valve DV24 to cylinder CY11.
• Cylinder CY11 retracts to raise stabilizer.
• Lock check valves CV14 and CV15 keep the cylinder from retracting
when there is no circuit pressure by locking oil in the cylinder. This
ensures the cylinder will remain in the same position when the control is
released and solenoids L18 and L19 are not powered.

NOTE: If stabilizer RAISE mode does not operate as expected, see

"Troubleshooting Stabilizer Function," page 9-15.
\

9-10
D36x50 Series II Navigator HDD Service Troubleshooting

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

If nothing obvious is found during the inspection, it may be necessary to

operate all other functions of the machine to help further isolate a
component problem. See "Troubleshooting Machine Performance," page 9-13.

Test Equipment Needed

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

• Multi meter for continuity tests, voltage measurements, resistance

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

NOTE: The hydraulic component test procedures discussed in this chapter

will refer the technician to the Vermeer Industrial Dealerships Technician’s
Shop Manual (Vermeer P/N 105400V80). Test procedures and equipment

Stabilizer
needed for performing the various test on hydraulic components will be
listed in the manual.

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

Electrical:

• Nominal circuit voltage - 12 volts DC

• Solenoid L26 resistance - 9.8 ohms at 68°F (20°C)
• Solenoid L18 and L19 resistance - 7.2 ohms at 68°F (20°C)
Hydraulic:

• PFC Pump PMP3 normal output flow - variable to 45 gpm (170 L/min)
• PFC Pump PMP3 standby pressure compensator valve setting - 250 psi
(17.2 bar)
• PFC Pump PMP3 high pressure compensator valve setting - 3000 psi
(207 bar)

9-11
 Troubleshooting D36x50 Series II Navigator HDD Service

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

Mechanical

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

Electrical

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

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

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

9-12
D36x50 Series II Navigator HDD Service Troubleshooting

Hydraulic

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

Check hydraulic components for any obvious problems.

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

Stabilizer
Also review information in the General Information chapter under
"Hydraulic Troubleshooting," page 1-12. Correct any problems found during
the inspection. Operate machine to verify the problem is fixed.

Troubleshooting Machine Performance

If there are malfunctioning components in other functions, they may affect
stabilizer function operation.

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

Make note of any functions not operating normally based on the normal
operation given in each chapter for that function. Comparing the results
with the normal operation given for each mode of a particular function will
help to isolate the fault(s) to one or more function or component.

After doing machine performance checks, if the problem is isolated to the

original function in question, return to the troubleshooting/testing for that
function. If multiple functions are affected, proceed with troubleshooting
based on the possible results listed below.

9-13
 Troubleshooting D36x50 Series II Navigator HDD Service

Possible Results: 1. If all machine functions are not working correctly, it would indicate a
function or component that is common to all the actuators is most likely
malfunctioning. The following functions and components should be
investigated:
• Engine. See Chapter 3.
• Shared hydraulic components. See Chapter 4.
• Remote Lockout. See Chapter 11.
2. If problems are noted in ground drive and stabilizer functions, as well as
rod loader, auto greaser, stakedown, drilling fluid and vise functions, and
other functions of the machine are operating normally, the hydraulic
components common to just these functions should be investigated,
including:
• Combination valve assembly A9. See "Troubleshooting Combination
Valve A9," page 9-16.
• PFC pump PMP3.
• Load sense control circuit.
3. If problems are noted in the stabilizer function and all other machine
functions are operating normally, the components associated with this
function should be investigated.
Stabilizer

Testing Stabilizer Performance

1. Start machine.
2. Enable Remote Lockout.
3. Press hydraulic enable button S30 to enable hydraulic circuits.
4. Ensure stabilizer cylinders are fully
retracted. If necessary, move 1
stabilizer switch S27 (1) to RAISE
position until stabilizer cylinder is
fully retracted.
5. Simultaneously start stopwatch and
move stabilizer switch to the
LOWER position. Stop timing when
stabilizer cylinder is fully extended.
Time required for stabilizer cylinder
to move from fully raised to fully
lowered position should be
approximately 7 seconds.

9-14
D36x50 Series II Navigator HDD Service Troubleshooting

Troubleshooting Stabilizer Function

The stabilizer circuit contains both electrical and hydraulic components. If
the steps in "Troubleshooting Machine Performance," page 9-13 indicate the
circuit is not operating properly, begin troubleshooting by following the
general guidelines in "Troubleshooting," page 9-11.

Continue by troubleshooting the electrical circuit.

1. With the engine running, Remote Lockout enabled, and no operator in

the seat, operate the stabilizer function from the rear control switch S27.
With operator in the seat, operate the stabilizer function from front
control switch S24. If the stabilizer will not function, investigate the
electrical circuit.
2. If cylinder fails to extend, disconnect wire
320E and 758 from solenoid L18 (2).
Check 320E for continuity to ground.
Check 758 for power when switch is
pushed. If cylinder fails to retract,
disconnect wire 320D and 758 from
solenoid L19 (1) and check 320D for
continuity to ground. Check 758 for power 2
when switch is pushed.
Expected result: 320 wires should have

Stabilizer
continuity to ground. If they do not, check 1
wire connections and black wires that
provide ground to solenoids back to circuit
breaker CB5 for the front stabilizer switch and seat switch relay K7 for
the rear stabilizer switch. Repair or replace faulty wires or connections.
758 wire should have power when switch is pushed. If not, trace power
wire back to circuit breaker CB5 for front stabilizer switch and CB6 for
rear stabilizer switch. Repair or replace faulty wires or connections. If
power and ground are present, continue.
3. Disconnect solenoid L18 (2) for extend mode and solenoid L19 (1) for
retract mode connections and check solenoid coil resistance.
Expected result: Resistance across the solenoid terminals should
measure 7.2 ohms ± 0.7 ohm. If not, replace solenoid. If so, valves may
not be functioning properly.
4. Remove stabilizer valve DV24 and check for damaged seals or
obstructions. If OK, continue.
5. Remove and inspect lock check valve cartridge CV10 on the stabilizer
cylinder for contamination or damage. If OK, continue.
6. If cylinder CY11 can not hold position of stabilizer steady and all
solenoids and valves have been checked, and correct voltage is being
supplied to the solenoid, replace entire cylinder/lock valve assembly.

9-15
 Troubleshooting D36x50 Series II Navigator HDD Service

Troubleshooting Combination Valve A9

If faults are noted in the vises, stabilizer, stakedown, rod loader, drilling
fluid, auto greaser, and ground drive functions, and all other machine
functions are normal:

1. Test for acceptable voltage starting at solenoid coil L26 of hydraulic

enable valve DV29. Then test voltage at solenoid L25 of load sense valve
DV28. If voltage is acceptable, continue with step 3. If not, continue with
step 4.
2. Test resistance of coils L25 and L26.
Expected result: Resistance should measure 9.8 ohms @ 68°F (20°C). If
OK, continue with step 5. If not, replace affected coil(s).
3. Continue testing for acceptable voltage in the rest of the circuit at pins/
terminals of components and wire harness connector, seat switch S26,
and seat switch relay K7.
Expected result: Voltage should be within specification (10.5 volts min.).
If not, repair or replace faulty component(s) or wire harness segment(s).
If OK, continue.
4. Inspect hydraulic enable valve DV29 in valve assembly A9 for damage or
contamination. Refer to component repair section for instructions on
removal and disassembly.
Stabilizer

9-16
D36x50 Series II Navigator HDD Service Component Repair

Component Repair/Replace
If troubleshooting procedures determine a component is in need of repair or
replacement, refer to the appropriate procedures at the back of the chapter
or other chapters where instructed. After repairs have been made, refer
to"Fluid Sample Collection Points," page 4-22 and follow instructions.

COMPONENT REPAIR
Combination Valve Manifold A9

Stabilizer
1 2

Remove 1. Label, disconnect and cap all hoses and fittings.

2. Disconnect electrical wiring harnesses from coils.
3. Remove bolts (1), washers (2) holding manifold (3) to pump.
4. Remove O-ring (4) between pump and manifold.

Install Inspect O-ring for damage and replace if necessary.

Reverse removal procedures to install manifold.

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

9-17
 Component Repair D36x50 Series II Navigator HDD Service

Stabilizer Valve Manifold A25

1. Lower stabilizer to access valve. You
may need to remove the stabilizer
pad, arm and cylinder for adequate
work space. Refer to "Stabilizer,"
page 9-23 and "Stabilizer Cylinder
CY5," page 9-19.
2. Label, disconnect and cap all hoses
and fittings.
3. Disconnect electrical wiring
harnesses from coils.
4. Remove bolts (1) and washers (2)
holding valve to undercarriage.
2
5. Remove nuts (3) holding solenoid
coils in place. 1

6. Remove solenoid coils (4).

7. Remove valve cartridges and O- 3
rings.
8. Inspect O-rings and valve body for
4
Stabilizer

contamination or wear. Replace O-

rings if necessary. Clean valve body.
Reverse steps above to install valve.

Torque solenoid coils to 24-26 ft-lb

(32.5-35 Nm). Torque solenoid nut to 4-
5 ft-lb (5.5-6.8 Nm). Torque mounting
bolts to 10 ft-lb (13 Nm).

9-18
D36x50 Series II Navigator HDD Service Component Repair

Stabilizer Cylinder CY5

5
4
3
10

1
10

Stabilizer
9

Remove

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

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

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

Continued on next page...

9-19
 Component Repair D36x50 Series II Navigator HDD Service

2. Remove bolt (5) and washer (4). Remove pin (1) holding bottom of
cylinder (9) from stabilizer. Refer to "Stabilizer," page 9-23.
3. Remove bolt (6) and nut (7). Remove pin (2) and spacers (8) holding
cylinder to undercarriage.

Disassembly 1. Carefully loosen and remove lock valve cartridge. Refer to "Stabilizer
Cylinder Lock Check Valve CV18," page 9-21.

15

4
Stabilizer

1 11
10
5 9 3 13 14 2 8
6 7 12
2. Release gland (2). Gland is secured by setscrew (4).
3. With a suitable device (wrench or come-along), pull rod (13) out of
cylinder body (14). Ensure ports are open and position to direct oil into a
suitable container.
Continued on next page...

9-20
D36x50 Series II Navigator HDD Service Component Repair

4. Remove nut (1) from rod.

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

5. Slide gland (2) and piston (3) off rod.

6. Remove and replace seals.

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

1. Slide gland and piston onto rod and tighten nut.

2. Push rod (13) into cylinder body.
3. Install gland into cylinder body and secure with set screw.
4. If equipped with lock valve cartridge, fill cylinder with hydraulic oil and
install lock valve cartridge.
5. Install pins holding cylinder to undercarriage and stabilizer. Torque bolt
on rod end pin to 20 ft-lb (27 Nm). Torque bolt on base end to 35 ft-lb (47
Nm).

Stabilizer
Stabilizer Cylinder Lock Check Valve CV18
Remove WARNING: Some residual pressure may remain in cylinders equipped
with lock valve cartridges. Use extreme caution when removing cartridges.
Cartridge will be released with extreme force if residual pressure is
present in cylinder. Do not stand in front of cartridge when removing it

1. Label, disconnect, cap and plug

hydraulic hoses going to valve.
2. Remove bolts and washers
mounting valve to cylinder.
Remove lock valve.
NOTE: Trapped pressure in cylinder
with a lock cartridge valve can be
removed by loosening the jam nut
and turning the Allen head screw
completely in. Cartridge must be
returned to Vermeer to be reset.

Continued on next page...

9-21
 Component Repair D36x50 Series II Navigator HDD Service

Disassembly 1. Remove cartridges from valve body.

2. Inspect cartridge for any damages and ensure no external contaminants
are present.
NOTE: Remember the orientation of the seals. This will be useful in
installing new ones.

3. Inspect seals. If necessary replace seals.

4. Dip valve in clean filtered oil.
5. Screw valve in by hand. Torque cartridge to 30–35 ft-lb (40–47 Nm).
Reverse removal procedure to install valve.
Stabilizer

9-22
D36x50 Series II Navigator HDD Service Component Repair

Stabilizer
12 11
10
15 14
1
9
15
7 8
13
6

3
5 4

16

Stabilizer
1. Remove bolt (12) on pin (10) holding cylinder CY5 to stabilizer. Lower
stabilizer to the ground.
2. Remove clasp (9) and pin (8) holding stabilizer arm (1) to pad (2).
3. Remove bolt (3) and nut (7) on pivot pin (13). Remove pivot pin and
bushings (16).
Reverse steps above to install stabilizer. Torque bolt on pivot pin to 300 ft-lb
(405 Nm). Torque bolt on cylinder pin to 35 ft-lb (47 Nm).

9-23
This page intentionally left blank.
D36x50 Series II Navigator HDD Service Circuits

Chapter 10: Vises

CIRCUITS
The vises function is comprised of three circuit groupings that rely on PFC
pump PMP3 for hydraulic activation.

Front Vise Circuit

Rear Vise Circuit
Rear Vise Rotate Circuit

OVERVIEW
The vise circuits control front and rear vise clamp and rear vise rotation.

Components

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

• Vise Valve Assembly A8, including:

• Directional Valve DV19 and Solenoid L13
• Directional Valve DV20 and Solenoid L14
• Directional Valve DV21 and Solenoid L21
• Directional Valve DV22 and Solenoid L16
• Rear Vise Clamp Cylinder CY17
• Rear Vise Rotate Cylinder CY16
• Front Vise Clamp Cylinder CY19
• Joystick Control A15, including:
• Front Vise Switch S34
• Rear Vise Switch S35
• Rear Vise Rotation Switch S36

10-1
 Overview D36x50 Series II Navigator HDD Service

Component Locations
REAR VISE ROTATE
REAR VISE ROTATE VALVE DV19 REAR VISE VALVE DV20
SOLENOID L13 REAR VISE SOLENOID L14

FRONT VISE VALVE DV21

FRONT VISE SOLENOID L15

CHECK
VALVE
CV5
POWER VISE SOLENOID L16
LOAD
SENSE
CHECK POWER VISE VALVE DV22
CV
LOAD
SENSE
CHECK
CV
Vises

FRONT VISE
CYLINDER CY19
FRONT VISE
REAR VISE SWITCH S34
REAR VISE ROTATION CYLINDER CY17
CYLINDER CY16
REAR VISE
EXTEND REAR VISE
ORIFICE FV15 SWITCH S35

VISE ROTATE
SWITCH S36

10-2
D36x50 Series II Navigator HDD Service Overview

Hydraulic Connections
REAR VISE
CYLINDER FRONT VISE
CY17 CYLINDER CY19
GEARBOX LOCK
CYLINDER CY18
VISE ROTATION
CYLINDER CY16

TO TANK

VISE MANIFOLD
A8

DIAGNOSTIC
PORT

PUMP PMP3

TO TANK
FROM TANK

Vises
TO TANK
TO PUMP LOAD
SENSE PORT
FROM PUMP

PROPORTIONAL/DUMP
VALVE MANIFOLD A9

10-3
 Overview D36x50 Series II Navigator HDD Service

Electrical Circuit

GROUND BUS TB1

TO 3-SPEED TO ROCKFIRE BALL

DIODE GEARBOX VALVE
D9 TO FLEET MANAGMENT

CIRCUIT
BREAKER
F2
REVERSE
TORQUE
LIMITER
SOLENOID L31
Vises

FRONT
VISE
TORQUE SWITCH
LIMITER S34
SOLENOID
L30

REAR
LOAD SENSE
SOLENOID L25 VISE S35

FRONT VISE
CLAMP
SOLENOID L15 REAR VISE
ROTATE SWITCH
FRONT VISE S36
UNCLAMP
SOLENOID L16

REAR VISE
CLAMP
SOLENOID
L14 REAR
VISE ROTATE
SOLENOID
L13

10-4
D36x50 Series II Navigator HDD Service Overview

Vise Hydraulic Circuit

REAR VISE ROTATE A8

CYLINDER CY16
DV19
REAR VISE
CYLINDER L13
CY17 FV15

DV20

L14
DV22
FRONT VISE
CYLINDER CY19 DV21
GEARBOX
LOCK CYLINDER L15
CY18
L16

Vises
A9
PRESSURE
RELIEF PV4
LOAD
SENSE
VALVE
DV28,
SOLENOID

HYDRAULIC ENABLE
VALVE DV29,
SOLENOID L26

PUMP PMP3 TANK

10-5
 Overview D36x50 Series II Navigator HDD Service

Operation Overview
The vise circuits control the front and rear vises which are used when
adding or removing drill rod from the drill string. They also control the vise
rotation cylinder which rotates the drill rod when the rear vise is clamped to
loosen it from the drill string, and the gearbox lock cylinder.

Oil flow from the implement pump is routed through the hydraulic enable
valve DV29 located in combination valve manifold A9. When the hydraulic
enable switch is pushed, oil flows from port B of A9 to port P of vise valve A8
which contains solenoid valves that control hydraulic oil flow to three vise
cylinders, and the gearbox lock cylinder. Return oil flows out of the vise
valve at Port T and on to the tank. Load sense pressure from valve port LS is
supplied back to port LS1 of manifold A9. From there it is routed from port
LS2 of A9 to the PFC pump. Load sense solenoid valve DV28 is energized
electrically by function switches through one of the load sense diode blocks
from load sense relay K4.

NOTE: Activating the front vise electrical circuit affects the rotation
function torque limiters, the water shutoff valve and 2-speed valve of the
thrust/pullback function.
Vises

10-6
D36x50 Series II Navigator HDD Service Operation

OPERATION
PFC Pump PMP3 PFC pump PMP3 supplies hydraulic flow at pressure according to demand.

Hydraulic Enable The hydraulic enable valve TO VISE VALVE TO GROUND DRIVE
Valve DV29 and DV29 located in proportional MANIFOLD A8 VALVE A5
Solenoid L26 dump valve A9 allows
pressurized oil from pump
PMP3 to reach vise valve
manifold A8. This valve also
allows oil flow to the rod A9
loader, stakedown, stabilizer,
rack angle, and water shutoff
circuits. The valve spool
movement in DV29 is
controlled by electric solenoid
L26.

L26

DV29

Vises
PMP3

OIL TANK

10-7
 Operation D36x50 Series II Navigator HDD Service

Hydraulic Enable
Solenoid L26
Control Circuit

TERMINAL BUS TB1

HYDRAULIC
ENABLE
SWITCH
S30

TO EDC JOYSTICK
Vises

ROD LOADER CONTROLS

POWER SOLENOID L6
S2

HYDRAULIC ENABLE CIRCUIT

LATCHING RELAY K6 BREAKER
F9

STABILIZER
HYDRAULIC ENABLE SWITCH
DIODE D3 TO ENGINE
SEAT SWITCH RELAY K7 START SHUT
DRILL/TRACK DOWN RELAY
SOLENOID L24
SEAT SWITCH S26 CIRCUIT
BREAKER
HYDRAULIC ENABLE
F6
SOLENOID L26

TRACK BRAKE SOLENOID

L4

10-8
D36x50 Series II Navigator HDD Service Operation

A series of relays and switches control the function of hydraulic enable

solenoid L26 which supplies oil to rod loader, vise, stakedown, stabilizer,
greaser and drilling fluid hydraulic circuits.

Breaker F6 supplies power to pin 1 of seat switch S26 and to pin 30 of seat
switch relay K7. When the seat switch is pressed, power is provided to
terminal 86 of seat switch relay K7. This energizes relay K7 connecting
terminals 30 and 87 which provides voltage to drill/track solenoid L24, track
brake solenoid L4, and hydraulic enable switch S30.

When hydraulic enable switch S30 is closed, voltage is provided to terminal

86 of hydraulic enable relay K6 by wire 718. This energizes relay K6,
connecting terminals 30 and 87. Terminal 87 is connected to wire 718 by
wire 718A. Voltage is supplied back through wire 718 to rod loader power
solenoid L6, drill/track solenoid L24, and hydraulic enable solenoid L26.
Relay K6 and solenoids L6, L24, and L26 remain energized until voltage at
terminal 30 (from circuit breaker F9) is interrupted.

Vises

10-9
 Operation D36x50 Series II Navigator HDD Service

Front Vise Circuit Operation

Front Vise Clamp Front vise circuit components control the function of the front vise cylinder.

Switch S34 receives voltage from circuit breaker F2 when the ignition switch
is in the ON position. When 3-position switch S34 is pushed forward,
contacts between pins 1-1 and 2-12 is closed. This supplies voltage through
wire 714 to power vise valve solenoid L15, which shifts the spool, allowing
oil to flow to the cylinder base. Pressurized oil fills the base end of front
clamp cylinder CY19, extending it, and fills the rod end of gearbox lock
cylinder CY18 which retracts it.

FRONT VISE CLAMP

CYLINDER CY19 VALVE DV21
(SHOWN SHIFTED)
Vises

SOLENOID
L15

FROM PORT B
GEARBOX LOCK TO OF VALVE A9
TO LS1 PORT
CYLINDER CY18 TANK
ON COMBINATION
VALVE A9

NOTE: In this position the front vise clamp switch also provides voltage to
load sense solenoid L25, and the reverse and forward rotation torque limiter
solenoids L31, and L30.

10-10
D36x50 Series II Navigator HDD Service Operation

Front Vise Unclamp Switch S34 receives voltage from circuit breaker F2 when the ignition switch
is in the ON position. When 3-position switch S34 is pushed back, contacts
between pins 1-1 and 2-11 is closed. This supplies voltage through wire 712
to power vise valve solenoid L16, which shifts valve DV22, allowing oil to
flow to the rod end of the front clamp cylinder CY19, and to the base end of
the gearbox lock cylinder CY18.

VALVE DV22
(SHOWN SHIFTED)
FRONT VISE CLAMP
CYLINDER CY19

Vises
SOLENOID
GEARBOX LOCK L16 FROM PORT B
CYLINDER CY18 OF VALVE A9
TO LS1 PORT TO
ON COMBINATION TANK
VALVE A9

NOTE: In this position the switch also provides voltage to the medium
speed solenoid of the rotation function, and the RockFire ball valve control
solenoid.

10-11
 Operation D36x50 Series II Navigator HDD Service

Rear Vise Circuit Operation

Rear Vise Clamp When the rear vise switch S35 is pushed, terminals 1-1 and 2-8 are closed.
wires 114 and 708 are connected and supply voltage to rear vise solenoid
L14. This shifts rear vise valve DV20 to the crossover position. Pressurized
oil from the implement pump is available at port P of manifold A8. It passes
through DV20 to the base end of cylinder CY17. This fills the base end of
rear vise cylinder CY17, extending it and clamping the rear vise.

REAR VISE CLAMP

CYLINDER CY17

VALVE DV20
(SHOWN SHIFTED)

SOLENOID L14
Vises

FROM PORT B
TO LS1 PORT OF VALVE A9
ON COMBINATION
TO
VALVE A9
TANK

10-12
D36x50 Series II Navigator HDD Service Operation

Rear Vise Unclamp When rear vise switch S35 is released, terminals 1-1 and 2-8 are
disconnected. Wires 114 and 708 are disconnected. When solenoid L14 is not
energized, spring pressure maintains valve DV20 in the straight through
position. Pressurized oil from the implement pump is available at port P of
manifold A8. It passes through valve DV20 to the rod end of cylinder CY17.
This fills the rod end of the cylinder, retracting it and opening the rear vise.

Rear Vise Rotation Circuit Operation

When rear vise rotation switch S36 is pushed, it connects terminals 1-1 and
2-7. Rear vise rotate solenoid L13 is energized, shifting rear vise rotate valve
DV19 to the crossover configuration. This allows oil from the pump to enter
port P of A8, pass through rear vise rotate valve DV19, orifice FV15, and fill
the base end of vise rotate cylinder CY16. This extends the cylinder which
rotates the rear vise assembly in the counterclockwise direction.
REAR VISE ROTATE
CYLINDER CY16 VALVE DV19
(SHOWN SHIFTED)

Vises
ORIFICE FV15

SOLENOID L13

FROM PORT B
TO LS1 PORT OF VALVE A9
ON COMBINATION TO
VALVE A9 TANK

Continued on next page...

10-13
 Troubleshooting D36x50 Series II Navigator HDD Service

When vise rotation switch S36 is released, the circuit opens and spring
pressure shifts valve DV19 to the straight-through configuration. This
allows oil from the pump to enter at port P of A8, pass through FV20 and fill
the rod end of cylinder CY16. This retracts the cylinder, rotating the vise
assembly in the clockwise direction.

Shared Components
The vise functions share the common hydraulic fluid distribution
components, as well as the combination valve assembly A9, load sense valve
DV25. The hydraulic fluid distribution components are shared by all
functions with hydraulic circuits. These components include:

• Hydraulic Fluid Storage Tank RES1

• Return Manifold A12
• Fluid Cooler HE1
• PFC Pump PMP3
Vises

TROUBLESHOOTING
Begin each troubleshooting procedure by performing a pretest inspection of
the machine. See "Pretest Inspection," page 10-15.

Often problems can be solved by doing a walk-around inspection of the

machine and looking for obvious problems.

If nothing is found during the pretest inspection, continue by operating all

other actuator functions of the machine to help further isolate problems. See
"Troubleshooting Machine Performance," page 10-17.

10-14
D36x50 Series II Navigator HDD Service Troubleshooting

Pretest Inspection
Visually check to inspect for obvious signs of failure before any exhaustive
troubleshooting or testing procedures are performed.

Mechanical

Inspect mechanical linkages, cables, and connectors from joystick controllers

and control valves for:

• damage, misalignment, or improper adjustment

Electrical

Inspect electrical circuits for clues to malfunction. Always check the

following items before turning on switches or running the machine.

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

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

Vises
Hydraulic

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

Continued on next page...

10-15
 Troubleshooting D36x50 Series II Navigator HDD Service

Check hydraulic circuits for any failures.

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

Test Equipment Needed

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

• Multimeter for continuity tests, voltage measurements, resistance

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

NOTE: The hydraulic component test procedures discussed in this chapter

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

10-16
D36x50 Series II Navigator HDD Service Troubleshooting

Troubleshooting Machine Performance

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

Operate all machine functions and document the performance of working

actuators.

Make note of any functions not operating normally based on the theory
given in each chapter for that function. Comparing the results with the
normal operation given for each mode of a particular function will help to
isolate the fault(s) to one or more function or component.

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

Possible Results: 1. If faults are noted when operating all machine actuators, it would
indicate a function or component that is common to all actuators is most
likely faulty. The following common functions and components should be
investigated:
• Engine. See "Engine Troubleshooting," page 3-21.

Vises
• Shared hydraulic components. See Chapter 4.

2. If faults are noted in the rod loader, auto greaser and vises, as well as the
stabilizer, stakedown and ground drive functions, and all other functions
are OK, the hydraulic components common to just these functions should
be investigated, including:
• PFC Pump PMP3. See "Troubleshooting/Testing PFC Pump PMP3," page
4-18.
• Load Sense Valve DV28.
• Combination Valve Assembly A9.

10-17
 Troubleshooting D36x50 Series II Navigator HDD Service

Testing Vise Performance

NOTE: 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. Ensure switches, listed in "Control Settings," page 2-11, are in correct

positions.
2. Conduct inspection before proceeding.
3. If the engine has not been started, refer to "Starting the Engine," page 2-2
and perform before proceeding.
4. Put Remote Lockout in RUN mode.
S30
5. Press hydraulic enable push button
S30 to enable hydraulic circuits.
Vises

6. Press front vise switch S34 at top to CLAMP

S34
position. Front vise cylinder will fully
extend in approximately 2 seconds.

7. Press front vise switch S34 at bottom to

RELEASE position. Front vise cylinder will
fully retract in 2 seconds.

Continued on next page...

10-18
D36x50 Series II Navigator HDD Service Troubleshooting

8. Move rear vise switch S35 to CLAMP

position. Rear vise clamp cylinder will fully S35
extend in approximately 2 seconds.
9. Move rear vise switch S35 to RELEASE
position. Rear vise clamp cylinder will fully
retract in 2 seconds.
S36
10. Press rear vise rotate switch S36 once to
ROTATE CCW position. Rear vise rotate
cylinder will fully extend in approximately 2
seconds.
11. Press rear vise rotate switch S36 again.
Rear vise rotate cylinder will fully retract in
approximately 2 seconds.

Troubleshooting/Testing the Vise Functions

Before beginning any troubleshooting or testing procedures, perform the
"Pretest Inspection," page 10-15. If nothing obvious is found continue.

Front Vise Function 1. In order to ensure the fault is isolated to just the front vise clamping

Vises
mode, the technician should operate all machine functions and observe
the actuators as discussed in "Troubleshooting Machine Performance,"
page 10-17.
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. If front vise does
not remain clamped, troubleshoot the circuit that controls solenoid L16
and valve DV22.
NOTE: Refer to the Vermeer Industrial Dealerships Technician’s Shop
Manual (Vermeer P/N 105400V80), for helpful information on testing
electrical circuits for shorts, opens, and high resistance.

3. Test for acceptable voltage starting at solenoid coil L15 of valve DV21. If
voltage is acceptable, continue with step 4. If not, continue with step 5.
4. 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 with step 5. If not, replace coil.
Continued on next page...

10-19
 Troubleshooting D36x50 Series II Navigator HDD Service

5. Review electrical circuit diagram and 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. If electrical circuit is operating properly, continue.
6. Test cylinder CY19 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 cylinders
test OK, continue.
7. Remove and inspect cartridge valve DV21 in vise valve assembly A8.
Refer to component repair information in this chapter. Repair or replace
faulty components.

Rear Vise Clamp 1. In order to ensure the fault is isolated to just the rear vise clamping
Function mode, operate all machine functions and observe the actuators as
discussed in "Troubleshooting Machine Performance," page 10-17.
2. If any functions other than the rear vise clamp function are faulty,
continue troubleshooting based on the possible results given. If all other
machine functions are operating normally, continue.
Vises

NOTE: Refer to the Vermeer Industrial Dealerships Technician’s Shop

Manual (Vermeer P/N 105400V80), for helpful information on testing
electrical circuits for shorts, opens, and high resistance.

3. Test for acceptable voltage starting at solenoid coil L14 of valve DV20. If
voltage is acceptable, continue with step 4. If not, continue with step 5.
4. Test resistance of coil L14.
Expected result: Resistance should measure 7.2 ohms @ 68°F (20°C). If
OK, continue with step 6. If not, replace coil.
5. Review electrical circuit diagram and 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. If electrical circuit is operating properly, continue.
6. Ensure load sense circuit is operating properly.
7. Test cylinder CY17 for internal leakage. Refer to the Vermeer Industrial
Dealerships Technician’s Shop Manual (Vermeer P/N 105400V80), for
information on testing and repairing hydraulic cylinders. Repair or
replace if necessary. If cylinders test OK, continue.
8. Remove and inspect cartridge valve DV20 in vise valve assembly A8.
Refer to "Vise Valve Manifold A8," page 10-23. Refer to repair information
in this chapter to repair or replace components.

10-20
D36x50 Series II Navigator HDD Service Troubleshooting

Rear Vise Rotate 1. In order to ensure the fault is isolated to just the rear vise rotating mode,
Function the technician should operate all machine functions and observe the
actuators as discussed in "Troubleshooting Machine Performance," page
10-17.
2. If any functions other than the rear vise rotation function are faulty,
continue troubleshooting based on the possible results given. If all other
machine functions are operating normally, continue.
NOTE: Refer to the Vermeer Industrial Dealerships Technician’s Shop
Manual (Vermeer P/N 105400V80), for helpful information on testing
electrical circuits for shorts, opens, and high resistance.

3. Test for acceptable voltage starting at solenoid coil L13 of valve DV19. If
voltage is acceptable, continue with step 4. If not, continue with step 5.
4. Test resistance of coil L13.
Expected result: Resistance should measure 7.2 ohms @ 68°F (20°C). If
OK, continue with step 6. If not, replace coil.
5. Review electrical circuit diagram and 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. If electrical circuit is operating properly, continue.
6. Ensure load sense circuit is operating properly.

Vises
7. Test cylinder CY16 for internal leakage. Refer to the Vermeer Industrial
Dealerships Technician’s Shop Manual (Vermeer P/N 105400V80), for
information on testing and repairing hydraulic cylinders. Repair or
replace if necessary. If cylinders test OK, continue.
8. Remove and inspect cartridge valve DV19 in vise valve assembly A8.
Refer to component repair information. Refer to repair section in this
chapter and repair or replace faulty components.

10-21
 Troubleshooting D36x50 Series II Navigator HDD Service

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

Electrical:

• Nominal circuit voltage - 12 volts DC

• Vise valve solenoid coils L13, L14, and L15 - 7.2 ohms @ 68°F (20°C)
• Vise valve solenoid coils L16 - 9.8 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)

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

replacement, refer to the appropriate procedures at the back of the chapter

or other chapters where instructed. After repairs have been made, refer to
"Hydraulic Fluid Sampling," page 4-20 and follow instructions.

WARNING: Pressurized fluid can penetrate body tissue and result in

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

10-22
D36x50 Series II Navigator HDD Service Component Repair

COMPONENT REPAIR
Vise Valve Manifold A8

6
5
4

2
1

Vises
7 4
9 8

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.
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).

10-23
 Component Repair D36x50 Series II Navigator HDD Service

Disassembly
VALVE DV19 VALVE DV20 VALVE DV21
SOLENOID L13 SOLENOID L14 SOLENOID L15

2
2 3

VALVE DV22
SOLENOID L16

1. Remove nuts (1) on solenoid coils (2) and solenoid coil (3).
Vises

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 valve
DV22 to 20 ft-lb (27 Nm). Torque solenoid nuts on coils (1) to 5 ft-lb (6 Nm).

10-24
D36x50 Series II Navigator HDD Service Component Repair

Front and Rear Vise Cylinders CY19 and CY17

4
3
2
1 1

1 7
6
4
Removal 1. Label, disconnect and cap hoses attached to fittings (1).
2. Remove bolt (2) and washer (3) holding pin to vise assembly.

Vises
3. Remove pin (4) that attaches cylinder to be removed.
4. Remove bolts (7) and fitting (5).
5. Remove trunnion bushing (4) and bushing (6).
Reverse steps for installation. Torque bolts (7) to 35 ft-lb (47 Nm). Torque
screw (3) to 90 ft-lb (120 Nm).

10-25
 Component Repair D36x50 Series II Navigator HDD Service

Disassembly

7 8
4 7 6 3 2 5

1. Use spanner wrench to remove head snap ring (1).

2. Pull rod assembly (2) out of cylinder body (3). Ensure ports are open and
Vises

positioned to direct oil into a suitable container.

3. Remove nut (4) from rod assembly.
IMPORTANT: Do not clamp onto unpainted portion of the rod. Scarring rod
can cause premature seal failure.

4. Slide gland (5) and piston (6) off rod.

5. Remove and replace seals (7). Refer to the Parts Manual for seal kit
components. Apply a light coat of petroleum jelly to seals before
installation.
6. Slide gland and piston onto rod and tighten nut.
7. Push rod assembly into cylinder body.
8. Install head gland into cylinder body and secure.
9. Install cylinder. Apply grease at fitting (8).

10-26
D36x50 Series II Navigator HDD Service Component Repair

Vise Rotate Cylinder CY7

5
6

4
2

3 4
3
2

Vises
1. Label, disconnect and cap hoses and fittings (1).
2. Remove bolts (2) that hold pivot plates (3) and bushings (4).
3. Remove cotter pin (3) and pin (4).
4. Remove cotter pin (5) and pin (6) at top of cylinder.
Reverse steps for installation. Torque bolt (2) to 90 ft-lb (120 Nm).

10-27
 Component Repair D36x50 Series II Navigator HDD Service

Disassembly

4
6

1
7 7

1. Remove retaining ring (1).

Vises

2. Pull the rod assembly (2) out of cylinder body (3).

3. Ensure ports are open and position to direct oil into a suitable draining
pan.
4. Remove nut (4) from rod assembly.
IMPORTANT: Do not clamp onto unpainted portion of the rod. Scarring rod
can cause premature seal failure.

5. Slide gland (5) and piston (6) off rod.

6. Remove and replace seals (7).
Continued on next page...

10-28
D36x50 Series II Navigator HDD Service Component Repair

Assembly 1. Instal seal kit components. Refer to the Parts Manual for seal kit
components and locations. Apply a light coat of petroleum jelly to seals
before installing.
2. Slide gland and piston onto rod and tighten nut.
3. Push rod assembly into cylinder body.
4. Slide gland into cylinder body and cover.
5. Install cylinder.

Vises

10-29
This page intentionally left blank.
D36x50 Series II Navigator HDD Service Overview

Chapter 11: Rack Angle

OVERVIEW
This chapter consists of information about components necessary for rack
angle function, also referred to as rack lift. This machine uses two hydraulic
cylinders to tilt the rack.

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

• Valve Bank Assembly A5, including:

• Rack Lift Valve DV25
• Pressure Relief Valve PV5
• Rack Lift Cylinder CY14

Rack Angle
• Rack Lift Cylinder CY13
• Lock Valve CV8
• Lock Valve CV9

11-1
 Theory D36x50 Series II Navigator HDD Service

Component Locations

Valve Assembly A5

LOCK/CHECK
VALVE CV13
LOCK/CHECK
VALVE CV14
Rack Lift Valve DV12
Rack Angle

RACK LIFT CYLINDER CY14

RACK LIFT CYLINDER CY13

DRILL/TRACK VALVE
DV27, SOLENOID L24

11-2
D36x50 Series II Navigator HDD Service Theory

Hose Connections
RACK LIFT CYLINDER CY1

RACK LIFT CYLINDER CY2

VALVE
BANK A5

Rack Angle
TO OIL COOLER

FROM HYDRAULIC
TANK RES1

PFC PUMP
PMP3

COMBINATION
VALVE A9

11-3
 Theory D36x50 Series II Navigator HDD Service

Schematic

RACK LIFT
CYLINDER
RACK LIFT
CY14
CYLINDER
CY13

LOCK/CHECK
VALVE CV9
LOCK/CHECK
VALVE CV8
TO RETURN
MANIFOLD A12

VALVE
BANK A5
Rack Angle

RACK
ANGLE DRILL/
VALVE TRACK VALVE
DV25 DV27, SOLENOID L24

PRESSURE RELIEF
VALVE PV5

PFC PUMP
PMP3
COMBINATION
VALVE A9

FROM HYDRAULIC TANK RES1 TO HYDRAULIC TANK RES1

11-4
D36x50 Series II Navigator HDD Service Shared Components

Specifications
Listed below are the electrical and hydraulic specifications for the rack lift
function.

Electrical:

• Nominal circuit voltage - 12 volts DC

Hydraulic:

• Pump PMP3 normal output flow - variable to 43 gpm (162 L/min)

• Pump PMP3 load sense spool setting - 250 psi (17 bar)
• Pump PMP3 high pressure compensator setting - 3000 psi (207 bar)
• Valve bank assembly A5 relief valve PV5 pressure setting - 3500 psi (241
bar)

SHARED COMPONENTS
The rack angle function shares some common hydraulic fluid distribution

Rack Angle
components, as well as the combination valve assembly A9. The hydraulic
fluid distribution components are shared by all functions with hydraulic
circuits. These components include:

• Fluid Storage Tank RES1

• Return Filters FL3 and FL4
• Return Manifold A15
• Oil Cooler HE1
• PFC Pump PMP3
For more information on common hydraulic components, refer to Chapter 4.

11-5
 Rack Lift Function D36x50 Series II Navigator HDD Service

RACK LIFT FUNCTION

Rack RAISE Mode

CYLINDER LOCK/CHECK VALVE CV8

CY13

CYLINDER LOCK/CHECK VALVE CV9

CY14

TO RETURN
MANIFOLD A12 TO PFC PUMP PMP3

VALVE BANK A5
Rack Angle

DV25
RELIEF VALVE
PV5

FROM COMBINATION VALVE A9

Operation To operate rack raise mode:

• Seat switch must be open (seat unoccupied).

• Engine must be running.
• Rack lift control handle must be pulled back.
When required operating conditions are met:

• Rack lift cylinders CY13 and CY14 extend.

• Check lock valves CV8 and CV9 open to allow oil flow to the cylinders.
3500 psi pressure relief valve PV5 protects the circuits from over-
pressurization. If pressure in the rack lift circuit reaches 3500 psi (241 bar),
the valve will open and direct fluid to the oil tank.

Continued on next page...

11-6
D36x50 Series II Navigator HDD Service Rack Lift Function

NOTE: If the raise mode does not operate as expected, see "Troubleshooting/
Testing the Rack Lift Function," page 11-12.

Rack LOWER Mode

LOCK/CHECK
VALVE CV8

CYLINDER CY13

LOCK/CHECK
VALVE CV9

CYLINDER CY14
TO RETURN
MANIFOLD A12

TO PFC PUMP PMP3 LOAD

SENSE PORT

Rack Angle
VALVE BANK A5

DV25
RELIEF VALVE
PV5

FROM COMBINATION VALVE A9

Operation To operate rack lower mode:

• Seat switch must be open (seat unoccupied).

• Engine must be running.
• Rack control handle must be pushed forward.
When required operating conditions are met:

• Rack lift cylinders CY13 and CY14 retract.

• Lock check valves CV8 and CV9 allow flow through the cylinders.
Continued on next page...

11-7
 Troubleshooting D36x50 Series II Navigator HDD Service

Backup pressure relief valve PV5 protects the circuits from over-
pressurization, if the main relief valve in PFC Pump PMP3 fails. If pressure
in the thrust or pullback circuits reaches 3500 psi (241 bar), the valve will
open and direct fluid to the oil tank.

NOTE: If the pullback mode does not operate as expected, see

"Troubleshooting/Testing the Rack Lift Function," page 11-12.

TROUBLESHOOTING
Troubleshooting procedures are given for each operating mode of the
different functions of this chapter. Start each procedure by performing a
pretest inspection of the machine. See "Pretest Inspection," page 11-8.

Often problems can be solved by doing a walk-around inspection of the

machine and looking for obvious problems.

If nothing obvious is found during the inspection, operate the other actuator
functions of the machine to help further isolate a problem. See
"Troubleshooting Machine Performance," page 11-10.
Rack Angle

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

Mechanical

Inspect the mechanical linkages and connectors from joystick controllers

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

Continued on next page...

11-8
D36x50 Series II Navigator HDD Service Troubleshooting

Electrical

Inspect electrical circuits for clues to the malfunction. Always check the
following items before turning on switches or running the unit.

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

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

Hydraulic

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

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

Check hydraulic circuits for any failures.

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

11-9
 Troubleshooting D36x50 Series II Navigator HDD Service

Test Equipment Needed

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

• Multimeter for continuity tests, voltage measurements, resistance

measurements in the various electrical circuits
• Various hydraulic testing tools

NOTE: Hydraulic component test procedures discussed in this chapter will

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

Troubleshooting Machine Performance

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

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

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

Make note of any functions not operating normally based on the theory
given in each chapter for that function. Comparing the results with the
normal operation given for each mode of a particular function will help to
isolate the fault(s) to one or more function or component.

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

Continued on next page...

11-10
D36x50 Series II Navigator HDD Service Troubleshooting

Possible Results: 1. If faults are noted when operating all the machine actuators, it would
indicate a component that is common to all the actuators is most likely
faulty. The following common functions and components should be
investigated:
• Engine. See "Engine Troubleshooting," page 3-21.
• Remote Lockout. See Chapter 15.
• Shared hydraulic components. See Chapter 4.

2. If faults are noted in the ground drive and stabilizer functions, as well as
the rod loader, auto greaser, stakedown, drilling fluid, and vise functions
and all other functions of the machine are OK, the hydraulic components
common to just these functions should be investigated, including:
• Combination Valve Assembly A9.

Testing Rack Angle Performance

1. Ensure switches listed in "Control Settings," page 2-11, are in correct
positions.

Rack Angle
2. If "Starting the Engine," page 2-2, has not been performed, refer to the
procedure and perform before proceeding.
3. Put Remote Lockout in RUN mode.
4. Press hydraulic enable button S30 to enable rack hydraulic circuits.
5. Move rack position handle at the transport station to RAISE position
until rack angle cylinders are fully extended.
6. Ensure rack cylinders are fully extended so that the rack is fully raised.
NOTE: If necessary, disconnect and remove stakedown augers from motor
shafts before proceeding to ensure damage does not occur to workplace floor.
Then raise stakedown cylinders to their maximum height.

7. Simultaneously start stopwatch and move rear control panel rack angle
handle to the LOWER position. Stop timing when rack angle cylinders
are fully retracted. Time required for rack angle to move from fully
raised to fully lowered position should be 12.00 ± 2 seconds.
8. Repeat step 7 moving handle to RAISE position. Time required for rack
angle to move from fully lowered to fully raised position should be 11 ±2
seconds.

11-11
 Troubleshooting D36x50 Series II Navigator HDD Service

Troubleshooting/Testing the Rack Lift Function

The rack lift function contains both electrical and hydraulic circuits. If the
steps in "Troubleshooting Machine Performance," page 11-10 indicate the
function is not operating properly, troubleshoot the electrical circuit that
controls drill/track valve DV27 which allows oil flow to rack control valve
DV27.

1. With the engine running, Remote Lockout in RUN mode, and no operator
seated at the controls, operate the ground drive function. If the ground
drive operates normally, solenoid L24 of combination valve A9 is
functioning properly. Go to step 4. If ground drive does not move, the
electrical circuit controlling solenoid L24 should be investigated.
2. Check for voltage at wire 720C of solenoid L24.
Expected Result: 12 volts DC at wire 720C of solenoid L24. If not,
troubleshoot the electrical circuit back to seat switch. If so, continue.
3. Disconnect solenoid L24 of combination valve A9 connections and check
solenoid coil resistance.
Expected result: Resistance across the solenoid terminals should
measure 9.8 ohms ± 0.7 ohm. If not, replace solenoid. If so, inspect valve
DV27 for proper operation.
Rack Angle

4. Inspect lock check valves CV8 and CV9 on the rack lift cylinders for
contamination or damage.
5. Cylinder CY13 or CY14 may be leaking internally.
Cylinder piston leakage is caused by damage or wear in the internal cylinder
tube wall or the piston seal.

The most common symptoms of problems associated with cross-piston

leakage are:

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

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

11-12
D36x50 Series II Navigator HDD Service Troubleshooting

Testing

Rack Angle
This test procedure will determine whether the rack lift cylinder is able to
hold pressure.

NOTE: It is recommended that cylinders be tested in the extend (rack raise)

position.

NOTE: The illustration above depicts the cylinder being tested in the rod
extend position. Damage to the test equipment can occur if not installed
correctly.

1. Lower rack to the ground

2. Follow "Shutdown Procedure," page 2-1.
3. Install flow meter and pressure gauge in line to piston end of cylinders.
4. Start machine and operate valve to raise rack fully and hold controls in
raise position while observing flow meter and pressure gauge.
5. If flow is observed at flow meter (1), test each cylinder individually to
determine which one is leaking.
6. If no flow is observed at flow meter (1), and pressure at gauge (2) will
not reach the high pressure compensator setting of 3000 psi,
troubleshoot the load sense circuit that supplies load sense pressure to
pump PMP3.

11-13
 Troubleshooting D36x50 Series II Navigator HDD Service

Troubleshooting Drill/Track Valve DV27

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

1. Test solenoid L24 in combination valve manifold A9.

2. Inspect valve DV27 in combination valve manifold A9. Remove for
instructions on removing and disassembly.

Component Repair/Replace
If troubleshooting procedures determine a component is in need of repair or
replacement, refer to the appropriate procedures at the back of the chapter
or other chapters where instructed. After repairs have been made, refer
to"Hydraulic Fluid Sampling," page 4-20 and follow instructions.
Rack Angle

11-14
D36x50 Series II Navigator HDD Service Component Repair

COMPONENT REPAIR
Valve Bank Assembly A5
Remove 1. Label, disconnect, cap and
plug hydraulic hoses going to 1
control valve.
2. Remove bolts (1), washers
(2) and nuts (3) mounting
control valve (4) to machine.
3. Remove control valve.

Rack Angle
Install When installing control valve, reverse removal procedures.

NOTE: Torque bolts (1) to 22 ft-lb (30 Nm).

11-15
 Component Repair D36x50 Series II Navigator HDD Service

Directional Valve DV25

4
5
6

5
4
3
6

1. Remove control lever (1) and bracket (2).

NOTE: Do not remove spool from valve.
Rack Angle

2. Remove positioner (3).

3. Remove seal retainer (4), backup washer (5), and O-ring (6) on each end
of valve housing.
4. Apply a light coat of petroleum jelly to O-ring and install with backup
washer, and seal retainer.
5. Install positioner, lever bracket, and control lever.
6. Install control valve, connect hydraulic hoses, and install console cover.

11-16
D36x50 Series II Navigator HDD Service Component Repair

Load Check Plug

8
7
6
5

1 4

1. Unscrew and remove load check plug (8).

NOTE: Document orientation of O-rings and backup washers (for
installation purposes).

2. Remove O-rings (4, 5 and 7) and backup washers (6). Inspect check

Rack Angle
spring (2) and poppet (1). Ensure they are clean and free of dirt.
3. Apply a light coat of petroleum jelly to new O-rings and install with
backup washers.
4. Install load check plug. Torque plug to 20 ft-lb (27 Nm).
5. Install control valve to machine. Connect hydraulic hoses. Install console
cover.

11-17
 Component Repair D36x50 Series II Navigator HDD Service

Relief Valve PV5

1

3
5 2
4
1. Remove tie rod (1) and nut (2) holding valve section (4) to valve
manifold.
Rack Angle

2. Remove O-rings (5).

3. Remove relief valve (3).
NOTE: Before installing components, apply a light coat of petroleum jelly to
O-rings.

4. Install O-rings and backup washer with relief. Torque relief to 20 ft-lb
(27 Nm). Torque tie rod to 12.5 ft-lb (17 Nm).
5. Install control valve. Connect hydraulic hoses, and install console cover.

11-18
D36x50 Series II Navigator HDD Service Component Repair

Rack Lift Cylinders CY13 and CY14

7 9
2

8 10

3 10

2
1
10

6
5
4 8
10

Rack Angle
1 7
5
6

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

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

2. Remove bolt (4), washer (5), and slug (6). Remove pin (3) holding bottom
of cylinder to rack.
3. Remove expansion pin (8). Remove pin (7) holding cylinder to
undercarriage.

11-19
 Component Repair D36x50 Series II Navigator HDD Service

13
5 10 12

1 2 3 4 6 7 9 11
8

15

14
Rack Angle

Disassembly

WARNING: Some residual pressure may remain in cylinders equipped with

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

1. Carefully loosen and remove lock valve cartridge. Refer to "Rack Lift
Cylinder Lock Check Valves CV8 and CV9," page 11-22.
2. Release gland. Gland is secured by setscrew.
Continued on next page...

11-20
D36x50 Series II Navigator HDD Service Component Repair

3. With a suitable device (wrench or come-along), pull the rod (12) out of
cylinder body (13). Ensure ports are open and positioned to direct oil into
a suitable draining pan.
4. Remove nut (1) from rod.
IMPORTANT: Do not clamp onto unpainted portion of the rod unless it is
adequately protected by a cloth or other soft material. Scarring rod can
cause premature seal failure.

5. Slide gland and piston (2) off rod.

6. Remove and replace seals (3, 4, 5, 7, 8,10, and 11).

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

1. Slide gland and piston onto rod and tighten nut.

2. Push rod into cylinder body.
3. Install gland into cylinder body and secure with setscrew.
4. Fill cylinder with hydraulic oil before installing lock valve cartridge.

Rack Angle
5. Install pins holding cylinder to undercarriage and rack. Torque bolt on
rod end pin to 900 ft-lb (120 Nm).

11-21
 Component Repair D36x50 Series II Navigator HDD Service

Rack Lift Cylinder Lock Check Valves CV8 and CV9

WARNING: Some residual pressure may remain in cylinders equipped with

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

1. Label, disconnect, cap and plug

hydraulic hoses going to valve.
1. Remove cartridges from valve body.
2. Inspect cartridge for any damages
and ensure no external
contaminants are present.
NOTE: Remember the orientation of
the seals. This will be useful in Front View
Rear View
installing new ones.

3. Inspect seals. If necessary replace seals.

4. Dip valve in clean filtered oil.
Rack Angle

5. Screw valve in by hand. Torque cartridge to 30–35 ft-lb (40–47 Nm).

Reverse removal procedure to install valve.

11-22
D36x50 Series ii Navigator HDD Service Overview

Chapter 12: Stakedown

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

CIRCUITS
The stakedown function is comprised of two circuit groupings that rely on
pump PMP3 for their hydraulic function. The two circuits are:

• Stake Rotation Circuit

• Stake Lower/Raise Circuit

Stakedown

12-1
 Circuits D36x50 Series II Navigator HDD Service

Component Locations

RIGHT STAKE LEFT STAKE DOWN

DOWN CYLINDER CY10 CYLINDER CY9

STAKEDOWN SELECT
SWITCH S31
STAKEDOWN THRUST
CONTROL SWITCH S32 RIGHT STAKEDOWN LEFT STAKEDOWN
MOTOR MH10 MOTOR MH9
STAKEDOWN
Stakedown

MOTOR CONTROL STAKEDOWN RAISE/LOWER

SWITCH S33 VALVE DV16 STAKEDOWN LOWER
LEFT/RIGHT CYLINDER SOLENOID L10
SELECT VALVE DV14
ROTATION DIRECTION
LEFT/RIGHT CYLINDER CONTROL VALVE DV17
SELECT SOLENOID L7

CHECK VALVE CV3

SOLENOID L12

STAKEDOWN
RAISE SOLENOID L9 SOLENOID L11

LEFT/RIGHT ROTATION
MOTOR CONTROL VALVE
DV15 SOLENOID
L8
STAKEDOWN
MANIFOLD A7
CHECK VALVE CV4
ORIFICE FV17
ORIFICE FV16

12-2
D36x50 Series ii Navigator HDD Service Circuits

Hydraulic Connections
RIGHT STAKEDOWN
CYLINDER CY10
RIGHT STAKEDOWN
MOTOR MH10

LEFT STAKEDOWN
CYLINDER CY9

LEFT STAKEDOWN
MOTOR MH9

STAKEDOWN
MANIFOLD A7

Stakedown
PUMP PMP3

DIAGNOSTIC PORT

COMBINATION VALVE
MANIFOLD A9

12-3
 Component Overview D36x50 Series II Navigator HDD Service

COMPONENT OVERVIEW
PFC Pump PMP3 PFC pump PMP3 supplies all hydraulic oil for stakedown and rack position
functions.

Load Sense Load sense solenoid valve L25 is energized any time a hydraulic function is
Solenoid Valve L25 operated with an electric switch which causes the pump to go to maximum
pressure (pressure compensator pressure). There is no load sense line from
either manifold to the pump.

Stakedown Manifold A 2-position, 3-way solenoid valve DV14 within the stakedown manifold
A7 selects right or left cylinder function. Valve DV15 simultaneously selects
between right or left motor functions. Individual 3-position, 4-way solenoid
valves select “stake down” or “stake up” operation of cylinders CY9, CY10
and motors MH9, MH10.

Stakedown Motors The stakedown motors are of the geroler type.

MH9 and MH10

Operation Correct operation of the function requires that the engine is turning at rated
RPM, PFC pump, Remote Lockout, and load sense systems are working
correctly.
Stakedown

SPECIFICATIONS
Specification Value

General
governed engine RPM 2500 rpm
Stakedown Motors
Displacement per revolution 66 cid (1082 cc)

12-4
D36x50 Series ii Navigator HDD Service Specifications

Hose Diagram - PFC Pump to Stakedown Manifold

DIVERTER VALVE A9
VISE
MANIFOLD A8

STAKEDOWN
MANIFOLD A7

ROD LOADER
MANIFOLD
A6
RETURN
MANIFOLD
RACK A12
MANIFOLD
A10

PUMP PMP3

Stakedown

12-5
 Specifications D36x50 Series II Navigator HDD Service

Hydraulic Schematic

LEFT STAKEDOWN RIGHT STAKEDOWN

LEFT CYLINDER RIGHT MOTOR MH9 MOTOR MH10
CY9 CYLINDER CY10

L7 L8

DV14 DV15
CV3
DV16 DV17
L9
L10 L11 L12

FV17
Stakedown

FV16 PRESSURE
RELIEF PV4
CV4

LOAD
SENSE
DV28

L25

HYD
ENABLE
L26
DV29

PUMP PMP3

HYDRAULIC TANK

12-6
D36x50 Series ii Navigator HDD Service Electrical Diagram

ELECTRICAL DIAGRAM
Diode Module
Diode Module D7
D6

To Load
Sense
Circuit

Thermal Breaker F7

Left/Right Solenoid
Stakedown Cylinder L7

Stakedown
Stakedown Rotation
Switch S33

Left/Right Solenoid
Stakedown Motor L8

Rotate CCW
Stakedown Thrust Solenoid L12
Switch S32

Rotate CW
Solenoid L11

Stakedown Select
Switch S31 Stake Up
Solenoid L9

Stake Down
Terminal Bus TB1 Solenoid L10

12-7
 Electrical Diagram D36x50 Series II Navigator HDD Service

Stake Up Circuit Operation

When switch S32 is pushed to the left, solenoid L9 is energized and S is
shifted to the straight-through position. Pressurized oil provided at the P
port of valve assembly A7 passes through orifice FV17, valve DV16, valve
DV14 and out of port C1 or C2 depending on the position of valve DV14 to
the base of cylinders CY9 and CY10. Cylinders CY9 and CY10 extend and
lift stakes out of the ground.

If selector switch S31 is pushed to the left, no voltage is available at solenoid

L7. Spring pressure maintains the DV14 valve spool in position and oil is
routed out of port C1 to the base end of left stakedown cylinder CY9. This
extends the cylinder, raising the left stake.

If cylinder selector switch S31 is pushed to the right, solenoid L7 is

energized and the spool in valve DV14 is shifted, routing oil out of port C2 to
the base end of the right cylinder CY10. This extends the cylinder, raising
the right stake.

Stake Down Circuit Operation

When switch S32 is pushed to the right, solenoid L10 is energized and valve
DV16 is shifted to the cross-over position. Pressurized oil provided at the P
port of valve assembly A7 passes through orifice FV17, Valve DV16, and out
port C3 and C4 to the rod end of cylinders CY9 and CY10. Return oil flow is
Stakedown

controlled by the position of valve DV14 and check valve CV3 which allows
flow out of the base end of cylinder CY9 or CY10 retracting it and pushing
stakes into the ground.

If selector switch S31 is pushed to the left, no voltage is available at solenoid

L7. Spring pressure maintains the DV14 valve spool in position and return
oil is allowed into port C1 from the base end of left cylinder CY9. This
retracts the cylinder, lowering the left stake.

If selector switch S31 is pushed to the right, solenoid L7 is energized and the
spool in valve DV14 is shifted. This allows return oil from the base end of
right cylinder CY10 into port C2 through manifold A7. This retracts the
cylinder, lowering the right stake.

NOTE: When selector switch S31 is pushed to the right, solenoid L8 that
controls directional control valve DV15 which selects left or right stakedown
motor operation is also energized.

12-8
D36x50 Series ii Navigator HDD Service Electrical Diagram

Stakedown Motor Counter Clockwise Operation (Stake Out)

When switch S33 is pushed to the left, solenoid L11 is energized and valve
DV17 is shifted to the straight-through position. Pressurized oil provided at
the P port of valve assembly A7 passes through orifice FV16. Oil is routed
through valve DV17, valve DV15 and out of port M1 or M2 depending on
valve DV15 position, to the B port of motor MH9 or MH10. This allows the
motors to rotate in the counterclockwise direction depending on valve DV15
position.

If selector switch S31 is pushed to the left, no voltage is available at solenoid

L8. Spring pressure maintains the DV15 valve spool in position and oil is
routed out of port M1 to the B port of left motor MH9. This rotates the left
motor in the counterclockwise direction.

If selector switch S31 is pushed to the right, solenoid L8 is energized and the
spool in valve DV15 is shifted, routing oil out of port M2 to the B port of
right motor MH10. This rotates the right motor in the counterclockwise
direction.

Stakedown Motor Clockwise Operation (Stake In)

Stakedown
When switch S33 is pushed to the right, solenoid L12 is energized and valve
DV17 is shifted to the cross-over position. Pressurized oil provided at the P
port of valve assembly A7 passes through orifice FV16. Pressurized oil is
routed through valve DV17, and out of port M3 and M4 and is available at
the A ports of motors MH9 and MH10. This allows the motors to rotate in
the clockwise direction depending on valve DV15 position.

If selector switch S31 is pushed to the left, no voltage is available at solenoid

L8. Spring pressure maintains the DV15 valve spool in position and return
oil from port B of the left motor is allowed into port M1, through valve DV15,
DV17, and on to tank. This rotates the left motor in the clockwise direction.

If selector switch S31 is pushed to the right, solenoid L8 is energized and the
spool in valve DV15 is shifted, return oil from port B of the right motor is
allowed into port M2, through valve DV15, DV17, and on to tank. This
rotates the right motor in the clockwise direction.

When selector switch S31 is pushed to the right, solenoid L7 that controls
directional control valve DV14 selecting right or left stakedown cylinder
operation is also energized.

12-9
 Troubleshooting D36x50 Series II Navigator HDD Service

TROUBLESHOOTING
SYMPTOM: Stakedown Operation Slow or Lacks Force

1. Are the machine common systems operating correctly? Hydraulic oil level, temperature,
and condition, oil cooler problems, or engine speed and power outside of specifications can cause or
contribute to faulty operation.

Possible Problem Possible Effect What to do

hydraulic oil level Low hydraulic oil level can cause a Fill hydraulic oil to correct level.
low variety of problems.
plugged suction A plugged suction screen will cause Clean suction screen.
screen machine operation problems and
eventually will cause extensive
equipment damage.
engine RPM too low Hydraulic functions that rely on Check engine RPM while operating
maximum pump flow will have slow under load
operation since maximum flow is
reduced when RPM is reduced.
overheating A blocked oil cooler or other conditions Check hydraulic oil cooler.
causing overheating of the hydraulic oil
can cause various problems.
Stakedown

SYMPTOM: Stakedown Will Not Operate

1. Is the hydraulic enable system OK? Each time the engine is started, the hydraulic enable
system must be activated.

Possible Problem Possible Effect What to do

hydraulic enable Each time the engine is started, the Ensure hydraulic enable circuit is
system not activated hydraulic enable system must be functioning properly.
activated in order to operate
stakedown hydraulic functions.

12-10
D36x50 Series ii Navigator HDD Service Troubleshooting

2. Are the controls working correctly? The rear control relay applies power to the rack/stabilizer
control switches in the rear control station if the seat is unoccupied, or in the front if the seat is occupied.
The solenoid apply signal also is sent to one of the two load sense splitter boxes to energize the load sense
solenoid.

Possible Problem Possible Effect What to do

grounds If the ground path is missing, is too
resistive, or voltage drop is 0.5V or
more, all electrical operation can be
effected.
current path Any damage to wiring, connectors or
connector pins that are not seated or
mated correctly or any unintended
short to power, resistance, or ground
can cause intermittent or constant
problems.
Check all grounding locations.
Check ground voltage between ground
buss and battery negative terminal
under no-load and loaded conditions.
Repair any condition causing high
ground voltage either at rest or under
load.
Check the entire current path.
Inspect visually or use an ohmmeter or
voltmeter.

Stakedown
3. Are the hydraulic components functioning correctly? Operation of a hydraulic system
requires the correct function of pump, flow and direction controls, and actuators.

Possible Problem Possible Effect What to do

PFC pump flow If pump does not deliver full flow, Check PFC pump flow.
problem functions will be slow.
system pressure If the PFC compensator is set too low, Set PFC compensator to 3000 psi
the functions will move slowly. (210 bar). Set subsystem pressure
If the system pressure relief is relief PV4 to 3500 psi (241 bar).
functioning near or below the
compensator setting, the relief will
operate too often, causing oil heating
and reduced force from actuators.
load sense If the load sense solenoid does not Check wiring to load sense solenoid.
receive a signal, the pump will stay at Check load sense solenoid operation.
standby pressure.

12-11
 Troubleshooting D36x50 Series II Navigator HDD Service

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

Mechanical

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

Electrical

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

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

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

burned insulation.

12-12
D36x50 Series ii Navigator HDD Service Troubleshooting

Hydraulic

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

Check hydraulic components for any obvious problems.

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

Also review information in the General Information chapter under

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

12-13
 Troubleshooting D36x50 Series II Navigator HDD Service

Troubleshooting Machine Performance

If there are malfunctioning components in other functions, they may have an
effect on stakedown function operation.

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

Note any functions not operating normally based on the normal operation
given in each chapter for that function. Comparing the results with the
normal operation given for each mode of a particular function will help to
isolate the fault(s) to one or more function or circuit.

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

Possible Results: 1. If all machine functions are malfunctioning, it would indicate a function
or component that is common to all the actuators is most likely
malfunctioning. The following functions and components should be
investigated:
• Engine. See "Engine Troubleshooting," page 3-21.
Stakedown

• Shared hydraulic components. See Chapter 4.

• Remote Lockout. See Chapter 15.
2. If problems are noted in the stakedown, drilling fluid, rod greaser, rod
loader, and vise functions, and all other functions of the machine are
operating normally, the hydraulic components common to just these
functions should be investigated, including:
• Combination Valve Assembly A9.
• PFC pump PMP3
• Hydraulic enable circuitry

12-14
D36x50 Series ii Navigator HDD Service Troubleshooting

Testing Stakedown Performance

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

1. Conduct machine inspection before

proceeding.
1
2. If the engine has not been started, 2
refer to "Starting the Engine," page 2-2
and perform before proceeding.
3. Enable Remote Lockout.
4. Press hydraulic enable push button
S30 (1) to enable stakedown
hydraulic circuits.
5. Select left or right stakedown circuit
using LEFT/RIGHT switch S31 (2).
NOTE: Raise the rack to its fully raised position and remove stakedown
augers before continuing.

NOTE: The performance values listed for stakedown functions are for
reference purposes only. Loaded circuit extension and retraction times
experienced under working conditions will vary from the unloaded

Stakedown
conditions in this test. Operating conditions of these circuits should not be
determined by the results of these tests alone. If circuit operation is in
question, operating the stakedowns in working conditions may be required.

Continued on next page...

12-15
 Troubleshooting D36x50 Series II Navigator HDD Service

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

position.
7. Press top of stakedown valve switch
(1) to the LOWER position.
Stakedown cylinder will fully retract 1 2
in approximately 3 seconds.
8. Press bottom stakedown valve switch
(1) to the RAISE position.
Stakedown cylinder will fully extend
in approximately 3 seconds.
9. Repeat process for the opposite
cylinder.
10. Press top of stakedown rotation valve switch (2) to CLOCKWISE
position (CW). Measure rotation speed of motor using phototach or
counting rotations for 60 seconds. Rotation speed will be approximately
20 rpm.
11. Press bottom of stakedown rotate switch (2) to counterclockwise position
(CCW). Measure rotation speed of motor using phototach or counting
rotations for 60 seconds. Rotation speed will be approximately 20 rpm.
Stakedown

Troubleshooting/Testing Stakedown Function

WARNING: Pressurized fluid can penetrate body tissue and result in

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

Continued on next page...

12-16
D36x50 Series ii Navigator HDD Service Troubleshooting

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

"Pretest Inspection," page 12-12. If nothing obvious is found continue.
2. In order to ensure the fault is isolated to the stake IN or OUT mode, the
technician should operate all the machine functions and observe the
actuators as discussed in "Troubleshooting Machine Performance," page
12-14.
If any functions other than the left or right stakedown functions are
faulty, continue troubleshooting based on the possible results given. If all
other machine functions are operating normally, continue with step 3.
3. Determine if the problem is with the right, left or both stakedowns.
If the problem is only with the right or left stakedown, check the function
of stakedown selector switch S31. Disconnect switch and check for
continuity. If OK, continue to step 4.
If the problem is with both stakedowns, continue to step 5.
4. Check for voltage at wire 722 of solenoid L8 and wire 722A of solenoid
L7.
Expected result: 12 volts DC at wire 722 of solenoid L8 and 722A of
solenoid L7. If not, wire is faulty and should be replaced. If so, continue
to step 12 and inspect DV28 and DV29.
5. Check the function of stakedown cylinder switch S22 and stakedown

Stakedown
motor switch S23. Disconnect switches and check for continuity.
Expected Result: Both switches will show continuity between pins 1 and
2 when not compressed, and between pins 1 and 3 when compressed. If
not, replace faulty switch. If so, continue.
6. Determine if the motors or
cylinders are operating abnormally.
If motors are suspected, check for L10
voltage at wire 730 of solenoid L31 L7
and wire 728 of solenoid L32. L9 L17
L8
Expected result: 12 volts DC at wire
L11
730 of solenoid L31 and wire 728 of
solenoid L32. If not, wire is faulty
and should be replaced. If so,
continue.
7. If cylinders are suspected, check for
voltage at wire 724 of solenoid L30
and wire 726 of solenoid L29.
Expected result: 12 volts DC at wire 724 of solenoid L30 and wire 726 of
solenoid L29. If not, wire is faulty and should be replaced. If so, continue.
Continued on next page...

12-17
 Troubleshooting D36x50 Series II Navigator HDD Service

8. Determine if the motors or cylinders are operating abnormally. See the

common symptoms of faulty hydraulic components under "Hydraulic
Troubleshooting," page 1-12. If only the cylinder is faulty, go to step 9. If
only the motor is faulty, go to step 10. If both are operating abnormally,
go to step 11.
NOTE: Hydraulic component testing is based on volumetric efficiency. Test
the components for excessive internal leakage to determine if they are worn
beyond design specification. Refer to the Vermeer Industrial Dealerships
Technician’s Shop Manual (Vermeer P/N 105400V80) for information on how
to test these components.

9. Test cylinder for internal cross-piston leakage. Cross-piston leakage can

be caused by damage or wear in the internal cylinder tube wall or piston
seals.
Expected result: No flow should be measured when deadheading with
PFC pump PMP3 high compensator setting of 3000 psi (207 bar). If so,
repair or replace cylinder. Refer to component repair at the end of this
section for information.
10. Test efficiency of motor. Excessive cross-port leakage can be caused by
damage or wear to internal components.
Expected result: Shaft speed should be 23 rpm or faster when tested with
PFC pump PMP3 high compensator setting of 3000 psi (207 bar). If not,
repair or replace motor. Refer to component repair at the end of this
Stakedown

section for repair information.

If one motor turns significantly slower than the other one, shut down
and swap hoses for the two motors at valve manifold A7. If the same
motor still turns slower, replace motor. If the other motor now turns
slower, remove and inspect valve cartridge associated with that motor.
Refer to component repair for information.
11. If both cylinder and motor are not working properly, it may indicate a
common component to both actuators is at fault. Disassemble stakedown
valve check valve CV4 and inspect for contamination or damage to
internal seals, O-rings, and internal components. Refer to component
repair in this section for information.

12-18
D36x50 Series ii Navigator HDD Service Troubleshooting

Test Equipment Needed

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

• Multimeter for continuity tests, voltage measurements, resistance

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

NOTE: The hydraulic component test procedures discussed in this chapter

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

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

Electrical:

Stakedown
• Nominal circuit voltage - 12 volts DC
• Stakedown valve solenoid coils L7, L8, L9, L10, L11 and L12 - 7.2 ohms
@ 68°F (20°C)
Hydraulic:

• PFC Pump PMP3 normal output flow - variable to 47 gpm (177 L/min)
• PFC Pump PMP3 standby pressure compensator valve setting - 250 psi
(17.2 bar)
• PFC Pump PMP3 high pressure compensator valve setting - 3000 psi
(207 bar)

Component Repair/Replace
If troubleshooting procedures determine a component is in need of repair or
replacement, refer to the appropriate procedures at the back of the chapter
or other chapters where instructed. After repairs have been made, refer to
"Hydraulic Fluid Sampling," page 4-20 and follow instructions.

12-19
 Component Repair D36x50 Series II Navigator HDD Service

COMPONENT REPAIR
Stakedown Valve Assembly A7
4

2
5
Stakedown

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.
4. Remove two sets of bolts (1), washers (2), and nuts (3) mounting valve to
side of rod box.
5. Remove control valve (5) from side of rod box.
Continued on next page...

12-20
D36x50 Series ii Navigator HDD Service Component Repair

Disassemble

1. Remove nuts (1) and solenoid coils (2).

2. Remove orifice disks, plugs, and seals.

Stakedown
3. Inspect valves 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.
Install When installing control valve, reverse removal procedures.

Torque mounting bolts to 35 ft-lb (47 Nm). Torque solenoid coils to 7–10 ft-lb
(9.4–13.5 Nm).

12-21
 Component Repair D36x50 Series II Navigator HDD Service

Stakedown Motors MH9 and MH10

Remove

5
Stakedown

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.

12-22
D36x50 Series ii Navigator HDD Service Component Repair

Motor Breakdown

28

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

3
11

Stakedown
1
29
30 4
2
10
31

10

Refer to 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...

12-23
 Component Repair D36x50 Series II Navigator HDD Service

9. Teflon backup seal 21. Rotor assembly

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

Install 1. When installing motor, reverse removal procedure. Torque mounting

bolts to 90 ft-lb (122 Nm).
Stakedown

2. Torque fitting in port A to 38 ft-lb (52 Nm).

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

12-24
D36x50 Series ii Navigator HDD Service Component Repair

Stakedown Cylinders CY10 and CY11

Remove 1. Label, disconnect and cap all
hydraulic hoses and fittings on the 2 1
cylinder. 3

2. Remove bolts (1) and nuts (2)

holding cylinder to motor slide
mount (3) at top of stakedown
assembly.

Stakedown
Disassemble

1 8 2 3 4 11 12 5 6 7

9 9 13 14
10
1. Remove set screw (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.
IMPORTANT: Do not clamp onto unpainted portion of the rod. Scarring rod
can cause premature seal failure.

Continued on next page...

12-25
 Component Repair D36x50 Series II Navigator HDD Service

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

5. Remove rod wiper (14) and loaded V-cup (13).
6. Remove threaded cap head (7), O-rings (10, 11, 12), and seals (8 and 9).
Install 1. Replace seals. Refer to the Parts Manual for seal kit components and
locations. Apply a light coat of petroleum jelly to seals before installing.
2. Slide gland and piston onto rod and tighten nut.
3. Push rod assembly and gland into cylinder body.
4. Install thread cap into cylinder body and secure with set screw.
5. Install cylinder on stakedown assembly.
Torque mounting bolts to 90 ft-lbs (120 Nm).
Stakedown

12-26
D36x50 Series II HDD Navigator Service Overview

Chapter 13: Rod Greaser

OVERVIEW
This chapter consists of information about circuits and components
necessary for operation of the optional auto rod greaser.

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

• Auto Greaser Cylinder CY12

• Auto Greaser Valve A24, including:
• Directional Valve DV18
• Solenoid L34

Rod Greaser
• Left Joystick Control A13, including:
• Auto Greaser Switch S17

13-1
 Theory D36x50 Series II Navigator HDD Service

Component Locations
AUTO GREASER
VALVE SOLENOID L34

AUTO GREASER
CONTROL VALVE DV18
Rod Greaser

AUTO GREASER
VALVE MANIFOLD A24
AUTO GREASER CYLINDER CY6
AUTO GREASER SWITCH S39

13-2
D36x50 Series II HDD Navigator Service Theory

Hose Connections

GREASER CYLINDER CY12

STAKEDOWN VALVE A7

GREASER VALVE A24

Rod Greaser
VISE VALVE A8

RETURN MANIFOLD A12

PFC PUMP PMP3

PROPORTIONAL DUMP
VALVE A9

13-3
 Theory D36x50 Series II Navigator HDD Service

Schematics

TERMINAL
BUS TB1 GREASER VALVE
SOLENOID L34

CIRCUIT
BREAKER F1
Rod Greaser

LEFT JOYSTICK A13

GREASER SWITCH S17

13-4
D36x50 Series II HDD Navigator Service Theory

CYLINDER CY12
SOLENOID
L34

VALVE
DV18

TO TANK

A9
PRESSURE
RELIEF PV4

Rod Greaser
HYDRAULIC
PUMP ENABLE DV29,
PMP3 SOLENOID L26

TANK

13-5
 Auto Greaser Function D36x50 Series II Navigator HDD Service

AUTO GREASER FUNCTION

Greasing Mode

GREASER CYLINDER CY12

GREASER VALVE
MANIFOLD A24 SOLENOID L34

SIGNAL FROM SWITCH S17

GREASER VALVE
DV18
FROM VISE VALVE A24
TO VISE VALVE A24
Rod Greaser

Operation To operate optional auto greaser:

• There must be grease available in greaser cylinder CY12.

• Operator must be seated at drill controls.
• Remote Lockout system must be in RUN mode.
• Greaser switch S17 must be pushed and held.
When required operating conditions are met:

• Solenoid L34 will be energized and flow is directed to cylinder CY12.

• Greaser cylinder CY12 will extend.
• Grease will be applied to the threads of drill rod.

NOTE: If the auto greaser function does not operate as expected, see
"Troubleshooting/Testing the Auto Greaser Function," page 13-9.

13-6
D36x50 Series II HDD Navigator Service Troubleshooting

TROUBLESHOOTING
Troubleshooting procedures are given for each operating mode of the
different functions in this chapter. Begin each procedure by performing a
pretest inspection of the machine.

Often problems can be solved by doing a walk-around inspection of the

machine looking for obvious problems.

If nothing is found during the pretest inspection, continue by operating all

other actuator functions of the machine to help further isolate problems.

Pretest Inspection
Visually check to inspect for obvious signs of failure before any exhaustive
troubleshooting or testing procedures are performed.

Mechanical

Inspect mechanical linkages, cables, and connectors from joystick controllers

Rod Greaser
and control valves for:

• damage, misalignment, or improper adjustment

Continued on next page...

13-7
 Troubleshooting D36x50 Series II Navigator HDD Service

Electrical

Inspect electrical circuits for clues to malfunction. Always check the

following items before turning on switches or running the machine.

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

• Look for broken, missing, corroded, or loose wires on the power wires
that supply electrical circuit components.
• Check 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.

Hydraulic

WARNING: Pressurized fluid can penetrate body tissue and result in serious
injury or death. Leaks can be invisible. Keep away from any suspected leak.
Relieve pressure in the hydraulic system before searching for leaks,
disconnecting hoses, or performing any other work on the system. If you must
Rod Greaser

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

Check hydraulic circuits for any failures.

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

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

Also review information in the General Information chapter under

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

13-8
D36x50 Series II HDD Navigator Service Troubleshooting

Troubleshooting/Testing the Auto Greaser Function

Before beginning any troubleshooting or testing procedures, perform the
"Pretest Inspection," page 13-7. If nothing obvious is found continue.

1. In order to ensure the fault is isolated to just the auto greaser, the
technician should operate all machine functions and observe the
actuators.
2. If any functions other than the auto greaser function are faulty, continue
troubleshooting based on the possible results given. If all other machine
functions are operating normally, continue.
NOTE: Refer to the Vermeer Industrial Dealerships Technician’s Shop
Manual (Vermeer P/N 105400V80), for helpful information on testing
electrical circuits for shorts, opens, and high resistance.

See schematic for testing reference.

3. Test for acceptable voltage starting at test point of solenoid coil L34 of
valve DV18. If voltage is acceptable, continue with step 4. If not,
continue with step 5.
4. Test resistance of coil L34.

Rod Greaser
Expected result: Resistance should measure 9.8 ohms @ 68°F (20°C). If
OK, continue with step 6. If not, replace coil.

5. Remove and inspect the check valve in greaser valve assembly A24.
Refer to "Auto Greaser Valve A21," page 13-11 for information. Repair or
replace any faulty components.

Test Equipment Needed

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

• Multimeter for continuity tests, voltage measurements, resistance

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

NOTE: Hydraulic component test procedures discussed in this chapter will

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

13-9
 Troubleshooting D36x50 Series II Navigator HDD Service

Specifications
Listed below are the electrical and hydraulic specifications for the rod
greaser function.

Electrical:

• Nominal circuit voltage - 12 volts DC

• Minimum circuit voltage - 10.2 volts DC from DSR module A31 to Strike
Alert circuit
• Greaser valve solenoid coil L34 resistance - 9.8 ohms @ 68°F (20°C)
Hydraulic:

• Pump PMP3 normal output flow - variable to 47 gpm (178 L/min)

• Pump PMP3 standby pressure setting - 250 psi (17 bar)
• Pump PMP3 high pressure compensator setting - 3000 psi (207 bar)

Component Repair/Replace
Rod Greaser

If troubleshooting procedures determine a component is in need of repair or

replacement, refer to the appropriate procedures at the back of the chapter
or other chapters where instructed. After repairs have been made, refer to
and follow instructions.

13-10
D36x50 Series II HDD Navigator Service Component Repair

COMPONENT REPAIR
Auto Greaser Valve A21

1
2

Rod Greaser
2
Remove 1. Disconnect wiring to solenoid (1).
2. Label, disconnect, and cap hoses and remove fittings (2).
3. Remove bolts (3) and washers (4).
4. Remove valve body (5).
Disassemble 1. Remove nut (1) and solenoid (2).
1
2. Remove valve (3).
2
3. Inspect valve and seals for damage
and ensure no external contaminants 3
are present.
4. Inspect valve body cavity for burrs or
other irregularities.
5. Replace seals if needed.
6. Dip valve in clean filtered oil.
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).

13-11
 Component Repair D36x50 Series II Navigator HDD Service

Auto Greaser Cylinder CY6

5
6
Rod Greaser

4 3
2

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

2. Label, disconnect, and cap hoses and remove fittings (1).
3. Remove bolts (2) and washers (3).
4. Disengage cylinder (4) from grease pump housing (5) and remove O-ring
(6).
Continued on next page...

13-12
D36x50 Series II HDD Navigator Service Component Repair

Disassemble

5 7 2 7 7 7 7 1
7 6

1. Remove head gland collar (1).

2. Remove head gland (2) by unthreading it from barrel.

Rod Greaser
3. Pull rod assembly (3) out of cylinder body (4). Ensure ports are open and
positioned to direct oil into a suitable container.
4. Remove nut (5) from rod assembly.
IMPORTANT: Do not clamp onto unpainted portion of the rod. Scarring rod
can cause premature seal failure.

5. Slide piston (6) off rod.

6. Remove and replace seals (7). Refer to parts book for seal kit
components. Apply a light coat of petroleum jelly to seals before
installation.
Assemble 1. Slide piston onto rod and tighten nut. Torque nut to 22 ft-lb (29 Nm).
2. Push rod assembly into cylinder body.
3. Install head gland collar (1) into cylinder body and secure.
4. Reverse removal steps to install cylinder.
Torque mounting bolts to 35 ft-lb (47 Nm).

13-13
This page intentionally left blank.
D36x50 Series II Navigator HDD Service Overview

Chapter 14: Drilling Fluid

OVERVIEW
This chapter consists of the functions and components necessary to supply
the drill string with drilling fluid while boring and the wash wand with
water for cleanup.

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

• Fluid Pump PMP4

• Hydraulic Motor MH8
• Combination Dump Valve Assembly A9, including:
• Hydraulic Enable Valve DV29

Drilling Fluid
• Pressure Relief Valve PV4
• Hydraulic Enable Solenoid L26
• Proportional Flow Control Valves FV3 and FV4
• Water Flow Control Solenoids L22 and L23
• Fluid Shutoff Cylinder CY15
• Fluid Shutoff Ball Valve
• Fluid Pressure Gauge GA3
• Fluid Control Module A20
• Left Joystick Assembly A27
• Right Joystick Assembly A30
• Drilling Fluid/Wash Wand Selector Switch S18
• Fluid Full Flow Selector Switch S16
• Fluid Pressure Switch S10
• Fluid Pump/RockFire Relay K5
• Fluid Pump Speed PPU B3
• Ball Valve Solenoid L17
• Breaker F2
• Breaker F1
• Breaker F5
Continued on next page...

14-1
 Theory D36x50 Series II Navigator HDD Service

• Ball Valve Control Manifold A26, including:

• Shutoff Cylinder Control Valve DV23
• Shutoff Cylinder Control Solenoid L17
• 2-Speed Shift Manifold A27, including:
• Motor Shift Control Valve DV26
• Motor Shift Control Solenoid L20

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

Electrical:

• Nominal circuit voltage - 12 volts DC

• Ball valve control solenoid coil L17 - 9.8 ohms @ 68°F (20°C)
• Fluid control valve solenoid coil L22 and L23 - 7.2 ohms @ 68°F (20°C)
Drilling Fluid

• 2-speed control valve solenoid coil L20 (SC-45 Aplex pump only) - 9.8
ohms @ 68°F (20°C)
Hydraulic:

• FMC Pump normal output flow - variable to 53 gpm, 1300 psi (89.6 bar)
• Aplex SC-65L pump maximum discharge - variable to 70 gpm @ 850 psi
(58.6 bar)
• Aplex SC-45 pump maximum discharge - LOW : 25 gpm @ 985 psi (68
bar)/HIGH : 50 gpm @ 492 psi (34 bar)

14-2
D36x50 Series II Navigator HDD Service Theory

Component Locations

WATER
ON/OFF
SWITCH
S43

FRONT VISE
FULL FLOW
CLAMP SWITCH
SWITCH
S34
S16

HIGH/LOW PRESSURE SWITCH S19

Drilling Fluid
WASH WAND SWITCH S18

WATER CONTROL
MODULE A20

FLUID PRESSURE GAUGE GA3

14-3
 Theory D36x50 Series II Navigator HDD Service

FLUID CONTROL FLUID SHUTOFF

VALVE MANIFOLD A26 CYLINDER CY12

FLUID BALL VALVE

FLUID SHUTOFF
VALVE SOLENOID
L17 FLUID SHUTOFF
VALVE DV23
Drilling Fluid

FLOW CONTROL VALVE

SOLENOID L23

FLOW CONTROL VALVE

SOLENOID L22

FLOW CONTROL VALVE

FV4
FLOW CONTROL
VALVE FV3

COMBINATION VALVE
MANIFOLD A9

WATER SUPPLY
PRESSURE SWITCH S10

14-4
D36x50 Series II Navigator HDD Service Theory

BREAKER F1

BREAKER F2

BREAKER F5

BALL VALVE
RELAY K5

2-SPEED SHIFT
MANIFOLD A27 (SC-45
water pump only)

Drilling Fluid
WATER PUMP PMP4

WATER PUMP
2-SPEED MOTOR MH8
CONTROL VALVE
DV26 (SC-45 water
pump only) WATER PUMP
SPEED PICKUP B3

2-SPEED CONTROL
SOLENOID L20 (SC-45 water
pump only)

14-5
 Theory D36x50 Series II Navigator HDD Service

Hose Connections

FLUID PUMP PMP4

MOTOR MH8
SHIFT VALVE DV26
(APLEX SC-45 PUMP)
PRESSURE
GAUGE GA3
Drilling Fluid

RETURN MANIFOLD A12

HYDRAULIC TANK RES1

CYLINDER FLUID SHUTOFF

CONTROL CYLINDER CY15
VALVE DV23

PFC PUMP PMP3

COMBINATION
VALVE A9

14-6
D36x50 Series II Navigator HDD Service Theory

Hydraulic Schematic
CYLINDER CONTROL CYLINDER CONTROL
VALVE DV23 SOLENOID L17

MOTOR SHIFT
CONTROL VALVE DV26 (SC-45 Aplex pump)

SHIFT SOLENOID L20 (SC-45 Aplex pump)

FLUID SHUTOFF
VALVE FLUID PUMP PMP4
CYLINDER CY15

COMBINATION VALVE A9

FLOW VALVE GAUGE

Drilling Fluid
FV3 GA3

FLUID PUMP
MOTOR MH8
FLOW VALVE
FV4

TANK
RETURN VALVE A12 RES1
HYDRAULIC ENABLE
VALVE DV29, SOLENOID L26

FROM PUMP PMP3

14-7
 Theory D36x50 Series II Navigator HDD Service

Electrical Schematic
GROUND BUSS TB1

WATER FLOW
SOLENOID L22

WATER FLOW
SOLENOID L23

FLUID
PRESSURE
SWITCH S10

CONTROL MODULE A20

FLUID PPU B3 2 SPD
MUD
Drilling Fluid

SWITCH BREAKER F5
S19

WATER SPEED L20

DRILL MODE SWITCH BALL VALVE RELAY K5
S23
BALL VALVE
L17

BREAKER F1
WASH
WAND
SWITCH S18

WATER ON S43 BREAKER F2

FRONT VISE S34

FULL FLOW
SWITCH S16

RIGHT
LEFT JOYSTICK A27 JOYSTICK A30

14-8
D36x50 Series II Navigator HDD Service Theory

Operation To operate drilling fluid function:

• Operator must be seated at drill controls.

• Remote Lockout system must be in RUN mode.
• Engine must be running.
• Hydraulic enable switch must have been pressed.
• Front vise switch S34 must be in open position.
• Fluid system 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 switch must be toggled up or down on fluid control module

A20.
• High (50 gpm)/low (25 gpm) pressure/flow switch S19 must be pressed at
top or bottom.
When required operating conditions are met:

• Solenoid L26 in combination valve manifold A9 is energized and

hydraulic flow is available to fluid shutoff manifold A26 (and shift
control manifold A27 if equipped with SC-45 Aplex pump).

Drilling Fluid
• Solenoids L22 and L23 in fluid control valve A26 is energized and flow
goes to pump motor MH8.
• Motor MH8 drives water pump PMP4, pushing drilling fluid to the ball
valve.
• Solenoid L17 that controls valve DV23 in fluid shutoff valve manifold
A26 is energized and hydraulic flow is supplied to cylinder CY15,
opening ball valve in-line to drilling fluid nozzle.
• Drilling fluid flow displayed on fluid control module A20 will indicate
proportional flow based on the signal from fluid PPU B3 located on the
water pump motor.
• When adjusted at toggle switch on control module A20, the fluid control
module sends a signal to solenoids L22 and L23 that control flow control
valves FV3 and FV4 in combination valve manifold A9 to adjust flow to
motor MH8.
• When pressed, high/low pressure/flow switch S19 energizes solenoid L20
in 2 speed shift manifold A27 that directs flow to S port of motor MH8,
shifting the motor displacement to low pressure/high flow.
NOTE: If drilling fluid mode does not operate as expected, see
"Troubleshooting/Testing the Drilling Fluid Function," page 14-15.

14-9
 Troubleshooting D36x50 Series II Navigator HDD Service

Drill Fluid OFF

Operation To turn drill fluid OFF, perform one of the following:

• Push bottom of fluid ON/OFF switch S43, or

• Push front vise switch S34 to closed position.
When required operating conditions are met:

• Output from pin 3 and pin 2 from control module A20 stops to
proportional solenoids L22 and L23 and to ball valve control solenoid
L17. This stops flow to motor MH8 and closes the fluid control ball valve.
NOTE: If drilling fluid OFF mode does not operate as expected, see
"Troubleshooting/Testing the Drilling Fluid Function," page 14-15.

Wash Wand
Operation To operate wash wand:

• Remote Lockout system must be in RUN mode.

• Engine must be running.
Drilling Fluid

• Hydraulic enable switch must be pressed.

• Front vise switch S34 must be in off position.
• Fluid system on/off button S43 must be toggled to ON position.
• Wash wand switch S18 must be in wash wand position.

TROUBLESHOOTING
Before performing any troubleshooting procedures, see "Pretest Inspection,"
page 14-11.

Often problems can be solved by simply doing a walk-around inspection of

the machine looking for the obvious.

If nothing obvious is found during the inspection, actuate other functions of

the machine to help further isolate faults. See "Testing Machine
Performance," page 14-13.

14-10
D36x50 Series II Navigator HDD Service Troubleshooting

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

Mechanical

Inspect the mechanical valve control linkages for damage, misalignment,

proper adjustment.

Electrical

Inspect electrical circuits for clues to malfunction. Always check the

following items before turning on switches or running the unit.

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

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

Drilling Fluid
awhile. They will often smell like burned insulation.

Hydraulic

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

Check hydraulic circuits for any failures.

• Look for broken, kinked, loose, or leaking hoses and fittings on supply,
pressure, and return to hydraulic components.
Continued on next page...

14-11
 Troubleshooting D36x50 Series II Navigator HDD Service

• Check level of hydraulic fluid in hydraulic tank. Low fluid can cause
hydraulic actuators to behave erratically. Correct level is between the
two lines on dipstick. If needed, add new fluid that has been filtered
through a 5-micron filter.
Also review information in the General Information chapter under
"Hydraulic Troubleshooting," page 1-12. Correct any problems found during
the inspection. Operate machine to verify any problem has been repaired.

Test Equipment Needed

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

• Multimeter for continuity tests, voltage measurements, resistance

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

NOTE: The hydraulic component test procedures discussed in this chapter

will refer the technician to the Vermeer Industrial Dealerships Technician’s
Shop Manual (Vermeer P/N 105400V80). Test procedures and equipment
Drilling Fluid

needed for performing the various tests on hydraulic components will be

listed in the manual.

14-12
D36x50 Series II Navigator HDD Service Troubleshooting

Testing Machine Performance

Possible faults may occur in the drilling fluid function that are directly
related to failed components in other functions. These other faults may not
be readily apparent because those particular functions were not currently
being operated.

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

Make note of any functions not operating normally based on the normal
operation given in each chapter for that function. Comparing the results
with the normal operation given for each mode of a particular function will
help to isolate the fault(s) to one or more function or component.

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

Possible Results 1. If faults are noted when operating all the machine functions, it would
indicate a function or component that is common to all the actuators is

Drilling Fluid
malfunctioning. The following shared functions and components should
be investigated:
• Engine. See "Engine Troubleshooting," page 3-21.
• Shared hydraulic components. See Chapter 4.
• Remote Lockout. See Chapter 15.
2. If problems are noted in the vises, stakedown, rod loader, auto greaser,
and drilling fluid functions, and all other functions are working properly,
the following functions should be investigated:
• combination valve manifold A9.
• Return manifold A12. See "Oil Filtering Function," page 4-12.

3. If problems are noted in drilling fluid functions, and all other functions of
the machine are working properly, the electrical and hydraulic
components common to just this function should be investigated.
Continued on next page...

14-13
 Troubleshooting D36x50 Series II Navigator HDD Service

Testing Water Shutoff Valve Performance

1. Conduct machine inspection.
2. Sit in seat.
3. Start engine.
1
4. Ensure Remote Lockout is in RUN
mode.
5. Ensure front vise is open.
6. Momentarily press hydraulic enable
push button S30 (1) to enable water
ball valve circuit and 2-speed control
hydraulic circuit if machine is
equipped with SC-45 water pump.
7. While observing water shutoff cylinder, move wash wand selector switch
S18 (2) to wash wand position. Water shutoff cylinder will rapidly retract
to shut off water (drilling fluid) flow to the rotation gearbox.
8. Move water switch to ON position.
Water shutoff cylinder will rapidly
Drilling Fluid

extend.
9. Time the results of cylinder
extension and retraction. It should
take approximately one second.
2
10. With engine at full throttle, toggle
flow control switch on control module
to full flow. Observe flow meter on
fluid control module A20. Refer to
"Specifications," page 14-2 for maximum flow rates.
11. Toggle flow control valve switch to low flow and observe flow meter on
fluid control module A20. Refer to "Specifications," page 14-2 for flow
rates of Aplex SC-45 equipped machine.

14-14
D36x50 Series II Navigator HDD Service Troubleshooting

Troubleshooting/Testing the Drilling Fluid Function

Before beginning any troubleshooting or testing procedures, perform the
"Pretest Inspection," page 14-11. If nothing obvious is found, continue.

1. In order to ensure the fault is isolated to just the drilling fluid functions,
the technician should operate all machine functions and observe the
actuators as discussed in "Testing Machine Performance," page 14-13.
2. If any functions other than the drilling fluid function are faulty, examine
the components discussed in "Testing Machine Performance," page 14-13.
If all other machine functions are operating normally, continue.
3. Review results from step 9 on the previous page. Gauge should show an
increasing flow in GPM in proportion to toggle switch activation.
4. Pressure can vary based on flow rates and nozzle sizes used in the
tooling. A maximum indication of psi (bar) on the drilling fluid pressure
gauge could be an indicator that flow has become restricted (drill head
clogged). If maximum pressure is indicated, continue with step 5.
If there is no or low flow, or flow does not increase when adjusting, it may
indicate a problem in the drilling fluid electrical or hydraulic circuit or
the water pump itself. If so, continue with step 6.

Drilling Fluid
WARNING: Relieve drilling fluid pressure in the drill string before
cleaning out nozzles with a tip cleaner. Drilling fluid under pressure
can penetrate body tissue and result in serious injury or death. Fluid
injected under the skin must be removed immediately by a surgeon
familiar with this type of injury.

5. Clean drill head nozzle with a tip cleaner.

NOTE: Refer to the Vermeer Industrial Dealerships Technician’s Shop
Manual (Vermeer P/N 105400V80), for helpful information on testing
electrical circuits for shorts, opens, and high resistance.

Continued on next page...

14-15
 Troubleshooting D36x50 Series II Navigator HDD Service

6. If an obstruction is suspected at the fluid shutoff cylinder, remove and

inspect ball valve. Refer to component repair section.
7. Test for acceptable voltage at
solenoid coil L17 (1) of fluid 2
shutoff valve manifold A26 which
supplies hydraulic oil to the ball
valve cylinder. If voltage is
acceptable, continue with step 8. If
not, continue with step 9.
8. Test resistance of solenoid coil
1
L17. Resistance should measure
9.8 ohms @ 68°F (20°C). If OK,
continue with step 8. If not, replace coil.
9. Test for acceptable voltage at solenoid coil L26 of hydraulic enable valve
DV29 which is located in combination valve A9. If voltage is acceptable,
continue with step 9. If not, continue with step 10.
10. Test resistance of solenoid coil L26. Resistance should measure 8.8 ohms
@ 68°F (20°C). If OK, continue. If not, replace coil.
11. Test the fluid control module. See "Troubleshooting/Testing Fluid Control
Drilling Fluid

Module A20," page 14-18. If OK, continue.

12. Continue testing for acceptable voltage in the rest of the circuit at pins/
terminals of components and wire harness connector INPUTS and
OUTPUTS. If voltage is not within specification (10.5 volts min.), repair
or replace faulty component(s) or wire harness segment(s). If everything
is OK, continue.
13. Test hydraulic circuit starting with the pump motor MH10 for excessive
internal leakage. Refer to the Vermeer Industrial Dealerships
Technician’s Shop Manual (Vermeer P/N 105400V80), for information on
testing hydraulic motors. If motor tests OK, continue.
14. Remove and inspect cartridge valves in fluid shutoff valve assembly A17.
Repair or replace any faulty components. If valve assembly is OK,
continue.
Continued on next page...

14-16
D36x50 Series II Navigator HDD Service Troubleshooting

15. Remove and inspect the cartridge valves in fluid control valve assembly
A18. Repair or replace any faulty components. If valve assembly is OK,
continue.
16. If the fluid shutoff valve is suspected, remove and test cylinder CY12.
Refer to the Vermeer Industrial Dealerships Technician’s Shop Manual
(Vermeer P/N 105400V80), for information on testing cylinders.
17. Test pump PMP4 for excessive internal leakage. Refer to the Vermeer
Industrial Dealerships Technician’s Shop Manual (Vermeer P/N
105400V80), for information on testing hydraulic pumps. If pump tests
OK, continue.
18. Disassemble and inspect drilling fluid pump PMP4 for damage or
contamination. Refer to "Fluid Pump PMP4 — Aplex or FMC," page 14-33
for information. Repair or replace if necessary.

Drilling Fluid

14-17
 Water Control Module D36x50 Series II Navigator HDD Service

Troubleshooting/Testing Fluid Control Module A20

WATER CONTROL MODULE
The water module A20 allows the operator to control water pump output
based on conditions encountered during a bore. An LCD display provides
water flow and configuration information.

A water pump speed pickup B3, attached to the water pump drive motor,
provides a frequency signal to the water control module. The module
converts the frequency signal into a gallons per minute (gpm) amount which
is shown on the LCD screen.

Inputs/Outputs
The water control module receives inputs and provides output through a
12-pin connector.
• Pin 1 main power input for the module. 12 volts is received at this pin
from #2 terminal of the drill mode switch S23 which is connected to 15-
amp circuit breaker F5.
• Pin 2 provides output to proportional valves L22 and L23. This actuates
valves FV3 and FV4 which control the amount of oil flow to the water
Drilling Fluid

pump drive motor MH8.

• Pin 3 provides output to ball valve solenoid L17. This actuates valve
DV23 which controls water shutoff cylinder CY15.
• Pin 4 receives input from wash wand switch S18. When the switch is in
wash wand position, closed 12 volts is provided to the control module.
• Pin 5 receives input from water on/off switch S17.
• Pin 6 receives input from full flow switch S16 when full flow switch on
joystick is depressed (closed).
• Pin 10 receives input from mud charge pressure switch S10 when
pressure is above 10 psi (69 kPa).
• Pin 11 receives input from water pump speed pickup B3 when water
pump drive motor is rotating.
• Pin 12 provides ground source to the water control module at ground bus
TB1.

14-18
D36x50 Series II Navigator HDD Service Water Control Module

Function Check
1. Turn key to ON position.
2. Hold down + key on control module until displayed number stops
increasing.
3. Display number should be 0038.
4. Start machine.
5. Hook up water supply and charge pump to machine.
6. Turn water ON/OFF switch to ON position.
7. D2 module light should flash red.
8. Start charge pump to supply water to machine water system.
9. D2 module light should turn to steady on. This indicates that the
pressure switch is closed. If the light does not come on, supply water
pressure may be below 15 psi or the pressure switch may be defective or
does not have power. Check switch circuit connections and switch
function.
10. Increase flow of water by pressing + button on flow control module.

Drilling Fluid
11. Continue to press + until 10 is displayed on the screen.
12. Display will change slightly to show actual flow produced. Display
should read 8–12. The display will vary slightly. If the display shows
“0000”, the speed pickup is not sending the correct signal to the water
module.
13. Turn water on/off switch to OFF position.
14. Shut down machine.

14-19
 No Water Output D36x50 Series II Navigator HDD Service

NO WATER OUTPUT
1. Is the water pump drive motor running? Water pump drive motor MH8 receives a variable
hydraulic oil flow. To provide this hydraulic flow, a varying electrical signal from the water control module
controls proportional solenoid valves FV3 and FV4 in combination valve manifold A9. Load sense pressure
from the water pump drive circuit is provided to the PFC pump from combination valve A9. This oil pressure
controls flow from the PFC pump.

Possible Problem Possible Effect What to do

water circuit breaker Water system power is provided from Check that power is available from
tripped or defective the water circuit breaker. If it is tripped circuit breaker F5.
or defective, no current will be
provided to the water control module.
no flow output The water control module controls Ensure a high enough setting is
selected water pump drive motor speed based selected.
on commands from the water flow
switch. If a low enough setting is
selected, there may be no flow at all.
pump failure Pump PMP3 provides oil flow to the Check that the water pump is turning.
water pump drive motor. If the pump If not, check pump PMP3 and controls.
does not supply flow, the motor will not
Drilling Fluid

turn and the water pump will not

operate.
drill head or drill Water output pressure is limited by the Ensure drill head or drill pipe is not
pipe is blocked 3300 psi (227 bar) relief pressure plugged.
setting on the water pump hydraulic
drive circuit. If the maximum pressure
is obtained on the pump, the water
pump will stall. This protects the water
pump from excess pressure
pump PMP3 is not If for any reason pressure is not Verify that pump PMP3 is providing
providing flow available from pump PMP3 to the flow to combination valve manifold
water control valve manifold, there will A9.
be no hydraulic flow to the water valve
cylinder to open the ball valve. There
will be no supplementary flow available
to the water pump drive motor for high
speed pump output.
Continued on next page...

14-20
D36x50 Series II Navigator HDD Service
2. Is the ball valve opening? Opening the ball valve requires that the wash wand switch must be
closed AND that either the front vise switch is OFF (i.e., the ball valve part of the switch must be closed) or
the full flow button switch AND the water switch are both closed.
Possible Problem Possible Effect
ball valve solenoid A minimum of two switches must be
valve is not opening closed to open the ball valve solenoid
valve which uses a hydraulic cylinder
to open the ball valve.
ball valve solenoid The ball valve solenoid valve is located
coil or valve in the rack manifold. If PFC pump
defective pressure is not available or if the
solenoid valve is defective, the ball
valve will not open.
3. Is the control circuit working correctly? Power, grounds, and current path must be correct in
order for the water control circuit to function correctly.
Possible Problem Possible Effect
grounds If the ground path is missing, is too
resistive, or the voltage drop more than
0.5V, all electrical operation can be
effected.
current path Any damage to wiring, connectors or
connector pins that are not seated or
mated correctly or any unintended
short to power, resistance, or ground
can cause intermittent or constant
problems.
control module The control module must receive 12V
from the drill mode (rock drill) switch.
No Water Output
What to do
Check front vise switch, full flow
button, water switch, diode condition,
and wash wand switch.
Check PFC pump system, ball valve
solenoid valve, and ball valve hydraulic
cylinder.
What to do
Check all grounding locations.
Drilling Fluid
Check ground voltage between
ground buss and battery negative
terminal at rest and while operating an
electrical load. Repair any condition
causing high ground voltage either at
rest or under load.
Check the entire current path.
Inspect visually or use an ohmmeter or
voltmeter.
Check power input to the water
control module.
14-21
 Pump Performance D36x50 Series II Navigator HDD Service

PUMP PERFORMANCE
1. Does the pump fail to deliver any flow? Ensure pump is turning and that water is available to
the inlet. Also check that the ball valve is actually open in case there is a problem with the ball valve lever
arm function.

Possible Problem What to do

Pump shaft not turning Verify function of hydraulic motor.

Supply tank empty Fill tank to correct level.
Inlet line blocked or restricted Trace inlet line.

2. Does the pump deliver a low flow rate? Pump flow rate is affected by these things: input shaft
speed (i.e. is the control and hydraulic system working), water supply (is there sufficient flow of water at a
positive pressure—under almost all circumstances the water pump requires a remote water charging pump;
the pump is not intended to operate under a vacuum), and water pump efficiency (if the pump is worn or has
defective components it will reduce water flow, particularly under pressure).

Possible Problem Possible Effect What to do

pump shaft speed If the hydraulic system is worn or there Verify correct hydraulic motor
too slow is a control problem so that the speed.
Drilling Fluid

hydraulic motor slows down under

load, the output of the water pump
under pressure will be limited.
excessive amount of The charge pump may be delivering a Check water/mud quality; check
air in fluid or mud certain volume of fluid that contains a inlet lines and fitting.
viscosity too thick high volume of air. When the fluid is
pressurized, the air is compressed
causing a loss of available flow. Leaky
inlet fittings can also cause air
entrainment.
restriction in inlet The water pump is intended to be run Correct the inlet condition.
line; remote water with a positive inlet pressure. Do not
charge pump system rely on the water pump to draw fluid
inadequate for pump from a tank or other source without
demand using a charge pump system that
delivers a positive pressure as
measured at the high pressure
pump inlet.
valves stuck open, Any mechanical condition that allows Repair pump.
worn or seats recirculation of fluid will reduce flow
washed out rate, especially under load.
Continued on next page...

14-22
D36x50 Series II Navigator HDD Service Pump Performance

3. Does the pump run rough and/or knock? Rough running or knocking can indicate either
cavitation, air entrainment, or a mechanical failure.

Possible Problem Possible Effect What to do

pump cavitation Cavitation is caused by inlet restriction Verify that mud mixture is not too
and other conditions that cause very heavy and mixed properly; verify that
low pressure in the pumping chamber. inlet line correct length and diameter;
Also, if the hydraulic hoses to the verify that any inlet strainer not
water pump drive motor are reversed, plugged with debris. Verify that the
similar symptoms may result. hydraulic motor is hosed correctly.
excessive amount of The charge pump may be delivering a Check water/mud quality.
air in fluid (entrained certain volume of fluid that contains a
air) high volume of air. When the fluid is
pressurized, the air is compressed
causing a loss of available flow. Leaky
inlet fittings can also cause air
entrainment.
valve problem or Repair pump.
piston problem

4. Does the pump leak mud during operation? Leakage should be very limited during operation
so significant mud leakage indicates a wear problem or mechanical failure. Pump should be serviced as soon

Drilling Fluid
as possible.

Possible Problem What to do

piston cups are wearing and about to fail Rebuild pump.

fluid cylinder bolts are not properly tightened Check bolt torque.
fluid O-rings or gaskets damaged Repair pump
piston holder O-ring failed Repair pump.
Continued on next page...

14-23
 Pump Performance D36x50 Series II Navigator HDD Service

5. Are there excessive piston cup failures? Refer to the chart below for possible causes of piston
cup failures.

Possible Problem What to do

pump allowed to run dry for extended periods of time Never run pump dry.
cylinder liner is damaged (scored or cracked) Replace cylinder liner.
piston holder O-ring damaged Repair pump.
pump cavitation (cups often run hot) Correct inlet or mud condition.
mud poorly mixed or contains lots of sand Use high quality, thoroughly mixed
mud.

6. Does the pump develop proper pressure? Pump flow may be normal under light load
conditions but be severely limited when the rod is downhole. Look for any condition that would contribute to
leakage or inefficiency under load.

Possible Problem Possible Effect What to do

valve problem If an inlet or exhaust valve is not Repair pump.

sealing, pump efficiency will be sharply
reduced.
pump not turning at If the hydraulic system is worn or there Verify motor/pump shaft speed.
proper speed is a control problem so that the
Drilling Fluid

hydraulic motor slows down under

load, the output of the water pump
under pressure will be limited.
pump cavitation Cavitation is caused by inlet restriction Correct inlet or mud condition.
(cups often run hot) and other conditions that cause very
low pressure in the pumping chamber.

Component Repair/Replace
If troubleshooting procedures determine a component is in need of repair or
replacement, refer to the appropriate procedures at the back of the chapter
or other chapters where instructed. After repairs have been made, refer
to"Hydraulic Fluid Sampling," page 4-20 and follow instructions.

14-24
D36x50 Series II Navigator HDD Service Component Repair

COMPONENT REPAIR

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

Combination Valve Manifold A9

Drilling Fluid
4
1 2

Remove 1. Label, disconnect and cap all hoses and fittings.

2. Disconnect electrical wiring harnesses from coils.
3. Remove bolts (1), washers (2) holding manifold (3) to pump.
4. Remove O-ring (4) between pump and manifold.

14-25
 Component Repair D36x50 Series II Navigator HDD Service

Install Inspect O-ring for damage and replace if necessary.

Reverse removal procedures to install manifold.

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

Drilling Fluid

14-26
D36x50 Series II Navigator HDD Service Component Repair

Flow Control Valves FV3 and FV4

Remove 1. Disconnect electrical harness from solenoid.
2. Remove nut (1) solenoid coil
(2) and cartridge valve (3). 1

3. Inspect seals and valve body

for contamination or wear. 2
Replace seals, if necessary.
Clean valve body.
3

Install Install O-rings on cartridge valve if needed.

Before installing components, apply a light coat of petroleum jelly to O-rings.

Drilling Fluid
Torque cartridge valve to 30 ft-lb (40 Nm). Torque nut on coil to 10 ft-lb (13
Nm).

Fluid Shutoff Valve Assembly A26 and Shift Valve Assembly A27
Remove 1. Label, disconnect and cap all hoses and
1
fittings.
2. Disconnect electrical wiring harnesses from 2
coil.
3. Remove bolts, washers, and nuts holding
valve to mounting plate on undercarriage. 3

14-27
 Component Repair D36x50 Series II Navigator HDD Service

Disassembly

2 3

1. Remove nut (1) solenoid coil (2) and cartridge valve (2).
2. Inspect O-rings and replace if necessary.
Drilling Fluid

3. Inspect seals and valve components (1) for contamination or wear. Clean
valve body.
NOTE: Before installing components, apply a light coat of petroleum jelly to
O-rings.

Install O-rings with cartridge valves (2). Torque cartridge valves to 20 ft-lb
(27 Nm). Torque nut on coils to 5 ft-lb (6.8 Nm).

When installing control valve, reverse removal procedures.

Torque mounting bolts to 10 ft-lb (13 Nm).

14-28
D36x50 Series II Navigator HDD Service Component Repair

Fluid Shutoff Cylinder CY15 and Ball Valve

4
3
5
2
3

7
6

Remove 1. Label, disconnect and cap hoses and fittings (1).

2. Remove bolt (2), washers (3), and nut (4) holding rod end of cylinder to

Drilling Fluid
lever arm (5).
3. Remove nut (6) and washer (7) holding base end of cylinder to pin.
4. Remove nuts on studs holding ball valve to mounting flange.
Reverse steps to install. Torque bolt (6) to 90 ft-lb (120 Nm). Torque nuts on
ball valve studs to 30 in-lb (3.3 Nm).

14-29
 Component Repair D36x50 Series II Navigator HDD Service

Cylinder
Disassembly

4 5 2
3 1

7
6 8

1. Remove head snap ring (1).

2. Pull rod assembly (2) out of barrel assembly (3).
3. Remove lock nut (4) from rod.
IMPORTANT: Do not clamp onto unpainted portion of the rod. Scarring the
rod can cause premature seal failure.

4. Remove piston (5) from rod.

Drilling Fluid

5. Remove seals (6) from piston.

6. Slide gland (7) off rod and remove seals (8).
7. Refer to D36x50 Series II Navigator Parts Manual for seal kit
components. Apply a light coat of petroleum jelly to seals before
installation.
Reverse steps for assembly.

14-30
D36x50 Series II Navigator HDD Service
Ball Valve
Disassembly
4 9
1
Note the position of
handle before
disassembly. Also, ball
must be rotated to the
closed position to
remove it.
Continued on next page...
Component Repair
16
14
13
15
7 8 12
6 11
5
4
1
2 10
14
Drilling Fluid
16
13
15
17
3
IMPORTANT: Drain the system and cycle the valve open and closed once to
relieve trapped pressure. Leave valve in the open position. During
disassembly, do not scratch internal bore surfaces.
1. Remove nuts (3) on one end of each stud (17).
2. Loosen four body studs, but remove only three studs (17). Swing out
body center (9), using a stud as pivot. Remove support rings (13) and
ball (12), saving them for assembly. Remove and discard O-rings (15)
and seat subassemblies (14).
3. Remove stem nut (1) and stem spring (4) holding lever arm on center
valve body (9). Discard the spring.
4. Remove grounding spring (2), nut (1), stem spring (4), and gland (5).
Discard the springs, gland and stem bearings.
5. Remove packing support (6). Carefully pry top and bottom packings (7)
and (8) out of the bore. Discard the packing support and packings.
14-31
 Component Repair D36x50 Series II Navigator HDD Service

6. Remove stem (11) and stem bearing (10).

7. Inspect valve body and all parts for contamination and damage.
Ball Valve Assembly 1. Thoroughly clean body center (9), stem (11) and sealing surfaces on
flanges (16). Also, clean support rings (13).
IMPORTANT: If lubricant is used on the stem shank, stem bearings, and
top and bottom packings, it must be a silicone or Teflon based lubricant. Do
not use a petroleum base lubricant. Also, do not apply lubricant to the stem
threads.

2. Slide new stem bearings (10) on the stem and install the stem. Insert
ball (12) in the body center until the stem tang is engaged, rotating the
stem to the open position. The ball is now secure.
Keep the packings and 3. Push new bottom and top packings (8) and (7), followed by new packing
packing support straight support (6), into the packing bore.
during installation.
4. Place new gland (5) and two new springs (4) (convex sides facing each
other) on the stem.
5. Thread nut (1) on the stem; hold the stem with handle; and torque the
nut to 100 in-lb (11.3 Nm).
Drilling Fluid

During assembly, the 6. Install handle, new spring (4) (convex side facing handle) and nut (1).
handle must be Torque nut to 100 in-lb (11.3 Nm).
positioned as it was
before disassembly to IMPORTANT: Lubricate new O-rings (15) and new seat sub-assemblies
indicate the proper (14), using a silicone or Teflon based lubricant. Do not use a petroleum base
direction of valve flow. lubricant.

7. Place support rings (13) (chamfered sides toward the ball), seat
sub-assemblies (metal springs away from the ball) and O-rings in body
center (9).
8. Swing body center back into position. Install
body studs (17) and nuts. With valve in the 4 1
fully open position, torque studs in five stages,
using the illustrated numerical, crisscross
sequence. Torque values for each stage are as
follows: 25 in-lb (2.8 Nm), 50 in-lb (5.7 Nm),
100 in-lb (11.3 Nm), 180 in-lb (20.3 Nm) and
180 in-lb (20.3 Nm).

2 3

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D36x50 Series II Navigator HDD Service Component Repair

Fluid Pump PMP4 — Aplex or FMC

Remove 1. Disconnect wire harness from voltage stake.
2. Remove bolts (1) that attach tank
support to rear control panel.

3. Swing fuel tank away from fluid pump assembly.

Drilling Fluid
4. Label, disconnect and cap hydraulic fittings and hoses on motor MH8
and water pump PMP4.
5. Disconnect drilling fluid hoses from pump.
6. Disconnect antifreeze hose from pump.
7. Disconnect electrical wire harness from motor.
8. Remove four bolts with washers mounting pump to frame.
NOTE: Ensure all electrical, hydraulic and water connections are
disconnected from pump.

9. Using a suitable lifting device, remove pump from frame.

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 Component Repair D36x50 Series II Navigator HDD Service

Fluid Pump PMP4 – Aplex SC-45

Valve Disassembly 1. Remove bolts (2) holding top plate
2
(1). Remove plate.
1
2. Remove O-ring (3).
3
7

6
Drilling Fluid

3. Use valve puller tool (4) to remove

discharge cage, spring and valve.
4

Continued on next page...

14-34
D36x50 Series II Navigator HDD Service Component Repair

4. Use threaded puller stem tool (5) to

remove valve seat.
5
5. Remove bolts (7) on side plate (6).
Remove plate and caps.
6. Put valve puller tool (5) down into
suction valve and remove cage, 8
spring and valve. You may need to
put arm in through hole (8) in side
to capture parts.
7. Use threaded puller stem tool to
remove suction valve seat.
Reverse steps for assembly. Torque top
cover bolts to 300 ft-lb (405 Nm).
Torque side cover bolts to 180 ft-lb (245
Nm).

Drilling Fluid

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 Component Repair D36x50 Series II Navigator HDD Service

Piston Cup and 1. Remove bolts (7) on side plate (6).

Piston Rod Remove side plate.
Disassembly
2. Remove three caps and seals. 6 7
3. Hoist pump up. Place shims under
pump and lower it back down until
fluid end assembly is raised
approximately one inch (2.5 cm).
4. Remove two bolts (9) holding fluid
end assembly. Use hoist to lift fluid
end assembly away.
9

5. Remove hex head

bolt (1) and star 6
washer from 2
1
piston rod (3).
6. Remove piston
cup (2) assembly.
Drilling Fluid

3 7

4 5

7. Remove piston hub (4), piston cup

housing (5), and piston keeper (6) 2 6 5 4
from the piston cup (2) and seal. It
may require very careful hits from a
soft mallet to free parts.
8. Remove two bolts on wiper
assembly (7). Work wiper assembly
down piston rods.
9. Use pipe wrench on threads of plunger rods to unscrew rods from
pistons.
10. Remove piston rod and wiper assembly.
Reverse steps for assembly.

14-36
D36x50 Series II Navigator HDD Service Component Repair

Piston and 1. Remove four bolts on motor mount

Crankcase flange. 1
Disassembly
2. Disengage motor shaft and remove
motor.
3. Remove six bolts (1) on motor
mount flange.
4. Remove flange and four thin plastic
seals. Note seal orientation of blue
face towards pump and yellow face
towards motor for later assembly.

5. Remove bolts (2) on crankcase

2 3 5
cover. Remove cover.
6. Remove oil level dipstick (3).

7. Remove bolts (4) on each of the

6 7 4

Drilling Fluid
three crank pin half bearings.
Each half bearing is marked with
a number. Make note of the
number and orientation of each
half bearing for later assembly.
8. If piston rod was removed for
piston cup removal, reattach
piston rod loosely back into piston
at wrist pin (5).
9. Pull piston/half bearing assembly out of crankcase.
10. Remove crank shaft plug (6) and O-ring (7).
Continued on next page...

14-37
 Component Repair D36x50 Series II Navigator HDD Service

11. Turn pump on its side so motor

shaft is facing down.
12. Use a press to push all crankshaft
and seal assembly components out
through motor shaft opening.
NOTE: Use care not to damage
components while pushing them out of
pump.

Reverse disassembly steps for

assembly. Torque bolts on crankcase
cover to 35 ft-lb (47 Nm). Torque bolts
on motor mount flange to 90 ft-lb (120
Nm).

Fluid Pump PMP4 – FMC

Drilling Fluid

Piston Cup Seal Removal/Installation

Special Tools and • Torque wrenches capable of producing 30 ft-lb (40 Nm) and 90 ft-lb
Materials (122 Nm)
• Rubber mallet
• FMC piston tool (Vermeer P/N 240141-019)
• FMC torque wrench adapter (Vermeer P/N 278825-003) for FMC piston
tool
• Glycerin for assembly lubricant

14-38
D36x50 Series II Navigator HDD Service Component Repair

Remove Piston Cup

Seals

2
1 3

Approximately 24" (60 1. Remove the six nuts retaining three diagonal cylinder cover clamps (1),
cm) of clearance is and pull the clamps from the fluid cylinder.
required between the
front of the pump and NOTE: Do not remove two nuts (2) on opposite, diagonal corners of the fluid
any obstructions to cylinder since they keep the fluid cylinder securely mounted on the pump.
service the piston cups.
2. Remove cylinder covers (3).

Drilling Fluid
3 4

3. Remove brass hex nuts from the piston assemblies, using socket wrench
(3) with long extension. These nuts secure the piston assemblies to the
crosshead rods.
4. Remove two nuts (4) on opposite, diagonal corners of the fluid cylinder.
Continued on next page...

14-39
 Component Repair D36x50 Series II Navigator HDD Service

2
2

5. Rock fluid cylinder (1) to loosen it from cylinder liners (2). Slide the fluid
cylinder from the studs. Do not allow the cylinder liners to fall and
become damaged.
6. Remove cylinder liners (2).

4
3
Drilling Fluid

7. Use a small amount of glycerin on the inner diameter of the cylinder

liners to lubricate the surface. Insert FMC piston tool (3) inside the
cylinder liners until flush with the face of slotted piston nuts (4). Twist
tool to engage and lock tabs of tool inside mating slots of piston nuts.
Push piston assemblies out of cylinder liners.
IMPORTANT: The interior surface of the cylinder liners must be smooth
and free of cracks and grooves. New piston cups fail prematurely if installed
in liners with damaged bores.
Continued on next page...

14-40
D36x50 Series II Navigator HDD Service Component Repair

2
2

8. Discard old cylinder cover O-rings (1), gaskets (2) and seal holder

Drilling Fluid
O-rings (3).

5
7

4 8

6 8

9. Clamp flats on the bottom of piston cup holders (4) in a vise. Using FMC
piston tool (5), unscrew piston nuts (6), removing the nuts, piston
washers (7) and piston cups (8). Discard piston cups.
Continued on next page...

14-41
 Component Repair D36x50 Series II Navigator HDD Service

Install Piston Cup

Seals

1 3
5
2

2
4

IMPORTANT: Inspect all parts for damage or unusual wear during each
step of assembly.

1. Thoroughly clean piston cup holders (1), and clamp bottom flats in a
vise.
2. Assemble piston cups (2), plastic piston washers (3) and piston nuts (4)
onto the piston cup holders. Bolt FMC torque wrench adapter (not
Drilling Fluid

shown) to FMC piston tool (5) and torque nuts to 25 ft-lb (34 Nm).
Continued on next page...

14-42
D36x50 Series II Navigator HDD Service Component Repair

3 1

IMPORTANT: The interior surface of cylinder liners (1) must be smooth

and free of cracks and grooves. New piston cups fail prematurely if installed
in liners with damaged bores.

Replace all three piston NOTE: Piston assemblies (2) must be installed in the cylinder liners with a
cups, not just those that press or vise. Use a soft jaw vise, wood blocks or another suitable method to
show signs of leakage. protect both ends of the assemblies from damage during assembly.
This ensures maximum
operational time 3. Thoroughly clean cylinder liners (3). Use a small amount of glycerin on
between service
the inner diameter of the cylinder liners to lubricate the parts during
intervals.
installation. Press piston assemblies (2) into the cylinder liners until

Drilling Fluid
sealing lip (3) of the piston cups just enters the front of the cylinder
liners.

4 6

4. Thoroughly clean the three counterbores in the power end (4) and three
counterbores in the fluid cylinder (not shown) for gaskets (5). Lightly
lubricate six new gaskets with oil, and seat them in the grooves of the
power end and fluid cylinder.
5. Thoroughly clean three metal seal holders (6) and their seats (7) on the
crosshead rods. Slide seal holders down the rods, pressing them against
the seats. Lightly lubricate three new O-rings. Carefully roll the O-rings
over the threads of the rods to avoid cutting them, and seat the O-rings
in the seal holders.
Continued on next page...

14-43
 Component Repair D36x50 Series II Navigator HDD Service

3
1

6. Install cylinder liners (1), being careful that they do not fall and become
damaged.
The two studs (opposite, 7. Mount fluid cylinder (2). Finger tighten the nuts on two studs (3)
diagonal corners) used (opposite, diagonal corners) to secure the fluid cylinder, but do not
to secure the fluid tighten the nuts.
cylinder varies on
different pumps.
Drilling Fluid

5
4

8. Engage and lock the tabs of FMC piston tool (4) inside the mating slots
of piston nuts (5). Strike the tool with a rubber mallet and fully drive the
piston assemblies to their stops.
Continued on next page...

14-44
D36x50 Series II Navigator HDD Service Component Repair

2
2

1
3 4

9. Thread brass hex nuts on the crosshead rods, using socket wrench (1)
with a long extension. Torque nuts to 25 ft-lb (34 Nm).
10. Thoroughly clean O-ring grooves on cylinder covers (2) and the mating
surfaces on the fluid cylinder. Lightly lubricate three new O-rings with
oil and seat them in the grooves. Install the three cylinder covers and
three cylinder cover clamps (3). Finger tighten six nuts (4) on the studs.

Drilling Fluid
7 3 1 6

5 2 4 8

1
5

The corner studs (1) 11. Torque nuts on the fluid cylinder in a 3-pass sequence: 30 ft-lb (40 Nm)
and (2) may be in on the first pass, 60 ft-lb (80 Nm) on the second pass and 90 ft-lb (122
differing positions, Nm) on the third pass. Follow above numerical sequence in torquing the
depending on factory nuts.
assembly. The torque
patterns should be
altered accordingly.

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 Component Repair D36x50 Series II Navigator HDD Service

Suction and Discharge Valve Removal/Installation

Special Tools and • torque wrenches capable of producing 30 ft-lb (40 Nm) and 90 ft-lb
Materials (122 Nm)
• rubber mallet
• FMC valve tool (Vermeer P/N 240141-017)

Remove Valves

1
Drilling Fluid

A minimum of 24" 1. Remove three suction drain plugs (1) and three discharge drain
(61 cm) of clearance is plugs (2).
required above, below
and in front of the pump
fluid cylinder to allow
valve service. Use the
stabilizer and block as
necessary to achieve
the correct clearance.
Continued on next page...

14-46
D36x50 Series II Navigator HDD Service Component Repair

3 4

4
1

2. Remove six diagonal nuts (1) retaining three cylinder cover clamps (2),
and pull the clamps from the fluid cylinder.
NOTE: Do not remove two nuts (3) on the opposite, diagonal corners of the
fluid cylinder since they keep the fluid cylinder securely mounted on the
pump.

3. Remove cylinder covers (4).

Drilling Fluid
5
6

4. Insert large end of FMC valve tool (5) into the fluid cylinder, making
contact with the bottom of each suction valve seat but not the valve
body. Strike valve tool with a rubber mallet to drive suction valves (6)
from their seats. Use valve tool to push the suction valves up and out
through the cylinder cover ports.
IMPORTANT: Using undersized tools to remove valves will cause damage
to the valve components.

5. Use same procedure to remove discharge valves (not shown) through

discharge drain plug holes (7) on top of the fluid cylinder.
6. Discard all old O-rings that were disturbed during disassembly.

14-47
 Component Repair D36x50 Series II Navigator HDD Service

Install Valves 1. Thoroughly flush inside of the fluid cylinder to remove all debris. Then,
clean the six valve seat tapers inside the fluid cylinder by wiping them
with a clean, lint-free towel. Also, clean the surface around all cylinder
cover ports, suction drain plug holes and discharge drain plug holes.
IMPORTANT: New valve assemblies are secured using a self-locking taper
and must make metal-to-metal contact to be effective. If debris between the
valve assemblies and mating valve seat tapers inside the fluid cylinder fails
to allow the valve assemblies to seat properly, damage to the new valve
assemblies and fluid cylinder will result. Carefully inspect each valve
assembly seat and valve seat taper inside the fluid cylinder for visible
damage.

1
Drilling Fluid

Replace all suction and 2. Insert suction valve assemblies (1) into the ports of the fluid cylinder.
discharge valve Position valve assemblies slightly above the valve seat tapers and drop
assemblies whenever them into place. If dropped straight, the valve assemblies will seize on
valve service is the taper and cannot be moved by hand.
required. Replacing only
valve assemblies that
have visible signs of
wear reduces the
operating time between
service intervals.
Replace complete valve
assemblies, never
individual valve parts.
Continued on next page...

14-48
D36x50 Series II Navigator HDD Service Component Repair

1 2

IMPORTANT: Correct use of FMC valve tool (1) is critical to prevent

permanent damage to the valve assemblies during installation.

3. Mate the small end of the FMC valve tool to valve stems (2), but not
valve cages (3). Drive the valve assemblies into the valve seat tapers,
striking the tool several firm blows with a mallet. Three blows are
usually sufficient. Contact with the valve cages will damage the valve
assemblies.
4. Insert the discharge valve assemblies (not shown) into discharge drain
plug holes (4), and utilize the same procedure to seat them in the valve

Drilling Fluid
seat tapers.

7 5

8 5

5. Thoroughly clean O-ring grooves on cylinder covers (5). Lightly lubricate

three new O-rings with oil and seat them in the grooves. Install the three
cylinder covers and cover clamps (6).
6. Fully loosen two nuts (7) on the opposite, diagonal corners of the fluid
cylinder. Then, finger tighten two nuts (7) and six nuts (8).
Continued on next page...

14-49
 Component Repair D36x50 Series II Navigator HDD Service

7 3 1 6

5 2 4 8

Corner studs (1) and (2) 7. Torque nuts on the fluid cylinder in a 3-pass sequence: 30 ft-lb (40.7 Nm)
may be in differing on the first pass, 60 ft-lb (81.4 Nm) on the second pass and 90 ft-lb (122
positions, depending on Nm) on the third pass. Follow above numerical sequence in torquing the
Drilling Fluid

factory assembly. The nuts.

torque patterns should
be altered accordingly.

8. Thoroughly clean the O-ring grooves on all suction drain plugs (3) and
discharge drain plugs (4). Lightly lubricate new O-rings with oil and seat
them in the grooves, being careful to not damage them on the threads of
the plugs. Thread all plugs in the holes and torque to 45 ft-lb (61 Nm).

14-50
D36x50 Series II Navigator HDD Service Component Repair

Motor MH10 – Eaton 4000 Series

Special Tools • torque wrenches capable of producing 50 in-lb (5.5 Nm), 30 ft-lb (40 Nm),
and 50 ft-lb (68 Nm)
• press
• plastic or rubber hammer
• Eaton seal installation tube
• Eaton seal driver
• Eaton tool for protective sleeve on motor shaft

Disassembly

Drilling Fluid
IMPORTANT: Inspect all parts for damage (scratches or burrs) or unusual
wear during each step of disassembly. Check condition of all mating
surfaces. Do not re-use O-rings or seals.

1. Drain oil from the motor and thoroughly clean the exterior.
2. Place motor in a soft-jawed vise with output shaft down. If possible, keep
motor in a vise during disassembly and assembly.
Continued on next page...

14-51
 Component Repair D36x50 Series II Navigator HDD Service

3. Remove four tie bolts from the motor. Lift valve housing straight up. If
done carefully, the springs and balance ring will remain on the valve.
Drilling Fluid

4. Carefully remove seals, plug assembly and check plug assembly from the
valve housing.

5. Remove 2 pins and 2 springs from balance ring subassembly. Remove

balance ring subassembly, and balance ring’s inner and outer face seals.
Remove valve.
Continued on next page...

14-52
D36x50 Series II Navigator HDD Service Component Repair

6. Remove valve plate and its seal. Remove valve drive.

Drilling Fluid
7. Remove geroler, being sure to retain rollers in the outer ring if they are
loose. Remove two seals from each side of the geroler.
8. Remove drive and 3-1/2'' seal from bearing housing.

9. Clamp bearing housing in a vise, loosen eight cap screws, and place
housing on a clean, flat surface.
Continued on next page...

14-53
 Component Repair D36x50 Series II Navigator HDD Service

10. Remove cap screws and mounting flange.

11. Remove shaft seal and pry dust seal loose, using a small screwdriver. Do
not damage mounting flange bore.
Drilling Fluid

12. Remove 3-1/2" seal from bearing housing, followed by the shaft and
bearing assembly. A press may be necessary.
13. Remove shaft face seal from the bearing housing bore. Be careful not to
damage the bore.
14. Clean all metal parts in clean solvent and blow dry with air. Do not wipe
with cloth or paper towels because lint or other matter could get into the
hydraulic system and cause damage. Do not use abrasives or try to file or
grind motor parts.
15. Check around the keyway and chamfered area of the shaft for burrs,
nicks or sharp edges that can damage seals during assembly.

14-54
D36x50 Series II Navigator HDD Service Component Repair

Assembly

NOTE: Use all new O-rings and seals. Coat with petroleum jelly to help
position them during installation.

1. Place bearing housing on a smooth, flat surface with the largest open end
of the housing up. Align Eaton seal installation tube with the seal seat.
Apply petroleum jelly to the shaft face seal. Install seal in the bore of the
tube exactly as shown. Then, insert Eaton seal driver in the tube. Push
face seal into the seal seat with rotating action. Seat seal properly in the
groove.

Drilling Fluid
2. Install shaft and bearing assembly in the bearing housing. A press may
be necessary. Do not distort shaft seal.

3. Apply petroleum jelly to the 3-1/2" seal. Install seal in the outer seal
groove of the bearing housing.
Continued on next page...

14-55
 Component Repair D36x50 Series II Navigator HDD Service

4. Install dust seal in the flange (metal side of seal facing flange as shown),
using a press. If a press is not available, use a plastic or rubber hammer.
Be careful not to damage or cock the seal in the bore.
5. Install shaft seal in the flange (flat, smooth side facing flange as shown).
Then, apply petroleum jelly to the inner diameter of the shaft seal and
dust seal.
6. Tape or apply a protective sleeve (Eaton tool) to the shaft to prevent
cutting or distorting the seals. Install flange, lubricate threads of eight
flange cap screws with oil, and finger tighten the screws.

7. Clamp bearing housing in a vise. Gradually torque cap screws to 20 ft-lb

(20 Nm), using the sequence shown.
Drilling Fluid

8. Reposition motor in a vise with the output shaft down, clamping the
motor across the flange edge. Pour a small amount of light oil inside the
shaft.
Continued on next page...

14-56
D36x50 Series II Navigator HDD Service Component Repair

9. Apply petroleum jelly to the 3-1/2" seal, and install seal in the groove of
the bearing housing. Install drive in the output shaft, inserting the
longer splined end first. Install two alignment studs in bolt holes
(diagonal corners) of the bearing housing.
10. Install two small seals in the case drain grooves of the geroler,
lubricating them with petroleum jelly.
Install Speed Sensor 11. Rotate shaft until a gear tooth is centered
in the speed sensor port. If this is not done, 1

Drilling Fluid
the sensor may be damaged during the
2 Speed Sensor Body
operation of the motor. Alignment Nut

12. Ensure lock nut (2) and its threads are 3 Lock Nut

clean and dry for proper torque. Position Washer

lock nut against alignment nut (1) as O-ring

4
shown.
Speed Sensor Port

13. Move washer (3) and O-ring (4) up against

the speed sensor body threads as shown. Housing

Gear/Target
Tooth

Continued on next page...

14-57
 Component Repair D36x50 Series II Navigator HDD Service

14. By hand, lightly thread the speed sensor

body (1) into housing (3) until sensor
touches against the motor gear tooth (4).
NOTE: Do not force the sensor against the 2
1
tooth; damage may result. Ensure O-ring and 3
washer do not touch the housing as shown.

15. Turn speed sensor body (1) out 1/4 turn

(CCW), plus the additional amount (CCW)
needed to make alignment notches (2)
perpendicular to the motor shaft center 4
line (90° ±5° from the motor shaft center
line.
16. Maintain speed sensor body alignment and tighten lock nut to 75–125 in-
lb (8.5–14 Nm). Torque values are for clean dry threads.
1
2 Mo
-
Alignment Notch
wi th line of
l r
alle cente
Alignment Notch Par

Alignment
Alignment nut
nut 9/16″
9/16″
3 90°
Drilling Fluid

hex
hex head
head

Back Out
Lock nut 11/16″ hex
Alignment Notch
head

17. Check speed sensor body for correct alignment. Reinstall sensor if it is
not correct.
Continued on next page...

14-58
D36x50 Series II Navigator HDD Service Component Repair

Timing

NOTE: There are three steps involved in timing the motor. Timing
determines the shaft rotation direction. Timing parts include geroler, valve
drive, valve plate and valve.

18. Timing step #1:

Drilling Fluid
• Locate largest open pocket in geroler, and mark it on outside edge.
• Align case drain hole and pressure relief hole in geroler with case drain
and pressure relief hole in bearing housing; install geroler on bearing
housing; and retain rollers in outer geroler ring if loose.
• Install valve drive in geroler.
• Apply petroleum jelly to 3-1/2'' seal and install in valve plate.
• Align case drain hole in valve plate with case drain hole in geroler; and
install valve plate (seal side toward geroler).
19. Timing step #2:
• Locate slot opening in valve plate which is in line with largest open
pocket of geroler.
20. Timing step #3:
• Locate any one of the side openings of the valve that goes through to
the face of the valve.
• Align selected side opening with open slot of valve plate that is in line
with largest open pocket of the geroler.
• Install valve by rotating clockwise 1/2 spline tooth until spline teeth
engage, providing correct rotation.
Continued on next page...

14-59
 Component Repair D36x50 Series II Navigator HDD Service

21. Apply clean grease to the balance ring assembly springs. Install two
springs and two pins in the holes of the valve housing bore.
22. Apply petroleum jelly to both seals and install them in the valve housing.
Drilling Fluid

IMPORTANT: The inner and outer face seals must be installed correctly for
the motor to operate properly. Damaged seals, resulting from forcing or
bending, will adversely affect motor operation.

23. Apply petroleum jelly to the inner and outer face seals. Install seals on
the balance ring exactly as shown.

BALANCE RING

24. Align two pins of the balance ring with two spring holes in the valve
housing. Install balance ring in the housing.
Continued on next page...

14-60
D36x50 Series II Navigator HDD Service Component Repair

25. Insert a finger through the port. Apply pressure to the side of the balance
ring, holding it in position until the valve housing is in place. Align case
drain hole (refer to steps 11–13 for case drain hole location) in the valve
housing with the case drain hole in the valve plate. Install valve housing
against the valve plate. Check between the body parts of the motor for
unseated seals.

Drilling Fluid
26. Gradually torque the bolts to 50 ft-lb (68 Nm), using the sequence shown.
27. Install plug assembly and check plug assembly.

14-61
This page intentionally left blank.
D36x50 Series II Navigator HDD Service Overview

Chapter 15: Remote Lockout

OVERVIEW
Remote Lockout is a communication and control tool that allows a worker
anywhere along the bore path or at the exit site, to directly lock out drill rod
rotation, thrust, and fluid flow. Lights, sound, and vibration indicate various
modes so the machine operator and remote user know that the lockout
system is operating properly and whether drilling functions are locked out.

NOTE: When in transport mode (operator not in seat), the machine will not
respond to Remote Lockout system commands until machine is returned to
drill mode (operator in seat).

Remote Lockout should not be considered as an emergency stop. It is very

unlikely that disabling thrust and rotation could be done quickly enough to
prevent death or serious injury.

Remote Lockout will not shut down the power units on stand-alone drilling
fluid systems or air compressors. These externally powered units must be
manually shut off.

Remote Lockout
Remote Lockout should be used to lock out the machine before working on or
near the drill string. Examples include:

• Before approaching the drill head.

• Before attempting any tooling change or attaching a product to be pulled
in.
• Before attempting to apply any wrench or other tool to drill string.
• Before manually adding or removing drill rod from drill string.
• Before entering an exit pit.

THEORY
Functions
The following Remote Lockout modes are covered in this chapter:

• Hydraulic Lockout Mode

• Backup Engine Shutdown for Hydraulic Lockout Mode
• Engine Shutdown Lockout Mode

15-1
 Theory D36x50 Series II Navigator HDD Service

Components
The function covered in this section include the following components.

• Remote Lockout Base Module A10

• Remote Unit
• Remote Lockout Dump Valve Relay K8
• Engine Shutdown Relay K3
• Remote Lockout Drill Function Shutdown Relay K12
• Starting Shutdown, EDC Controller Power Input Relay K11
• Load Sense Drain Relay K9
• Battery Charger
• Indicator Lights DS2–DS4
• Horn AD2
• Alarm Cancel Switch S29
• Check Valve Manifold Assembly A4, including:
• Pressure Transducer B1
Remote Lockout

• Directional Control Valve DV8

• Check Valves CV10-CV12
• Solenoid Coil L21

15-2
D36x50 Series II Navigator HDD Service Theory

Component Locations
BASE MODULE A10 REMOTE CHARGER
(under seat)

HORN AD2

Remote Lockout
REMOTE UNIT

ALARM CANCEL SWITCH S29

RUN MODE LIGHT DS2
SIGNAL LOSS LIGHT DS4
LOCKOUT MODE LIGHT DS3

15-3
 Theory D36x50 Series II Navigator HDD Service

VALVE
CHECK
MANIFOLD A4

CONTROL
VALVE
DV8

SOLENOID
L21
Remote Lockout

PRESSURE
TRANSDUCER
REMOTE LOCKOUT
B1
DUMP VALVE RELAY K8

STARTING SHUTDOWN
CONTROLLER POWER
INPUT RELAY K11
REMOTE L/O
DRILL FUNCTION
RELAY K12

LOAD SENSE
REAR E-STOP, ENGINE DRAIN DURING
SHUTDOWN RELAY K3 START RELAY K9

15-4
D36x50 Series II Navigator HDD Service Theory

Electrical Schematic
ENGINE SHUTDOWN RELAY K3 PRESSURE TRANSDUCER B1
GROUND BUSS TB1

E-STOP
S11

EDC
CONTROLS
ROT. THRUST

ENGINE A23
SOLENOID L21

LIGHT DS4 DIODE

D10

LIGHT DS3

Remote Lockout
LIGHT DS2 LOAD SENSE DRAIN
RELAY K9

MODE ENGINE
SELECTOR
JUMPER RELAY K11
HYDRAULIC

REMOTE LOCKOUT K12

SEAT
SWITCH
S26

HORN REMOTE
AD2 CHARGER
REMOTE LOCKOUT
BASE MODULE A10 DUMP VALVE RELAY K8

F3
HORN
F6 CANCEL
F7 SWITCHS29
F8 IGNITION
SWITCH
S2

15-5
 Theory D36x50 Series II Navigator HDD Service

Hydraulic Schematic
FROM ROTATION PUMP
SHUTTLE VALVE
FROM THRUST PUMP
SHUTTLE VALVE LOAD SENSE
DUMP VALVE DV8,
FROM PFC PUMP LOAD SOLENOID L21
SENSE LINES

CHECK VALVE CV12 CHECK VALVE

MANIFOLD A4
CHECK VALVE CV11
CHECK VALVE CV10
PRESSURE
TRANSDUCER
B1 TANK
Remote Lockout

15-6
D36x50 Series II Navigator HDD Service Theory

Hydraulic Lockout Function

NOTE: See electrical and hydraulic circuit schematics to view voltage and
hydraulic paths with machine in hydraulic lockout mode.

Operation To operate hydraulic lockout mode:

• Operator must be seated at drill controls.

• Remote Lockout system must be in RUN mode.
The following theory of operation explains how the electrical and hydraulic
functions react when the hydraulic remote lockout is activated under normal
conditions:

• At start-up, voltage is present at the base module A10 through ignition

switch S2.
• Once the operator is seated, seat switch S26 will close, sending a signal
to Remote Lockout base module A10.
When remote lockout transmitter sends a lockout command to the base
module A10:

• Base module A10 removes voltage to de-energize Remote Lockout drill

Remote Lockout
function shutdown relay K12.
• Relay K12 removes power from the rotation and thrust/pullback
joysticks which results in the rotation and thrust/pullback pumps to
destroke and return to NEUTRAL.
• The de-energized Remote Lockout relay will provide voltage to energize
solenoid coil L21 in check valve manifold A4. Valve DV8 in A4 will shift,
allowing flow back to the hydraulic tank, depressurizing the circuit.
• Hydraulic lockout confirmation is verified by pressure transducer B1 if
the transducer output voltage is between 0.25 and 1.0 volts.
• The Remote Lockout base module A10 transmits a signal to the remote
lockout transmitter confirming the machine is hydraulically locked out.
NOTE: If the hydraulic LOCKOUT function does not operate as expected,
see "Troubleshooting/Testing the Remote Lockout Function," page 15-18.

Backup Engine If rotation or thrust/pullback hydraulic pressure increases above 750 psi (51
Shutdown Function bar) while the machine is in hydraulic lockout, base module A10 will disable
for Hydraulic the fuel enable circuit by removing power from engine shutdown relay K3,
Lockout causing the engine to be shut down.

Pressure transducer B1 is installed in check valve assembly A4 to monitor

rotation and thrust/pullback hydraulic pressures to ensure drill lockout
during a confirmed hydraulic lockout.

Continued on next page...

15-7
 Theory D36x50 Series II Navigator HDD Service

NOTE: The nominal output voltage of transducer B1 is 0.5–4.5 volts (zero

pressure to maximum system pressure of the circuit). If the transducer
voltage is outside these limits, or if a transducer is disconnected, the base
module will consider the transducer defective, or missing, and will not
confirm hydraulic lockout. A lockout is confirmed only if the transducer
output voltage is less than 1.0 volts. A hydraulic lockout will not be
confirmed if transducer output voltage is between 1.0 and 4.5 volts. If
transducer output voltage exceeds 1.0 volts after hydraulic lockout is
confirmed, the system enters backup engine shutdown mode.

Engine Shutdown Lockout Function

Option Procedure The Remote Lockout function is equipped with an option to operate as an
engine shutdown.

To activate the engine shutdown

option, jumper plug (1) must be moved
from hydraulic connector (power
applied to circuit 780) to engine
Remote Lockout

shutdown connector (ground connected

to circuit 780).

To change system back to hydraulic 1

lockout, reverse above procedure.

Operation To operate Engine Shutdown Lockout mode:

• Operator must be seated at drill controls.

• Remote Lockout system must be in normal RUN mode.
The following theory of operation explains how the electrical and hydraulic
functions react when the engine shutdown lockout is activated under normal
conditions:

• At start-up, voltage is present at base module A10 through ignition

switch S2.
• Once the operator is seated, seat switch S26 will close, sending a signal
to base module A10.
When remote lockout sends a lockout command, the remote unit will signal
base module A10.

• Remote Lockout module A10 interrupts power output at pin 2 and 9 to

de-energize engine shutdown relay K3, Remote Lockout relays K8 and
K11.
Continued on next page...

15-8
D36x50 Series II Navigator HDD Service Troubleshooting

• Engine shutdown relay K3 removes battery power to the engine ECU,

causing the engine to shut down.
• Remote Lockout drill function shutdown relay K11 will remove battery
voltage from the rotation and thrust/pullback joysticks which will return
rotation and thrust/pullback pump EDC’s to neutral position.
• Remote Lockout relay K8 will energize solenoid coil L21 in check valve
manifold A4. Valve DV8 will shift, allowing flow back to the hydraulic
tank RES1.
NOTE: If the engine shutdown lockout function does not operate as
expected, see "Troubleshooting/Testing the Remote Lockout Function," page 15-
18.

NOTE: Engine shutdown lockout confirmation is defined as base module

connector Pin 7 connected to ground. Not confirmed is defined as 12 volts on
Pin 7.

TROUBLESHOOTING

Remote Lockout
General System Information
Remote Lockout is equipped with an option to operate as either a hydraulic
lockout (default) or an engine shutdown system. For theory of operation of
hydraulic lockout, refer to "Hydraulic Lockout Function," page 15-7. For theory
of operation on engine shutdown lockout, refer to "Engine Shutdown Lockout
Function," page 15-8.

The remote unit user can select either RUN or LOCKOUT mode. System
status is indicated by indicator lights DS2–DS4 and horn AD2.

NOTE: When the machine is started and there is a loss of radio signal
between the remote transmitter and machine will cause a steady warning
horn AD2 at the control panel. The horn can be silenced by pressing the horn
cancel button.

If the machine is not in LOCKOUT mode, yellow indicator light DS4 will
flash. If the machine is in LOCKOUT mode, red lockout indicator light DS3
will be on.

15-9
 Troubleshooting D36x50 Series II Navigator HDD Service

Base Module Indicators.

NOTE: The light patterns shown below are in 0.1 second units.

Light A indicates power supply

• Power OFF

• Power ON (green)
Remote Lockout

Light B indicates status of radio connection.

• Base module is in “Registering” mode (red)

• Base module is initializing remote unit (green)

• No communications with remote unit (green),

• Remote unit is in range (green)

Light C, on this machine, allows user to verify software (green) (LK1

- P/N 296272304 & 296272509).

Light D indicates lockout state.

• Run (green)

Continued on next page...

15-10
D36x50 Series II Navigator HDD Service Troubleshooting

• Engine Lockout requested (green)

• Engine locked (red)

• Hydraulic Lockout requested (green)

• Hydraulic locked (red)

• Hydraulic sensor failure (red)

Remote Lockout

15-11
 Troubleshooting D36x50 Series II Navigator HDD Service

Power On
Remote Unit On Turn on remote unit by either pressing
Power ON/OFF Button (1) and holding
for 2 seconds or pressing the lockout
button (2) and holding for 2 seconds.

2
1

Base Module Run Turn the ignition key to ON.

The ignition key must be ON before the Remote Lockout system is turned
on. If not, a loss of radio signal will be indicated at the remote unit. A loss of
signal indicates that the remote unit and base module are not
communicating with each other. Reasons for a loss of signal are:
Remote Lockout

• The remote unit is too far away from the machine. Range is up to 3300 ft
(1 km).
• The remote signal is blocked by an obstruction between the remote unit
and machine.
• The remote battery is fully discharged.
• The remote unit is turned on when machine is off.
• The system is not operating correctly.
• The antenna connection is poor or broken.
NOTE: Range of signal can be significantly affected by obstructions, such as
buildings or equipment, located between the remote unit and machine.

If there is no communication with the

remote unit, the yellow signal light DS4 1 2
3
begins to flash. If the machine was
unlocked prior to shutdown, the green
RUN light (3) turns on. The engine can
be started and machine can be operated.
If there is no communication with remote
for 10 seconds after turning power on, the
base module A10 sounds a continuous
alarm until alarm cancel switch S29 is
pressed and held for a second.

Continued on next page...

15-12
D36x50 Series II Navigator HDD Service Troubleshooting

If the Remote Lockout system is in Hydraulic mode, and the base module
was locked out prior to shutdown, then the red lockout light (2) turns on. In
this state, the engine can be started, but thrust and rotation will be
disabled.

If the Remote Lockout system is in Engine Shutdown mode, and the base
module was locked out prior to shutdown, then the red lockout light (2)
turns on. If the machine is in Drill mode (operator in seat), the engine can
not be started until the machine is unlocked. If the machine is in transport
mode (operator not in seat), the engine can be started and the Transport
functions will work. If the operator then sits down, the engine will be shut
down immediately.

Lockout Mode
When pressed, the red lockout button sends a lockout command for drill
string rotation, thrust and pullback, and fluid flow. See "Hydraulic Lockout
Function," page 15-7. When the machine has confirmed successful lockout,
the red light comes on solid, followed by a cycle of three 1/2-second beeps

Remote Lockout
then a pause. This cycle occurs three times.

IMPORTANT: The Remote Lockout system can take up to 5 seconds to

process the lockout. During this time the green lights will flash. The lockout
is not complete until the three beeps cycle occurs three times and the red
light is on.

Power Off
Press black Power ON/OFF button and hold for 2 seconds to shut off remote
power. Turn ignition switch S2 to OFF to shut off base module power.

15-13
 Troubleshooting D36x50 Series II Navigator HDD Service

Remote Registration
In the event that the base module A10 or remote unit are replaced,
registration of the two units must take place.

NOTE: Perform these steps within one minute of turning on the machine.

1. Turn ignition switch to ON position

(engine not running). The yellow
signal light DS3 will flash steady.
Wait more than five seconds.
2. Remove 2-pin jumper (1) used to
select Engine Shutdown or
Hydraulic mode. Wait for 3 seconds
and put jumper back into position. 1

3. View lights on base module. Light B (2)

will change from a flashing green to a 2
Remote Lockout

double flashing red.

From this

To this

The remote signal light DS3 on control panel will be double blinking.
4. The base module is now in Registration mode.
5. Turn remote unit ON.
6. Press and hold red and black buttons
on remote unit until yellow light (3)
double flashes.

Continued on next page...

15-14
D36x50 Series II Navigator HDD Service Troubleshooting

Wait for registration results. It

normally takes less than 30 seconds to
complete registration. 1

After successful registration, Light B

(1) on base module is solid green.

Remote unit is now registered to the

base module and all previous
registration information is erased.

Remote unit should now respond to

commands.

Battery Condition
Low Battery NOTE: Low battery indication is only
displayed on the remote transmitter.

When there is approximately 10% of

Remote Lockout
battery life left, blue light (1) on remote
transmitter will flash.

Discharged Battery If battery discharges and a loss of signal occurs in RUN mode, the system
will allow drilling to continue uninterrupted. If battery discharges in
LOCKOUT mode, a new battery must be installed and RUN mode selected
before drilling can continue.

Recharge Battery The docking station will charge battery while installed in battery charging
compartment with power cord plugged into power receptacle, even when the
machine has been shut down. It is recommended to keep a second battery in
battery charging compartment in the event of transmitter battery failure.

An amber light located on underside of charging compartment will flash

when battery is fully charged. Green light in same location will come on to
indicate power to charger.

IMPORTANT: The battery will not recharge if left in the remote

transmitter. The battery must be removed and installed in battery charging
outlet.

15-15
 Troubleshooting D36x50 Series II Navigator HDD Service

Performing Remote Lockout Functions

DANGER: Rotating drill string can kill. Unexpected start-up possible.

Lockout before working on drill string.

It is essential that the machine is

locked out before entering an exit pit,
changing tools, repairing drill rod,
manually adding or removing drill rod,
or performing any other work on the
drill string or tools.

IMPORTANT: Remote Lockout will 1

not shut down the power units on
stand-alone drilling fluid systems or air
compressors. These external power
Remote Lockout

units must be manually shut off.

The following lockout procedure must be performed by remote transmitter

operator.

1. Communicate by radio with the machine operator that you intend to lock
out the machine.
2. Direct machine operator to idle engine down.
3. Press red Lockout Button (1) on remote transmitter, and wait for three
buzzer cycles of three beeps and a pause, which will indicate lockout is
successful. The red lockout light must also be lit to indicate a successful
lockout. Confirmation could take up to five seconds.
NOTE: To ensure maximum communication range of the transmitter, lock
out machine before entering an exit pit.

4. If lockout is not successful, a warning buzzer will sound and the remote
transmitter will vibrate continuously for 60 seconds. The green light will
flash continuously until lockout is achieved, or until the LOCKOUT
command is canceled.
Continued on next page...

15-16
D36x50 Series II Navigator HDD Service Troubleshooting

Never approach drill string or attempt to apply a tool to the drill string until
after Remote Lockout is confirmed by the three beeps/pause buzzer cycle and
illumination of the red lockout light, and by radio communication between
the remote transmitter operator and the machine operator.

NOTE: Any time that a remote lockout command is not successful, ensure
machine is running, is in Drill mode (operator seated at controls), and that
transmitter is within range. If still unsuccessful, refer to "Troubleshooting/
Testing the Remote Lockout Function," page 15-18.

NOTE: Remote Lockout is not operational when in the machine is in

transport mode.

5. Complete whatever work is required to change tools or repair and

replace drill rod or tooling only after the machine is locked out.

Resuming Operation After Remote Lockout

1. Verify that drill rod and cutting

Remote Lockout
tools are ready for operation.
2. Warn everyone who may be exposed
to drill string or cutting tools that
operation will resume.
3. Confirm everyone has evacuated
the exit pit and is away from drill
string and cutting tools, and that no 1
wrenches or breakout tools are
attached to drill string or cutting
tools.
4. Press Run Button (1) on transmitter and hold for 2 seconds to return
control of drilling functions to the machine operator.
NOTE: If RUN command is not successful and the remote lockout
transmitter is within range, Remote Lockout must be repaired before the
machine can resume drilling.

5. Communicate by radio with machine operator that normal operation can

resume.
Flashing Lights When green and/or yellow lights are flashing without the buzzers sounding,
the system is processing a transition from one mode to another.

NOTE: If the hydraulic lockout with backup engine shut down function
does not operate as expected, see "Troubleshooting/Testing the Remote Lockout
Function," page 15-18.

15-17
 Troubleshooting D36x50 Series II Navigator HDD Service

Troubleshooting/Testing the Remote Lockout Function

The following test can be performed to verify the Remote Lockout
components are functioning properly. For additional troubleshooting
information, refer to "Flow Chart for Determining Machine Problem (Without
Remote)," page 15-22 and "Flow Chart for Determining Machine Problem (With
Remote)," page 15-23.

Remote Unit To test green run switch, lights, horn, and vibrator:

1. Turn radio off with black power button.

2. Press and hold the green unlock button for 2 seconds:

• All lights should turn on in sequence and flash.

• Horn should sound with two different tones.

• Vibrator should function.

To test radio module:

Remote Lockout

1. Turn machine (receiver) OFF.

2. Turn remote ON by pressing and holding the black button.
3. The yellow signal light should flash in the pattern indicated below
(initializing remote),

then turn to this pattern (radio initialized).

4. If the radio enters the initialized mode, RF module is OK. If the radio
does not leave the initializing mode, RF module needs to be returned for
repair.
To test red lockout button:

1. Turn radio OFF with black button.

2. Press and hold red lock button.
Continued on next page...

15-18
D36x50 Series II Navigator HDD Service Troubleshooting

3. The yellow signal light should flash in the pattern indicated below
(initializing remote),

then turn to this pattern (radio initialized).

4. The yellow light should turn OFF.

5. The green light should begin to flash.

6. After 5 seconds the horn should sound. The red button works.

Base Module See if power is getting to the unit. If so, light

A will light solid.

To test radio module:

1. Turn machine ON.

2. Watch light B, it should flash green in the pattern indicated below

Remote Lockout
(initializing remote),

then turn to this pattern (remote in range).

3. If the radio enters the initializing mode, RF module is OK. If the radio
does not leave the initializing mode, RF module needs to be returned for
repair.

Verify Software To verify the unit’s software:

1. Check part number of the hardware that is supposed to be on the

machine.
2. Compare part number to the numbers below and verify that light C is
flashing properly for the software.
Color Light C Flash Pattern Part Number of Unit
Green LK1–Stand Alone
296272304 (US),
296272509 (Intel)

Continued on next page...

15-19
 Troubleshooting D36x50 Series II Navigator HDD Service

Hydraulic or Engine To determine shutdown mode:

Shutdown Lockout
Mode 1. Turn machine and remote ON.
2. Press lockout button on remote.
3. The following patterns indicate Hydraulic Lockout.

Flashing Green Request Hydraulic Lockout

Solid Red Hydraulic Lockout Confirmed

4. These patterns indicate Engine Shutdown Lockout.

Flashing Green Request Engine Shutdown

Flashing Red Engine Shutdown Lockout Confirmed

Remote Lockout

Battery Check battery condition:

• Full battery charge will be 7.2–7.9 Volts between

the + and - terminals.
• Low battery charge (battery is in need of charge).
Battery is below 6.9 Volts between the T and -
terminals.
The remote Blue low battery light will illuminate.
• To check if thermal protection is functional, check for 7.5–6.0K ohm
between the T and - terminals.

Continued on next page...

15-20
D36x50 Series II Navigator HDD Service Troubleshooting

Battery Charger NOTE: Two versions of the battery

charger have been produced. Check the
label (1) for the revision number to verify
which revision is on the machine. Rev. A is
2.253.1001; Rev. B/C is 2.250.1452. Rev. A
has an orange light (2) and a green light
(3). Rev. B/C has one light (2) that flashes
orange and green.
1 2 3
The charger lights indicate as follows:

NOTE: The indications listed below apply to all versions, unless otherwise
stated.

• Power test to unit: Green light is ON (input voltage is between 9–36

Volts DC).
• Battery is not detected:
Rev. A. Orange light is OFF.
Rev. B/C. Green light is ON.
• Battery is charging: Orange light is on SOLID.
• Battery is charged and trickle charging: Orange light flashes fast at

Remote Lockout
4 times a second.

Charge is complete after 6 hours in the charger for a completely

discharged battery.
• Battery is detected but not charging:
Rev. A. If Orange light flashes slowly at 1 flash every 2 seconds, battery
is hot or T terminal is damaged.

Rev. B/C. If Orange light flashes slowly at 1 flash every second, battery is
hot or T terminal is damaged.

If so:
1. Check resistance on battery T terminal.
2. Check voltage on charger’s T terminal.

Terminal Test With battery out of holder, test voltage:

• between - tab and the +. Voltage should be around 13.4 Volts.

• between - tab and the T. Voltage should be around 2.1 Volts.
The H tab is not connected.

15-21
 Troubleshooting D36x50 Series II Navigator HDD Service

Flow Chart for Determining Machine Problem (Without Remote)

Machine and Turn Machine ON. All three remote lockout lights on the
Radio are OFF. Leave Radio OFF. machine turn on for 2 seconds as a system
check. Place the drill into DRILL mode.
Check:
1. If horn is connected to
ground.
2. If wiring between pin 6
on receiver and horn has Wait 10
seconds, No communication
continuity. NO light (yellow) DRILL
horn will Last state of
sound. flashes other lights (UNLOCKED)
3. Connection to ground for are OFF. the drill
the horn. LOCKED
4. If pin 6 on receiver
produces 12V when horn
sounds. Lock light (RED)
is ON, all other
YES lights are OFF.

Check:
Check:
1.That horn is connected to
1. If switch contacts close ground.
on press.
Press 2. That wiring between pin 6
2. Wiring between pin 6 on HORN Horn will
Warning on receiver and horn has
receiver and switch has ON continuity. sound
continuity. OFF Button. NO
3. The connection to ground lockout
3. If one side of switch is for the horn. pattern.
attached to ground.
4. That pin 6 on receiver
produces 12 Volts when
Remote Lockout

HORN OFF horn should sound.

YES

Check:
1. Wiring between pin 2 on
receiver and hydraulic
control circuit. Do machine
YES Will Engine YES functions
START? 2. That pin 9 is producing 0
Volts and light D is on solid operate?
RED.
NO Otherwise retest.

NO
Will thrust
and rotation
operate? Check:
1. Wiring between pin 2 on receiver
and hydraulic control circuit.
Will engine ENGINE Determine
2. That pin 9 is producing 12 volts, start or run?
and light D is on solid green. SHUTDOWN Mode.
YES NO
Otherwise retest.

YES
No Problem Found. HYDRAULIC
NO

Check:
Check:
1. Wiring between pin 9 on
1. Wiring between pin 2 on receiver and starter and fuel No problem found
receiver and hydraulic control control circuit.
circuit. To start engine, Will engine
2. That pin 9 is producing 0 place into UNLOCK start or run?
2. That pin 9 is producing 12 volts, and light D is on mode.
volts, and light D is on solid flashing RED.
green. YES
Otherwise retest.
Otherwise retest.
NO

Continued on next page...

15-22
D36x50 Series II Navigator HDD Service Troubleshooting

Flow Chart for Determining Machine Problem (With Remote)

Machine and Turn Machine ON. Turn All three remote lockout lights on the machine
Radio are OFF. radio ON with black button. turn on for 2 seconds as a system check.

Remote not married to Remote

machine or flashes
YELLOW LIGHT yellow then
RF module has a problem. goes to solid
See functional chart. red or green.

Set the machine to

DRILL mode, lock light
GREEN LIGHT RED LIGHT (red) is ON all other
lights are OFF

Check:
1. That horn is connected to ground.
Will engine
start? NO 2. Wiring between pin 6 on receiver
and horn has continuity. Horn will
NO sound
3. Connection to ground for the lockout
horn. pattern.
Check:
4. That pin 6 on the receiver
YES 1. Wiring between pin 9 on produces 12 volts when horn should
receiver and starter and sound.
fuel control circuit. YES

Remote Lockout
2. That pin 9 is producing
12 volts, and light D is on
solid green. Check:
Will thrust Otherwise retest. 1. Wiring between pin 2 on receiver
and rotation and hydraulic control circuit.
operate? Do machine
2. That pin 9 is producing 0 volts, YES functions
and light D is on red. operate?
Otherwise retest.
YES NO

NO
No problem found,
change state and
re-test.

Will engine ENGINE Determine

start or run? SHUTDOWN mode.

Check:
1. Wiring between pin 2 on YES
receiver and hydraulic NO
control circuit. HYDRAULIC
2. That pin 9 is producing
12 volts, and light D is on
solid green. Check: No problem
1. Wiring between pin 9 on found.
receiver and starter and fuel
To start YES Will engine
control circuit. engine, place start or run?
2. That pin 9 is producing 0 into UNLOCK
volts, and light D is on mode.
flashing RED.
Otherwise retest.
NO

15-23
This page intentionally left blank.
D36x50 Series II Navigator HDD Service Overview

Chapter 16: Strike Alert

OVERVIEW
The Strike Alert function alerts personnel near the machine of an electrical
hazard. It sounds an alarm if current is passing through the drill rod, or if
there is a difference in voltage between the machine and the voltage stake.

If the drilling tool or rod strikes a source of electrical power, the rod, the
machine and the ground around the machine will become electrically
charged. If anyone touches both the ground and the machine at the same
time, they may be injured or killed by electrical shock.

A worker walking near the machine or drill string may also be shocked from
the voltage difference on the surface of the ground.

THEORY

Strike Alert
Circuits
The following circuits are included in this chapter:

• Acceptable Voltage
• Voltage Strike
• Current Strike
• Voltage Test
• Current Test

16-1
 Theory D36x50 Series II Navigator HDD Service

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

• Strike Alert Module A17

• Alarm Horn AD1
• Strike Alert Coil A30
• Voltage Stake E1
• Test Switch S12
• Horn Cancel Switch S13
• Indicator Light DS7
Strike Alert

16-2
D36x50 Series II Navigator HDD Service Theory

Component Locations

HORN AD1

HORN CANCEL SWITCH S13

Strike Alert
TEST SWITCH S12
INDICATOR LIGHT DS7

COIL ASSEMBLY A30

Continued on next page...

16-3
 Theory D36x50 Series II Navigator HDD Service

STRIKE ALERT MODULE A17

Strike Alert Module Daily Tests

The D36x50 Series II Operator’s Manual directs the operator to conduct a test
of the Strike Alert system each time the machine is started. The Strike Alert
system test consists of two separate tests: a current test and a voltage test.

Current Test When test switch S12 is closed, AC current from terminal 4 of A17 passes
Strike Alert

through the sensing ring A30. This induces a current in the sensing coil of
the sensing ring. A wire connects the coil to the module, delivering the
induced current to module A17. Module A17 responds by sounding the alarm
horn.

Voltage Test The voltage test is performed with the voltage stake E1 inserted in the
ground. When the test button on the control panel is pressed, strike alert
module A17 allows voltage to be passed through the voltage stake. The
module then senses the voltage difference between that point and machine
ground. The module then verifies proper operation. Module A17 responds by
sounding the alarm horn.

The horn AD1 should sound in response to the higher-than-threshold

voltage at the ground sense stake.

NOTE: It is important that the ground sense stake be inserted in the

ground and the machine make electrical contact with the ground during the
test. It might be required to the stake down augers, or drill in one rod length
to ensure good electrical connection between the machine and the ground.
Wetting the surfaces by the machine and voltage stake might also help to
ensure the electrical connection.

16-4
D36x50 Series II Navigator HDD Service Theory

Electrical Schematic

IGNITION SWITCH S2

COIL ASSEMBLY A30

HORN AD1 VOLTAGE STAKE E1

Strike Alert
TEST SWITCH S12

RESET SWITCH S13

INDICATOR LIGHT DS7

STRIKE ALERT MODULE A17

16-5
 Theory D36x50 Series II Navigator HDD Service

Voltage Strike Circuit

Operation The module’s voltage strike circuit senses if the machine is electrically
charged by:

• Detecting a difference in the voltage of the machine, compared to the

voltage at the ground sense stake E1 through terminal 6.
• If the voltage difference exceeds 25 volts DC or at a frequency of 25-85
Hertz, the module sounds the alarm.

NOTE: If a problem is suspected with the strike alert circuitry, see

"Troubleshooting/Testing," page 16-7.

Current Strike Circuit

Operation The module’s current strike circuit senses current flow through the drill
rod by:

• Detecting the induced current in the sensing coil A30. The coil is
mounted so it encircles the drill rod.
Strike Alert

• If the module detects approximately 0.10 Amps of current at a frequency

of 25-85 Hertz in the coil, the module sounds the alarm.

NOTE: If a problem is suspected with the strike alert circuitry, see

"Troubleshooting/Testing," page 16-7.

16-6
D36x50 Series II Navigator HDD Service Troubleshooting/Testing

TROUBLESHOOTING/TESTING
IMPORTANT: If a job site is being visited because the Strike Alert “keeps
going off,” assume that the ground and/or machine is electrified. Ensure the
operator has contacted utility companies to have local power turned off and
repaired before drilling resumes. Do not assume this has been done. Before
you approach a machine connected to a drill string in the ground, verify with
the crew that all the statements below are true:

• The local utility has turned off the power.

• Utility personnel have been or are on the scene.
• Utility personnel have checked with their instruments and verified that
the area is not electrified.
• Since then, the crew has not drilled out or pulled back any farther,
possibly contacting another underground power source.

Determining What If you are called to troubleshoot the Strike Alert circuits:
To Troubleshoot
• perform the daily test for the Strike Alert module
• check the integrity of the wiring harness
• check the alarm cancel button on the control panel

Strike Alert
• check the lights on module A17 and the green light on the control panel
NOTE: If the horn sounds and you know no strike has occurred, check light
D on the module. Then, troubleshoot wiring and components based on what
the light indicates.

Daily Test The test causes Strike Alert module A17 to test both the voltage and current
sensing circuits, and to sound horn AD1 while the test button is pressed.

If the test works, the green indicator light D37 comes on steady. The test
confirms that:

• Horn AD1 is connected and working.

• Voltage stake E1 is connected to control module A17.
• Module A17 is responding correctly to the voltage at terminal 3.
• Sensor ring A30 is complete (not shorted) and connected to A17.
• Module A17 is sending current through terminal 9 and responding
correctly when it receives current through the coaxial cable.
Focus on the items above if the test fails.

16-7
 Troubleshooting/Testing D36x50 Series II Navigator HDD Service

Control Panel Light

The green light on the control panel indicates the following:

• Off when a test is in progress or the light is burned out

• Flashing when the ground stake is not in the ground

• Double flashing when the current sensor has failed

• Triple flashing when there is a ground stake wiring problem

• Solid On when a test is passed or system is ready

Strike Alert

16-8
D36x50 Series II Navigator HDD Service Troubleshooting/Testing

Strike Alert Module Lights

Light A indicates power supply.

• Power off

• Power on (green)

Light B indicates status.

• Self-test passed

• Ground stake not in ground (red)

Strike Alert
• Current sensor failed (red)

• Ground stake wiring failed (red)

Light C indicates no CAN bus is present (red) (normal operation)

Light D indicates alarm state.

• No alarm (green)

• Voltage alarm (red)

• Current alarm (red)

16-9
 Component Repair D36x50 Series II Navigator HDD Service

COMPONENT REPAIR
Voltage Stake E1

3 2

6
7
9
4
7
5

1
Strike Alert

7 8

1. Remove screws (5) and washers (7) on clamp (9) and wire loops (6)
holding cable (4) to underside of voltage stake. Note the location of the
wires before removing.
2. Remove bolts (3) on handle (2).
3. Remove bolt (8) and washer (7) to remove voltage stake assembly from
machine.
To assemble the voltage stake, reverse the steps above.

16-10
D36x50 Series II Navigator HDD Service Component Repair

Strike Alert Coil Assembly L25

3
5
7

5
6

Strike Alert
1. Ensure no rod is currently in vises or wiper.
2. Remove wiper (2) from mounting bracket (1).
3. Unscrew bolts (7) holding mounting bracket to vise assembly.
4. Remove screws holding housing (4) in mounting bracket.
5. Remove roller bolt (6) and washers (5). Remove guide roller and bushing
(3) from center of strike alert.
6. Disconnect strike alert harness from coil.
Reverse steps for installation.

16-11
This page intentionally left blank.
D36x50 Series II Navigator HDD Service Overview

Chapter 17: Rock Adaptable Terrain Tool

OVERVIEW
The Rock Adaptable Terrain Tool chapter consists of the CAN based control
system which includes two controllers, a transducer manifold, a rotation
PPU and one LED display. This chapter also consists of control conditions
needed to perform machine operations, truth tables of inputs and desired
outputs.

WARNING: Fault monitoring routines DO NOT allow for unauthorized introduction of

components. Adding unauthorized components may cause faults within the controller,
impaired operation and improper system functions which may cause the machine to react
unpredictably to commands. Serious injury or death may occur if machine reacts different
than expected.

Rock Adaptable Terrain Tool

LED Display
L
E
D

D D
i
s
p
l
C a
y

A
M

17-1
 Overview D36x50 Series II Navigator HDD Service

Service Screen Buttons

Service Screen Toggle—Press to view any active faults

D Key

Parameter Selector activates Parameter Adjustment Sub-

Menus.

C Key

Activates and toggles between Thrust/Pullback Pressure

limit, Rotation Pressure limit, and no pressure limits. Use
Trim Switches to adjust limits.

B Key

Auto-Rotation ON/OFF Toggle activates the Auto-Rotation

Rock Adaptable Terrain Tool

mode (Oscillation).

A Key

Activates Parameters

Increase

Decrease

Continued on next page...

17-2
D36x50 Series II Navigator HDD Service Overview

Enter Key

If light is blinking, fault is present; press Service Screen

button to view on display.

ANTI-CRASH LED indicates the anti-crash is activated

LOW inlet Pressure LED indicates LOW Pump Inlet

Rock Adaptable Terrain Tool

Pressure (less than 10 psi).

RATT Mode ENABLED LED indicates RATT Drill Mode

(Oscillation Only) is ENABLED.

Auto-Rotation LED indicates the Rotation pressure limiter is

active.

Thrust Limiter LED indicates the Thrust/Pullback pressure

limiter is active.

17-3
 Overview D36x50 Series II Navigator HDD Service

Autodrill LED

Solid.................. indicates AutoDrill mode is active

Flashing.............. indicates AutoDrill mode in standby

Off................................... AutoDrill OFF

R.A.T.T. Enabled Mode Indicates R.A.T.T. (Straight/

RATT Oscillation) Mode is active.

ON - R.A.T.T. Mode Active

OFF - R.A.T.T. Mode Inactive

Numbers Displayed on LED Display:

Oscillation Degrees LH Side= RATT Oscillation Degree (Max 3 characters);

Mud Pump Flow Rate RH = Actual Pump Flow Rate (Max 2 characters)
Rock Adaptable Terrain Tool

Seat Switch
When the operator is seated, the Seat switch (S26) will close and +12Vdc is
sent through Seat switch relay (K7) to the MC050-010; C1-P6 and all
functions, including Rotation EDC’s, Thrust/Pullback EDC’s, Front Vise and
Mud Pump Functions (Mud Pump PWM at MC024-010: A2-P9) will operate.
If the Seat switch (S26) is OPEN, the signals from the Rotation and Thrust/
Pullback Joysticks will not result in an output, but the Vise and Mud Pump
functions will still operate.

17-4
D36x50 Series II Navigator HDD Service Overview

Trim Switches

Rock Adaptable Terrain Tool

Rotation and Thrust switches increase or decrease in 10 psi (69 kPa)
increments. Drilling fluid trim switch increases or decreases in 1-gpm (3.8-
L/min) increments.

IMPORTANT: Rotation Trim switch will not operate in R.A.T.T. Mode.

17-5
 Overview D36x50 Series II Navigator HDD Service

Drilling Fluid Speed Switch

If machine is equipped with either a 50 gallon FMC or a 70 gallon Aplex

drilling fluid pump, there will be no speed switch (1) for the drilling fluid
pump.
Rock Adaptable Terrain Tool

Transducer Manifold
Manifold is
located under
pump stack on the
operator side of
machine. If
ignition switch is
ON and the
engine is not
running. The LED
Display will show
a fault for both
Rotation and
Thrust after 10
seconds because
of the lack of
pressure to the
transducers. If
this does not
occur, check the wiring harness connections.

17-6
D36x50 Series II Navigator HDD Service Overview

Rotation PPU

The Pulse Pickup (PPU) is externally powered; it needs a magnetic field to

pass by its Hall switch(s) in order to provide a speed signal. The speed ring

Rock Adaptable Terrain Tool

attached to the cylinder block has alternately magnetized north and south
segments. The digital (on-off-on-off) pulse train is fed to a controller, which
interprets its rate of change as a speed. The PPU uses two Hall sensors
mounted side-by side in the same case. For quad directional signal, the logic
is bypassed and the direction signal is phase shifted by a nominal of 90°
from the signal A.

PPU Wiring

136-RD

890-WH

888-GN

351-BK

17-7
 Overview D36x50 Series II Navigator HDD Service

Rotation Sensor Phase - Adjust

WARNING: Entanglement in rotating shaft while adjusting sensor can result in serious
injury or death. Never adjust the sensor unless the operator is at the controls and in
visual contact with the person doing the adjustment. Never place fingers between
sensor mounting plate and the rotating shaft when adjusting the sensor.

IMPORTANT: This procedure requires two people.

3 4 5
a

23 & 24
Rock Adaptable Terrain Tool

1. Disconnect drill string from drive chuck.

2. Position carriage at most rearward position on rack.
3. Remove four bolts (a) and swing rear control station (b) outward to
access jam nut (23) and sensor (24).
4. With the drive chuck stopped, loosen sensor jam nut (23)and rotate
sensor (24) clockwise until it touches the metal pulse ring (25).
Continued on next page...

17-8
D36x50 Series II Navigator HDD Service Overview

23 & 24 23
25

24

IMPORTANT: Do not rotate drive chuck with the sensor in contact with
the pulse ring. The pulse ring can be damaged from the sensor rubbing on it.

5. Rotate sensor 1/8 turn counterclockwise, away from pulse ring.

6. Press Buttons (13), then (14).
13 14
Rotate the operator console so that
technician adjusting the phase

Rock Adaptable Terrain Tool

sensor can see the phase angle
display (11).
7. The technician in the seat begins
rotating the drive chuck in a 11
clockwise position at full rpm.
8. The second technician slowly
rotates the sensor counterclockwise
until phase angle at display reads a 1
positive 85–95°.
9. Tighten jam nut.
10. Test that phase angle is in correct range.
11. To test: press Button (13) and Button (14) while rotating the Drive
chuck clockwise. The LED display (11) should read 90 degree. If drive
chuck fails to oscillate, readjust.
12. Move control station back into place and install bolts.

17-9
 Overview D36x50 Series II Navigator HDD Service

Controllers
Rock Adaptable Terrain Tool

Controllers are located under the seat.

NOTE: A CAN node connector P/N 296276033, will be available on

electrical wiring harness for CAN/USB diagnostic and service software with
a laptop computer.

17-10
D36x50 Series II Navigator HDD Service Pin Assignments for MC024010 Controller

PIN ASSIGNMENTS for MC024010 Controller

MC024-010 Inputs/Outputs
Power Ground (-) A1-P1
Power Supply(+) A1-P2
CAN + A1-P3
CAN- A1-P4
AIN/CAN Shield A1-P5 IN
DIN DRILL/TRI-HAWK READY DETECTION SIGNAL (+12V) A1-P6 IN
DIN MUD PUMP FULL FLOW OVERRIDE (+12V) A1-P7 IN
5 V DC sensor power (+) A1-P8
Sensor Power Ground (-) A1-P9
DIN WASHWAND SIGNAL (+12V) A1-P10 IN
DIN MUD PUMP TRIM SWITCH (-) A1-P11 IN
DIN MUD PUMP TRIM SWITCH (+) A1-P12 IN

DIN TRI-HAWK/ROCKFIRE THRUST LIMIT DETECTION SIG. (+12V) A2-P1 IN

DIN/AIN/FreqIN MUD PUMP INLET PRESSURE (>=10 psi) (+12V) A2-P2 IN

Rock Adaptable Terrain Tool

DIN/AIN/FreqIN TWO SPEED MUD PUMP SWITCH (1X/2X) 2X => +12V A2-P3 IN
DIN/AIN/FreqIN WATER PUMP RPM SENSOR (PPU) +12V A2-P4 IN
DIN/AIN/FreqIN FRONT VISE (BACKSIDE) DETECTION SIGNAL (+12V) A2-P5 IN
DIN/AIN/FreqIN TWO-SPEED THRUST SIGNAL (+12V) A2-P6 IN
AIN/Temp/Rheo MUDPUMP SWITCH “ON” DETECTION SIGNAL (LH Joystick) (+12V) A2-P7 IN
AIN/Temp/Rheo A2-P8
PWMOUT/DOUT/PVG power supply MUD PUMP CONTROL SOLENOID (PWM) A2-P9 IN
PWMOUT/DOUT/PVGOUT BAL VALVE SOLENOID (+12V) A2-P10 OUT
PWMOUT/DOUT/PVGOUT A2-P11 OUT
PWMOUT/DOUT/PVGOUT A2-P12 OUT

17-11
 Pin Assignments for MC050010 Controller D36x50 Series II Navigator HDD Service

PIN ASSIGNMENTS FOR MC050010 CONTROLLER

MC050-010 Inputs/Outputs
Power Ground (-) C1-P1
Power Supply(+) C1-P2
CAN1 + C1-P3
CAN1 - C1-P4
AIN/CAN1 Shield AUTO-DRILL - ON SWITCH (+12V) C1-P5 IN
DIN SEAT SWITCH (+12V) C1-P6 IN
DIN FRONT VISE SWITCH (“CLAMPED”) (+12V) C1-P7 IN
5 V DC sensor power (+) ROTATION (PPU) SENSOR POWER (5 VDC) C1-P8
Sensor Power Ground (-) ROTATION (PPU) SENSOR POWER GROUND C1-P9
DIN ROTATION PRESSURE- TRIM (+) C1-P10 IN
DIN ROTATION PRESSURE- TRIM (-) C1-P11 IN
DIN THRUST PRESSURE TRIM (+) C1-P12 IN
DIN THRUST PRESSURE TRIM (-) C1-P13 IN
DIN/AIN ROTATION JOYSTICK SIGNAL C1-P14 IN
DIN/AIN THRUST JOYSTICK SIGNAL C1-P15 IN
DIN/AIN THRUST/PULLBACK PRESSURE SIGNAL C1-P16 IN
DIN/AIN 3-SPEED G.B. SWITCH- MED C1-P17 IN
DIN/AIN/FreqIN ROTARY PRESSURE SIGNAL C1-P18 IN
DIN/AIN/FreqIN 3-SPEED G.B. SWITCH- HIGH C1-P19 IN
Rock Adaptable Terrain Tool

CAN2 + C1-P20
CAN2 - C1-P21
AIN/CAN2 Shield ANTI-CRASH SIGNAL C1-P22 IN
DIN/AIN/FreqIN CARRIAGE SPEED SENSOR SIGNAL C1-P23 IN
DIN/AIN/FreqIN QUADRATURE SIGNAL “A” C1-P24 IN
DIN/AIN/FreqIN QUADRATURE SIGNAL “B” C1-P25 IN
DIN/AIN/FreqIN C1-P26
AIN/TEMP/RHEO FRONT SLOW DOWN SIGNAL C1-P27 IN
AIN/TEMP/RHEO FRONT STOP SIGNAL C1-P28 IN
AIN/TEMP/RHEO REAR STOP SIGNAL C1-P29 IN
AIN/TEMP/RHEO REAR SLOW DOWN SIGNAL C1-P30 IN
DOUT C1-P31
DOUT C1-P32
DOUT C1-P33
DOUT/PVE Pwr1 C1-P34
DOUT/PVE Pwr2 C1-P35
DOUT/PVE Pwr3 C1-P36
PWMOUT/DPUT/PVE1OUT ROTATION PUMP EDC- CW C1-P37 OUT
PWMOUT/DPUT/PVE1OUT ROTATION PUMP EDC- CCW C1-P38 OUT
PWMOUT/DPUT/PVE1OUT PUMP EDC- THRUST C1-P39 OUT
PWMOUT/DPUT/PVE1OUT PUMP EDC- PULLBACK C1-P40 OUT
PWMOUT/DPUT/PVE2OUT C1-P41
PWMOUT/DPUT/PVE2OUT VISE CLAMP SOLENOID OUTPUT (+12V) C1-P42 OUT
PWMOUT/DPUT/PVE2OUT C1-P43
PWMOUT/DPUT/PVE2OUT C1-P44
PWMOUT/DPUT/PVE3OUT C1-P45
PWMOUT/DPUT/PVE3OUT C1-P46
POWER SUPPLY (+) C1-P47
POWER SUPPLY (+) C1-P48
POWER SUPPLY (+) C1-P49
POWER SUPPLY (+) C1-P50

17-12
D36x50 Series II Navigator HDD Service Pin Assignments for MC050010 Controller

Universal Program
The Universal Program will allow one master program to be used for either
the D24x40II or D36x50II drills. When a new program is downloaded, no
drill functions will work until the Universal Program is set-up to operate
with the specific drill model, either D24x40II or D36x50II.

Default parameters, pressure settings, maximum limits, are defined for the
D24x400II and D36x50II sub-program.

To select the specific SUB-PROGRAM (D24 or D36), the following sequence

is used.

1. Prior to turning the ignition Switch ON, decrement and hold the
Rotation trim switch while simultaneously incrementing and hold the
Thrust trim switch.
2. While holding the Thrust and Rotation trim switch, turn power ON
3. Continue holding the THRUST and ROTATION trim switches for 5

Rock Adaptable Terrain Tool

seconds to activate program setup sub-routine.
4. After 5 seconds, the words, “SELECT PROGRAM” will scroll across the
display.
5. Release Thrust and Rotation trim switches.
6. The “SELECT PROGRAM” message will continue to scroll across
display.
7. Press DISPLAY “+” key once.
8. The DISPLAY will flash “D24x40”.
NOTE: You have only one chance to select the appropriate machine. If you
accidentally selected (and pressed ENTER) a D36x50 program for a D24x40
machine, you must call the factory to obtain instructions how to re-select the
D24x40 program.

9. If D24x40 is the correct, press ENTER. The “D24x40” LEDs will stop
flashing, indicating the program has been selected.
10. If D24x40 is not the correct sub-program, the press the DISPLAY “+”
key a second time.
11. DISPLAY will flash “D36x50”.
Continued on next page...

17-13
 Initial Pressure Setting D36x50 Series II Navigator HDD Service

NOTE: You have only one chance to select the appropriate machine. If you
accidentally selected (and pressed ENTER) a D24x40 program for a D36x50
machine, you must call the factory to obtain instructions how to re-select the
D36x50 program.

12. If D36x50 is the correct, press ENTER. The “D36x50” LEDs will stop
flashing, indicating the program has been selected.
13. Turn power OFF.
14. Turn power ON, or start machine.
15. The Display will show either “D24x40” or D36x50” followed by the
program version “VXXX”.
16. Calibrate Thrust and Rotation Handles.
17. Proceed to setting all of the parameter values.
After sub-program has been selected and power turned on, simultaneously
holding the Rotation and Thrust trim switches as described in Item 1 above
will not activate the program setup menu.
Rock Adaptable Terrain Tool

INITIAL PRESSURE SETTING

When the controller is powered up for the “first time” after program
installation, the rotation/thrust pressure settings corresponding to the
various drilling modes will correspond to default MIN/MAX pressure values
as shown in TABLE 1.

TABLE 1 – Initial Default MIN/MAX Thrust/Rotation Settings (V231)***

RATT ON RATT OFF

Drilling Mode Thrust (psi) Rotation (psi) Thrust (psi) Rotation (psi)

Normal 6000 n/a n/a n/a

TriHawk 1300 n/a 1300 n/a

RockFire 1300 n/a 1300 n/a

“B” Key Limit n/a n/a 6000 6000

*** Any pressure settings shown in Table 1 may be incremented with the rotation/thrust increment/
decrement toggle switches.

17-14
D36x50 Series II Navigator HDD Service Initial Pressure Setting

Handle Calibration
Unplug handle from wiring harness with ignition switch in the ON position.
The controller will register a handle fault. Reconnect handle to wiring
harness. Move handle to the forward position and hold for five seconds. Move
handle to the middle position and hold for 5 seconds. Move handle to the
rearward position and hold for 5 seconds, then return to the middle position.
This will calibrate a properly functioning handle assembly.

Front Vise/Autodrill Interlock

When “clamped” the Front Vise switch provides an INPUT signal (+12vDc)
to the controller at MC050-010: C1-P7. Depending on the status of the
Autodrill feature, +12vDc signal (MC024-010: C1-P42) will be output to the
Front vise solenoid (“Clamp”) thereby allowing the Front Vise to physically
move to a clamped position. The order which the INPUTS are assigned,
whether the Autodrill or the Front Vise switch has been enabled first, will

Rock Adaptable Terrain Tool

determine the state of the Front Vise Solenoid (“Clamp”) OUTPUT at
MC024-010: C1-P42.

Autodrill Mode-Enable and Vise “CLAMP” Interaction

If Autodrill is Enabled (including Thrust, Normal Rotation or R.A.T.T.
oscillation) and the operator (either intentionally or accidentally) closes the
Front Vise Switch thereby providing a +12vDc controller input signal
(MC050-010: C1-P7), the controller will recognize that the Autodrill is
Enabled, but will not provide a Front Vise Solenoid OUTPUT signal
(MC024-010: C1-P42). The Autodrill (including R.A.T.T. Steering) feature
will not be Disabled. Drilling will continue. If the Autodrill feature has been
Enabled, and the Front Vise switch is placed in the “vise clamped” position
(either intentionally or accidentally) and then the Autodrill feature is then
shut off by the operator through normal thrust/rotation joystick movement,
the Front Vise will not physically (and/or automatically) close, even though
the Front Vise switch is still in the “vise closed” position. The Front Vise
switch must be re-set to the “vise unclamped” position before the Autodrill
Resume function can be Enabled. The Display will flash “VISE” until
operator moves the Front Vise switch to the “vise un-clamped” position.
When the Front Vise switch is placed in “vise un-clamped” position, the
Display will return to previous display entry.

17-15
 Initial Pressure Setting D36x50 Series II Navigator HDD Service

Parameters
* Regardless of the 2-Speed Thrust switch position (H or L), when Front Vise
is CLOSED, carriage speed will automatically shift to High (H)

Steps to Adjusting Parameters (Refer to TABLE 2.)

1. Turn Key “ON” to verify and change parameters or Start Engine to

verify, change and test parameters.
2. Press DISPLAY Service Button “D” Key once.
3. Press DISPLAY “C” Key once. The DISPLAY will show, “PW” followed by
“Present Program Revision Number”. To obtain access to the Parameter
Menu, a password (numeric value) equal to the current Revision Number
plus 2 must be entered. The password prompt message will only display
when the controllers have been initially powered (i.e. ignition switch has
been turned ON). Provided that the Parameter Menu has been exited as
described in Step 15, and the ignition switch has not been turned OFF,
the password message will not appear on the display and will not be
Rock Adaptable Terrain Tool

required to re-access the Parameter Menu.

4. To access the Parameter Menu, press the “+” Key twice and then press
the ENTER Key.
5. Parameter P1 and its corresponding parameter value will be displayed.
6. To scroll to the next Parameter, press the “+ or -” Key once.
7. To change a Parameter's Value, scroll to the parameter to be adjusted
and press the Display ENTER Key once. The Parameter Name will begin
to flash, indicating the parameter can be adjusted. Use the “+ or -” Key to
change the parameter value to the desired setting. Increasing/decreasing
the parameter number will increase/decrease the carriage speed. The
parameter value is automatically downloaded to the controller when
the“+ or -” key is pressed. With engine at high idle, test the carriage
speed and re-adjust the parameter as required.
8. Press ENTER to exit out of the Parameter Change Menu. The Parameter
Name will now be displayed as a solid (non-flashing) name.
9. Repeat Steps 6-8 for all parameters.
10. Scroll to Parameter 13, Mud Pump Selection. The present Mud pump
model will be displayed.
11. To change the Mud Pump Option, press the ENTER Key and the display
will flash. Using the “+ or -” keys, select either the A45, FMC or A65 Mud
pump option.
Continued on next page...

17-16
D36x50 Series II Navigator HDD Service Initial Pressure Setting

12. Press the ENTER Key to select the Mud Pump Option.
13. Scroll to the Mud Pump Efficiency Parameter P14. To change, press the
ENTER Key and P11 will begin to flash. Use the “+ or -” keys to adjust
the volumetric efficiency. Press ENTER.
14. To RESET Parameter Settings (P1-P16) to controller defaults, Scroll to
the RESET parameter. To RESET the parameters, press and hold the
ENTER key, and then simultaneously press and hold both the “+ or -”
keys for 3 seconds. The DISPLAY will show one of the following error
messages: LT-HAN, RT-HAN, T-SENS or R-SENS. Re-calibrated the
Thrust and Rotation Joysticks.
15. To EXIT out of the Parameter Menu, Press the Service key “D” once.
16. If ignition switch is turned OFF, the controllers will restart requiring
Password entry to Parameter Menu to make further changes (step 3).

Rock Adaptable Terrain Tool

17-17
 Parameter Settings D36x50 Series II Navigator HDD Service

PARAMETER SETTINGS
TABLE 2- D24x40II and D36x50II Universal Program Parameter Settings (Revision 231)

Parameter Controller Function 2-Speed Vise Front Rear Pipe Shuttle

Default Thrust Slowdown Slowdown (toward
Parameter Switch* Switch Switch operator)
Settings Activated? Activated?
(D24/D36)

P1 30/30 Thrust H or L Closed yes n/a n/a

P2 40/20 Pullback H or L Closed yes n/a n/a

P3 20/20 Thrust H or L Closed n/a yes n/a

P4 20/20 Pullback H or L Closed n/a yes n/a

P5 20/20 Thrust H Open yes n/a n/a

P6 50/40 Pullback H Open yes n/a n/a

P7 40/55 Thrust H Open n/a yes n/a

Rock Adaptable Terrain Tool

P8 20/20 Pullback H Open n/a yes n/a

P9 40/40 Thrust L Open yes n/a n/a

P10 50/40 Pullback L Open yes n/a n/a

P11 40/55 Thrust L Open n/a yes n/a

P12 40/40 Pullback L Open n/a yes n/a

P13 A45 Mud Pump Selection - - - - -

P14 93 Mud Pump efficiency - - - - -

P16 100 Thrust or Pullback H Open/ Off Off n/a

Carriage Speed Closed

RESET n/a Resets to Default - - - - -

Parameters

17-18
D36x50 Series II Navigator HDD Service Parameter Settings

Parameter Settings
P1 - Front Vise CLOSED, Front Slowdown; THRUST Speed
P2 - Front Vise CLOSED, Front Slowdown; PULLBACK Speed
P3* - Front Vise CLOSED, Rear Slowdown; THRUST Speed
P4* - Front Vise CLOSED, Rear Slowdown; PULLBACK Speed
P5 - Front Vise OPEN, 2 Speed Thrust/PB-HIGH, Front Slowdown;
THRUST Speed
P6 - Front Vise OPEN, 2-Speed Thrust/PB-HIGH, Front Slowdown;
PULLBACK Speed
P7 - Front Vise OPEN, 2-Speed Thrust/PB-HIGH, Rear Slowdown;
THRUST Speed
P8 - Front Vise OPEN, 2-Speed Thrust/PB-HIGH, Rear Slowdown;
PULLBACK Speed
P9 - Front Vise OPEN, 2-Speed Thrust/PB-LOW, Front Slowdown;

Rock Adaptable Terrain Tool

THRUST Speed
P10 - Front Vise OPEN, 2-Speed Thrust/PB-LOW, Front Slowdown;
PULLBACK Speed
P11 - Front Vise OPEN, 2-Speed Thrust/PB-LOW, Rear Slowdown;
THRUST Speed
P12 - Front Vise OPEN, 2-Speed Thrust/PB-LOW, Rear Slowdown;
PULLBACK Speed
P13 - MUD Mud Pump Selection Menu
• Mud Pump Option 1: DISPLAYS “A45”
• Mud Pump Option 2: DISPLAYS “FMC”
• Mud Pump Option 3: DISPLAYS “A65”
P14 - Mud Pump Volumetric Efficiency
FLAG1 =0. Thrust/Pullback Carriage Speed is controlled by value stored in
P3 when Front Vise is CLOSED, Rear Slowdown Switch is activated, and
Rod Shuttle is located in ANY position.

FLAG1 =1. Carriage Speed is controlled by value stored in P4 when Front

Vise is CLOSED, Rear Slowdown Switch is activated, depending on the state
(OPEN/CLOSED) of the Anti-Crash Switch located on Rod Shuttle. When
Rod Shuttle is moved “IN” towards rod box, thereby activating the anti-
crash switch, carriage speed is controlled by position of Thrust/Pullback
Joystick. When Rod Shuttle is moved “OUT” towards drill string, thereby de-
activating the anti-crash switch, carriage speed will be controlled by value
stored in Parameter P4. * Refer to FLAG1 Setting

Continued on next page...

17-19
 Parameter Settings D36x50 Series II Navigator HDD Service

P16 - Carriage speed control (no slowdowns activated, vise closed or two-
speed carriage switch in HIGH)

Temporary Memory Pressure Settings

During manual operation, while in the preferred drilling
mode (Normal, Trihawk, Rockfire or Pressure Limit Key),
the operator may use the thrust or rotation toggle switches
to change any the numerical default pressure values listed in
"TABLE 1 – Initial Default MIN/MAX Thrust/Rotation Settings
(V231)***," page 17-14.

For a “first” drilling mode, when a particular rotation or thrust pressure

setting is incremented or decremented, the corresponding pressure value
shown by the DISPLAY will be stored to a first temporary memory location.

When a “second” drilling mode is selected, the corresponding thrust or

Rock Adaptable Terrain Tool

rotation pressure value shown by the DISPLAY will be stored to a second

temporary memory location.

If the “first” drilling mode is re-selected, then the thrust/rotation pressure

value corresponding to the “first” temporary memory location will be active.

The observed DISPLAY pressure setting corresponding to a particular

drilling mode will remain active only while the controller is ON. If the
controller is turned OFF (engine shutdown), all pressures corresponding to a
temporary memory location will be lost.

When the controller is re-power, all values that were previously stored in
“first”, “second”, “third”, and so on, temporary memory locations prior to
turning the controller OFF will automatically reset to the default MIN/MAX
pressure values as shown in TABLE 1.

Permanent Memory Pressure Settings

If the operator would like the present “temporary” rotation or thrust
pressure settings to be available when the controller is powered up, then
Prior to turning the controller OFF (i.e. turning engine off), press the
Display ENTER key corresponding the active drilling mode.

Continued on next page...

17-20
D36x50 Series II Navigator HDD Service Parameter Settings

Example 1
For example, after the controller is powered up, the operator makes the
following “first” temporary pressure settings:

1. Rockfire thrust setting = change from default 1300 to 2000 psi

2. Trihawk thrust setting = change from default 1300 psi to 2700 psi

3. Limit Mode (Pressure Limit Key) Rotation = change from default 6000 psi
to 5500 psi

4. Limit Mode (Pressure Limit Key) Thrust = change from default 6000 psi
to 4200 psi

If the drill mode selector switch is in Trihawk mode and the ENTER key is
pressed then, ONLY the 2700 psi value will be saved to permanent memory.
No other pressure settings corresponding to the other drill modes will be
saved.

Rock Adaptable Terrain Tool

If another drill mode pressure settings need to be saved, then the
corresponding drill mode (Rockfire, Pressure Limit Key) must be activated
before the ENTER key pressed.

Once the ENTER key has been pressed, the controller (Engine) may be shut
off.

For a particular drilling mode, once the ENTER Key has been pressed, this
value will become the “new temporary” pressure setting when the controller
is re-powered.

Example 2
Assuming the steps shown in Example 1 have been completed, when the
controller is re-powered, the new temporary rotation and thrust pressure
settings will be as follows:

1. Rockfire thrust setting = (1300 psi)

2. Trihawk thrust setting = 2700 psi

3. Limit Mode (Pressure Limit Key) Rotation = (6000 psi)

4. Limit Mode (Pressure Limit Key) Thrust = (6000 psi)

Notice that only the Trihawk thrust setting has changed. All other pressure
settings (in parentheses) remain at their default setting.

17-21
 Parameter Settings D36x50 Series II Navigator HDD Service

Fault Codes
Press Service Screen Toggle to view any active faults. All except “NONE”
will disable machine operation.

LT-HAN................left handle out of range or not calibrated. Possible cause,

No power to handle, faulty handle or handle unplugged from harness.

RT-HAN.............. right handle out of range or not calibrated. Possible cause,

No power to handle, faulty handle or handle unplugged from harness.

T-SENS...................thrust/pullback pressure sensor fault

R-SENS.........................rotation pressure sensor fault (charge pressure less

than 175 psi for more 15 seconds).

NOTE: If ignition key is in the ON position for more than 10 seconds

without engine running, both Thrust and Rotation pressure sensors will
show fault for lack of pressure.
Rock Adaptable Terrain Tool

CRASH..................... anti-crash activated for rod loader

THREDC.....................thrust/pullback EDC output fault

ROTEDC...........................rotation EDC output fault

NONE.................................... no faults present

Four faults will cause Fault light to blink but machine will still operate:

MUDCAN...........................mud controller is off-line

BALOUT..............................ball valve output fault

MUDOUT................drilling fluid pump PWM output fault

VISE.... vise initially clamped and then Autodrill button pressed

HI-SPD.............. 2-Speed Thrust/Pullback switch in HIGH when Autodrill

button pressed

17-22
D36x50 Series II Navigator HDD Service Parameter Settings

R.A.T.T. LIMITS
When R.A.T.T. mode is selected and the drill is operated in manual mode,
the thrust pressure limit is controlled by the pressure value corresponding
to the presently selected drill mode (Normal Drill, Trihawk or Rockfire).

Autodrill Pressure Settings

Autodrill setting always reset to ZERO when controller is turned ON.

R.A.T.T. ICON - LED

New to Version 231, when the R.A.T.T. drilling mode is selected, the Display
“M” LED see "LED Display," page 17-1 will be active.

The LED will remain active, when the switching between both the R.A.T.T.
oscillating and straight drilling modes. Decal P/N 7000D272 DECAL-RATT
is available from Vermeer Parts Center

Rock Adaptable Terrain Tool

17-23
 R.A.T.T. Component D36x50 Series II Navigator HDD Service

R.A.T.T. COMPONENT
Disassembly/Assembly
Rock Adaptable Terrain Tool

IMPORTANT: Do not proceed until familiar with Field Breakout Bench

Manual, Order No. 105400Z62.

17-24
D36x50 Series II Navigator HDD Service R.A.T.T. Component

Breakout Bench
Tighten wrench
vise bolts with an
impact. Leave
main vise bolts
loose so R.A.T.T.
and wrench can
be rotated and
attached to the
hydraulic ram.

NOTE: If

Rock Adaptable Terrain Tool

attaching
wrench with
bolts facing
down,
inadequate space
may not allow
tightening of
bolts.

17-25
 R.A.T.T. Component D36x50 Series II Navigator HDD Service

Torque Push
Torque for Midsize Bench Torque for Midsize Bench

psi torque (ft-lb) bar torque (Nm) psi torque (ft-lb) bar torque (Nm)
100 650 10 1290
200 1310 15 1930 1900 12440 100 12870
300 1960 20 2570 2000 13090 105 13510
400 2620 25 3220 2100 13740 110 14160
500 3270 30 3860 2200 14400 115 14800
600 3930 35 4505 2300 15050 120 15450
700 4580 40 5150
800 5230 45 5790
900 5890 50 6440
1000 6550 55 7080
1100 7200 60 7720
1200 7850 65 8370
1300 8510 70 9010
Rock Adaptable Terrain Tool

1400 9160 75 9650

1500 9820 80 10300
1600 10470 85 10940
1700 11130 90 11580
1800 11780 95 12230
1

17-26
D36x50 Series II Navigator HDD Service R.A.T.T. Component

Torque Pull
Torque for Midsize Bench Torque for Midsize Bench

psi torque (ft- bar torque (Nm) psi torque (ft- bar torque (Nm)
lb) lb)
100 490 10 970
200 980 15 1450 1900 9330 100 9650
300 1470 20 1930 2000 9820 105 10130
400 1970 25 2420 2100 10310 110 10620
500 2450 30 2900 2200 10800 115 11100
600 2950 35 3380 2300 11290 120 11590
700 3440 40 3860
800 3920 45 4340
900 4420 50 4830
1000 4910 55 5310
1100 5400 60 5790
1200 5890 65 6280

Rock Adaptable Terrain Tool

1300 6380 70 6760
1400 6870 75 7240
1500 7370 80 7730
1600 7850 85 8210
1700 8350 90 8690
1800 8840 95 9170

Bent Sub Assembly

(1) Bent Sub

(2) O-ring

(3) Seal Gland

Stop

(4) Compression
Spring

(5) Seal Gland

Assembly

17-27
 R.A.T.T. Component D36x50 Series II Navigator HDD Service

Bent Sub Removal

1. Loosen Bent
Sub from
Rock
Steering Tool
clutch.
Rock Adaptable Terrain Tool

2. Remove and
clean Seal
Gland Stop
and Seal
Gland
Assembly.

17-28
D36x50 Series II Navigator HDD Service R.A.T.T. Component

3. Inspect O-
rings P/N
296274245
and replace if
needed.

Rock Adaptable Terrain Tool

17-29
 R.A.T.T. Component D36x50 Series II Navigator HDD Service

4. Remove, clean
and inspect
compression
spring from
Bent Sub
assembly.
5. Clean Bent
Sub, inspect
and replace O-
ring P/N
296274241 if
required.
Rock Adaptable Terrain Tool

17-30
D36x50 Series II Navigator HDD Service R.A.T.T. Component

6. Position
R.A.T.T. in V-
blocks to allow
removal of
clutch

Rock Adaptable Terrain Tool

NOTE: There
are NO user
serviceable items
in Rock Steering
Tool clutch. If
defective, replace
P/N 296274239.

NOTE: Rock
Steering Tool is a
one-way clutch.
Clutch will
engage in one
direction and free
wheel in opposite
direction.

17-31
 R.A.T.T. Component D36x50 Series II Navigator HDD Service

R.A.T.T. viewed
from machine end
of tooling.
Rock Adaptable Terrain Tool

7. Flip R.A.T.T.
end for end to
ease removal
of bearing
housing.
Wrench will
be placed on
Retaining Nut
Assembly.

17-32
D36x50 Series II Navigator HDD Service R.A.T.T. Component

8. With a pipe
wrench
remove
retaining nut
assembly.
NOTE: Field
Breakout bench
wrench V-blocks
will be too wide to
remove Retaining
nut assembly.

NOTE: Retaining
nut assembly will
turn to unthread
from bearing
housing and
remain fixed to driveshaft.

Rock Adaptable Terrain Tool

9. Pull
driveshaft
assembly from
bearing
housing still
fixed in Field
Breakout
bench.

17-33
 R.A.T.T. Component D36x50 Series II Navigator HDD Service

10. Remove
bearing
housing from
Field
Breakout
Bench. Place
driveshaft
assembly in
Field
Breakout
Bench so V-
block does not
overlap
Retaining nut
assembly.
Remove 1/4-20
setscrew.
Rock Adaptable Terrain Tool

11. Remove 1-7/8

nut from
driveshaft.
Remove
bearings.

17-34
D36x50 Series II Navigator HDD Service R.A.T.T. Component

12. Remove
retaining nut
assembly. A
soft-faced
hammer may
help in
dislodging the
assembly.

Rock Adaptable Terrain Tool

Clean and inspect
driveshaft.

17-35
 R.A.T.T. Component D36x50 Series II Navigator HDD Service

13. Clean and

inspect
retaining nut
assembly.
Lightly
lubricate seal
P/N
296274233
with ATF to
ease assembly.
NOTE: Raised
step on seal is to
be placed toward
the tool bit end of
assembly.
Rock Adaptable Terrain Tool

14. Lubricate
driveshaft
with ATF to
keep from
damaging seal
during
assembly.
NOTE: O-ring
296274066 is
shown installed in
groove above
threaded portion
of retaining nut
assembly.

17-36
D36x50 Series II Navigator HDD Service R.A.T.T. Component

15. Slide
retaining nut
assembly
against tool
shoulder. Use
soft-faced
hammer as
needed.

Rock Adaptable Terrain Tool

16. Place six
bearings P/N
296274071
with text
toward
machine end,
facing camera.
The seventh
bearing is
placed with
text facing 1 3
away from 2
5
4 6
camera or
7
toward tooling
end of
driveshaft
assembly.

17-37
 R.A.T.T. Component D36x50 Series II Navigator HDD Service

17. Apply Loctite

518 to
threads.
Torque nut to
500 ft-lb (680
Nm).
Rock Adaptable Terrain Tool

18. Apply Loctite

518 to 1/4-20
setscrew
threads and
tighten.

17-38
D36x50 Series II Navigator HDD Service R.A.T.T. Component

19. Install O-ring

P/N
296274066 in
Bearing
Housing.

20. Lubricate
outer bearing
surfaces to

Rock Adaptable Terrain Tool

prevent O-ring
damage
during
assembly.

17-39
 R.A.T.T. Component D36x50 Series II Navigator HDD Service

21. Flip end for

end after
threading
Bearing
housing by
hand. Torque
Bearing
Housing to
approximately
800 ft-lb (1085
Nm). Apply
Loctite 518 to
threads of set
screws.
Tighten
setscrews.
Rock Adaptable Terrain Tool

22. Flip R.A.T.T.

end for end.
Install O-ring
P/N
296274241 on
tool bit end of
Bearing
Housing.
Apply Loctite
to threads of
Bearing
Housing.
Thread Clutch
Assembly on
to Bearing
Housing and
torque to 5000
ft-lb (6779
Nm).

17-40
D36x50 Series II Navigator HDD Service R.A.T.T. Component

23. Lubricate
driveshaft
with ATF.

Rock Adaptable Terrain Tool

24. Install Seal
Gland P/N
296274246 on
driveshaft.

17-41
 R.A.T.T. Component D36x50 Series II Navigator HDD Service

25. Install Seal

Gland Stop on
driveshaft.
Rock Adaptable Terrain Tool

26. Place
Compression
Spring P/N
296274248 in
Bent Sub.
NOTE: See "Bent
Sub Assembly,"
page 17-27 for
order of assembly.

17-42
D36x50 Series II Navigator HDD Service R.A.T.T. Component

27. Apply anti-

seize to
threads.

Rock Adaptable Terrain Tool

28. Torque Bent
Sub to R.A.T.T.
to 5000 ft-lb
(6779 Nm).

17-43
 R.A.T.T. Component D36x50 Series II Navigator HDD Service

29. Sonde housing

may be
attached at
this time. Use
anti-seize on
threads.
Torque to
3000 ft-lb
(4070 Nm).
Rock Adaptable Terrain Tool

17-44
D36x50 Series II Navigator HDD Service R.A.T.T. Component

WARNING: Some residual pressure may remain in the R.A.T.T. body. Use caution
when removing any plugs. If residual pressure is present in the tool body it will be
released. Do not stand in front of any plugs when removing them.

Filling R.A.T.T.

Rock Adaptable Terrain Tool

1

1. Elevate the fill vent plug (2) end of tool at a minimum angle of 10
degrees.
2. Remove vent plug (2)
3. Remove fill zerk cap (1)
4. Use oil gun provided to fill tool with Automatic Transmission Fluid. Use
slow even strokes. The attached pressure gauge will read around 500 psi.
5. As soon as ATF fluid flow out of the vent hole, reinstall plug (2).
6. Continue to fill the tool until gauge reads approximately 700 psi. The
tool is now ready for use.
7. Refill tool immediately after each use is required.

17-45
 R.A.T.T. Component D36x50 Series II Navigator HDD Service

Oil Gauge Assembly

2
Rock Adaptable Terrain Tool

1. Remove fill tube (1) fom oil gun (3).

2. Install “Tee” fitting (2), use thread sealant during assembly.
3. Attach fill tube (1) to “Tee” fitting (2).
4. Install pressure gauge (4).

17-46
D36x50 Series II Navigator HDD Service
Numerics
15A Circuit Breakers F1–F10, 3-19
2-Speed Shift Manifold A27, 14-2
2-Speed Solenoid L3, 6-22
40A Circuit Breaker CB1, 3-18
40-amp circuit breaker CB1, 3-3
A Clamp, 10-14
A7, 16-3
A9, 16-3
AD2, 16-3
Adjusting Proximity Switch, 6-39
Alarm Cancel Switch S29, 15-2
Alarm Horn AD1, 16-2
Alternator ALT1, 3-3, 3-38
Anti-crash Switch S7, 8-13
Aplex Pump, 14-8
Arm Extend Switch S38, 8-13
Arm Retract Switch S39, 8-13
Auto Greaser, 13-6
Auto Greaser Cylinder, 13-12
Auto Greaser Cylinder CY12, 13-1
Auto Greaser Switch S17, 13-1
Auto Greaser Valve, 13-11
Auto Greaser Valve A24, 13-1
Auto-greaser, 13-1
Avoid Entanglement—Stay Away, 1-4
Avoid Pinch Points, 1-4
B Coolant Temperature Gauge GA1, 3-27
Ball Valve, 14-29, 14-31
Ball Valve Control Manifold A26, 14-2
Ball Valve Solenoid L17, 14-1
Battery, 15-15, 15-20
Battery Charging, 3-5
Brake Shuttle Valve, 7-34
Breaker F1, 14-1
Breaker F2, 14-1
Breaker F5, 14-1
Breaker F6, 3-13, 8-11, 10-9
C Cylinder Selector Switch S31, 12-8
Charge Filter FL1, 4-8
Charge Filter FL2, 4-11
Charge Filters FL1 and FL2, 4-16
Charge Pressure, 4-7, 4-10
Charge Pressure Relief Valve, 6-42
Charge Pump, 4-7, 4-10, 5-8, 6-11, 6-42
Charge Pump Relief Setting, 5-42
Charge Pump Relief Valve, 5-42
Check Ground Disconnect Switch S1, 3-20
Check Lock Valve CV8, 11-6
Check Lock Valve CV9, 11-6
Check plug, 11-17
Index
Check Valve CV3, 12-8
Check Valve Manifold Assembly A4, 15-2
Check Valves, 11-22
Check Valves CV10-CV12, 15-2
Checking Machine Performance, 2-9
Circuit Breaker CB8, 3-34
Circuit Breaker F9, 8-11
Closed Loop Pump, 4-7, 4-10
Code Scroll Button S73, 3-27
Code Scroll Switch S40, 3-12
Cold Weather Starting, 2-3
Combination Dump Valve, 15-9
Combination Dump Valve Assembly A9, 14-1
Combination Manifold A9, 9-10
Combination Valve Assembly A9, 8-17, 9-1
Combination Valve Manifold A9, 4-6, 10-6
combination valve manifold A9, 10-6
Component Locations
Drilling Fluid, 14-3
Hydraulic Fluid Distribution, 4-2
Rack lift, 11-2
Remote Lockout, 15-3
Rod greaser, 13-2
Vises, 10-14
Component locations
Strike alert, 16-3
Connecting a Needle Valve, 1-17
Connecting Flow Meters, 1-16
Cooler HE1, 4-13
Crankcase, 14-37
Current, 16-4
Current strike, 16-6
Cylinder CY1, 8-14
Cylinder CY10, 12-4
Cylinder CY11, 9-9, 9-10
Cylinder CY2, 8-14
Cylinder CY9, 12-4
Cylinder Lock Check Valves, 11-22
D
Daily test, 16-4, 16-7
Diagnostic Port, 6-33
Directional Control Valve DV8, 15-2
Directional Valve DV18, 13-1
Directional Valve DV19, 10-1
Directional Valve DV20, 10-1
Directional Valve DV21, 10-1
Directional Valve DV22, 10-1
Discharge Valve, 14-46
Drill Fluid Off, 14-10
Drill Rotation Performance, 2-13
Index D36x50 Series II Navigator HDD Service

Drill/Track Solenoid L24, 7-1, 8-11, 10-9 Front Vise Switch S34, 5-14, 6-22, 10-1
Drill/Track Valve DV27, 7-1, 7-7, 7-9 Fuel Delivery, 3-32
Drilling Fluid, 14-1 Fuel Gauge GA2, 3-34
Drilling Fluid Motor, 14-51 Fuel Gauge GA5, 3-13
Drilling Fluid On, 14-9 Fuel Sender B1, 3-35
Water On, 14-8 Fuse F6, 6-16, 7-1
Drilling Fluid Pump, 14-33 Fuse F7, 6-22
Drilling Fluid/Wash Wand Selector Switch S18, 14-1
G
E Gearbox Lock Cylinder CY18, 10-10, 10-11
ECU, 15-9 Gears, 7-49
Electric Displacement Control (EDC), 5-15 Greaser cylinder CY12, 13-6
Electrical Displacement Control (EDC), 4-8, 4-11 Greaser switch S17, 13-6
Electrical schematic Greasing, 13-6
Strike alert, 16-5 Ground Disconnect Switch S1, 3-6
Electrical Troubleshooting, 1-11 Ground Drive Control Valve Assembly A5, 7-7
Engine, 2-7 Ground Drive Performance, 2-18
Engine Overview, 9-1 Ground Drive, Rod Loader, Vise, Stakedown, Stabilizer/
Engine Shutdown Lockout, 15-1, 15-8 Rack Angle, and Water Shutoff Performance, 2-16
Engine Shutdown Relay K3, 15-2
Engine Specifications, 2-5
H
Excessive Heat, 4-20 Horn AD2, 15-2
Excessive Leakage, 4-20 Horn Cancel Switch S13, 16-2
Excessive Noise, 4-15 Hose Connections
Excessive Vibration, 4-15 Drilling Fluid, 14-6
Extend Solenoid L18, 9-1 Hydraulic Fluid Distribution, 4-3
Rack lift, 11-3
F Rod greaser, 13-3
Flow Chart, 15-22, 15-23 Hydraulic, 1-12
Flow Control Valve FV10, 8-14 Hydraulic Connections, 1-15
Flow Divider Valve FV10, 8-12 Hydraulic Enable Solenoid L26, 14-1
Fluid Control Module A20, 14-1 Hydraulic Enable Switch S30, 8-11, 8-18, 9-9, 9-10
Fluid Control Valve, 14-25 Hydraulic Enable Valve DV29, 9-1, 10-6, 14-1
Fluid Cooler HE1, 4-1 Hydraulic Fluid Sampling, 4-20
Fluid Full Flow Selector Switch S16, 14-1 Hydraulic Lockout, 15-1, 15-7
Fluid Pressure Gauge GA3, 14-1 Hydraulic Motor MH8, 14-1
Fluid Pressure Switch S10, 14-1 Hydraulic Tank, 4-13
Fluid Pump, 14-33 Hydraulic Tank RES1, 4-1
Fluid Pump PMP4, 14-1 Hydraulic Troubleshooting, 1-12
Fluid Pump Speed PPU B3, 14-1
Fluid Pump/RockFire Relay K5, 14-1
I
Fluid Shutoff Ball Valve, 14-1 Ignition Switch S1, 3-4
Fluid Shutoff Cylinder, 14-29 Ignition Switch S2, 3-3, 3-17
Fluid Shutoff Cylinder CY15, 14-1 Indicator Light DS7, 16-2
Fluid Shutoff Valve, 14-27 Indicator Lights DS2–DS4, 15-2
Fluid Tank RES1, 4-5 J
Front Clamp Cylinder CY19, 10-10, 10-11
Joystick Control A15, 10-1
front clamp cylinder CY19, 10-11
Joystick Controls A18 and A19, 3-37
Front Slow Switch S4, 6-23
Front Stop Switch S3, 6-23 L
Front Vise, 10-14 L4, 16-3
Unclamp, 10-14 Left Brake Manifold A28, 7-1
Front Vise Clamp Cylinder CY19, 10-1 Left Joystick Assembly A27, 14-1
Front Vise Cylinder, 10-25 Left Joystick Control A13, 13-1
D36x50 Series II Navigator HDD Service
Left Stakedown Cylinder CY9, 12-8
Left Stakedown Motor MH9, 12-4
Left Track Brake Valve DV31, 7-1
Left Track Control Valve DV10, 7-1
Left Track Motor MH5, 7-1
Load Check Plug, 7-32, 11-17
Load Sense Drain Relay K9, 15-2
Load Sense Relay K4, 8-1, 10-6
Load Sense Solenoid Valve DV28, 10-6
Load sense solenoid valve L25, 12-4
Load Sense Valve DV28, 4-6
Loader Anti-Crash Switch S7, 6-23, 8-1
Loader Arm Extend Switch S38, 8-19
Loader Arm Retract Switch S39, 8-19
Lock Check Valve CV14, 9-9
Lock Check Valve CV15, 9-9, 9-10
Lock Check Valves CV14, 9-10
Lock Valve CV15, 9-1
Lock Valve CV8, 11-1
Lock Valve CV9, 11-1
Lockout, 15-13
M Pressure Relief Valve PV5, 7-1, 11-1
Machine Interlocks, 2-7
Machine Performance, 2-8
Drilling Fluid, 14-13
Ground drive, 7-25
Rack lift, 11-10
Rod Loader, 8-17
Stakedown, 12-14
Vises, 10-17
Machine Specifications, 2-5
Manifold A12, 6-36
Manifold A3, 5-14
Measure Battery Voltage, 3-20
Measuring Current, 1-19
Measuring Resistance, 1-18
Measuring Voltage, 1-18
Motor, 14-51
Motor MH5 and MH6, 7-29
Motor MH7, 8-23
Motor Shift Control Solenoid L20, 14-2
Motor Shift Control Valve DV26, 14-2
Multi-Function Valve, 6-12
Multifunction Valve, 4-8, 4-11, 5-41
Multifunction valve, 4-27
Multifunction Valves, 6-40
O Rear Throttle Switch S25, 3-15
Oil Cooler, 4-35
Oil Cooler HE1, 4-20
Oil Cooling, 4-13
Oil Filtering, 4-12
Oil Filtering Function, 4-12
Index
Oil Supply, 4-5
Operator Seat Switch S26, 9-9, 9-10
Orifice FV15, 10-13
Orifice FV7, 8-12, 8-14
Outrigger Cylinder CY11, 9-1
Outrigger Manifold A25, 9-9
Outrigger Valve Assembly A25, 9-1
Outrigger Valve DV24, 9-10
P
Performing Remote Lockout, 15-16
PFC Pump, 4-26
PFC Pump PMP3, 4-1, 4-5, 4-14, 4-18, 7-1, 7-6, 7-29
PFC Pump sampling, 4-22
Pilot Operated Check Valve CV14, 9-1
Piston, 14-37
Piston Cup, 14-36, 14-39
Piston Rod, 14-36
Planetary Gears, 7-49
Power On, 15-12
Power Vise Valve Solenoid L16, 10-11
Pressure Relief Valve PV4, 14-1
Pressure Transducer B1, 15-2
Proportional Control Valve FV4, 14-1
Proportional Flow Control Valve FV3, 14-1
Pump PMP2, 6-23, 6-35, 6-43
Pump PMP3, 4-5, 4-19, 8-1
Pump pmp3, 8-12
pump PMP3, 8-17, 12-1, 12-4
R
Rack angle, 11-1
Rack Angle Performance, 2-26
Rack lift, 11-1
Rack Lift Cylinder, 11-22
Rack Lift Cylinder CY13, 11-1, 11-6
Rack Lift Cylinder CY14, 11-1, 11-6
Rack Lift Cylinders, 11-19
Rack Lift Valve DV25, 11-1
Rack LOWER, 11-7
Rack RAISE, 11-6
R.A.T.T., 17-1
Rear Loader Presence Switch S6, 8-1
Rear Rotation Motor MH3, 5-14
Rear Slow Switch S8, 6-23
Rear Stop Switch S9, 6-23
Rear Throttle Relay K3, 3-40
Rear Vise, 10-20, 10-21
Unclamp, 10-14
Rear Vise Clamp Cylinder CY17, 10-1
Rear Vise Cylinder, 10-25
Rear Vise Cylinder CY17, 10-12
Index D36x50 Series II Navigator HDD Service

Rear Vise Rotate Cylinder CY16, 10-1 L34, 14-9

Rear Vise Rotate Solenoid L13, 10-13 L35, 14-9
Rear Vise Rotate Valve DV19, 10-13 L9, 15-9
Rear Vise Rotation Switch S36, 10-1, 10-13 MH10, 14-9, 14-51
Rear Vise Solenoid L14, 10-12 MH5, 7-35
Rear Vise Switch S35, 10-1, 10-13 MH6, 7-35
Rear Vise Valve DV20, 10-12 MH7, 8-28
Reference Designator MH8, 12-22
A12, 8-24 MH9, 12-22
A14, 10-23 PMP1, 4-7
A15, 4-24 PMP2, 4-10
A16, 12-20 PMP3, 4-5, 4-18, 4-26
A17, 14-9, 14-27 PMP4, 14-9, 14-33, 14-34, 14-38
A18, 14-9, 14-25 PV9, 7-33, 11-8, 11-18
A21, 13-11 RES1, 4-13
A22, 4-34 S16, 14-9
A24, 15-7, 15-8 S17, 14-10
A29, 14-9, 14-18 S27, 15-7
A3, 15-9 S36, 14-9, 14-10
A32, 11-7, 11-22 SV4, 7-34
A33, 11-7, 11-22 SV5, 7-34
A8, 7-30, 11-14, 11-15 Relay K7, 7-16
A9, 14-9 Relief Valve, 7-33, 11-18
B1, 15-7 Relief Valve PRL1, 6-41
CY1, 11-7, 11-19 Relief Valve PV4, 8-12
CY10, 12-25 Relief Valve PV5, 7-7, 11-6
CY11, 12-25 Relief Valve PV9, 7-29
CY12, 14-9, 14-29 Remote Lockout, 15-1
CY2, 11-7, 11-19 Remote Lockout Base Module A10, 15-2
CY3, 8-26 Remote Lockout Battery Charger, 15-2
CY4, 8-26 Remote Lockout Drill Function Shutdown Relay K12,
CY6, 13-12 15-2
CY8, 10-25 Remote Lockout Dump Valve Relay K8, 15-2
CY9, 10-25 Remote Lockout Manifold A4, 4-1
DV10, 7-31 Remote Lockout Module A10, 3-3
DV11, 7-31 Remote Registration, 15-14
DV12, 7-31, 11-16 Remote Unit, 15-2
DV15, 11-14 Repair Guidelines, 1-20
DV16, 11-14 Required Tools, 1-15
DV19, 8-25 Resuming Operation After Remote Lockout, 15-17
DV20, 8-25 Retract Solenoid L19, 9-1
DV22, 8-25 Return Filter FL3, 4-1
DV34, 14-29, 14-31 Return Filter FL4, 4-1
DV4, 15-9 Return Filter Manifold, 4-34
DV5, 15-9 Return filters, 4-12
FL3, 4-12 Return Manifold A12, 4-1, 4-13
FL4, 4-12 Return Manifold A22, 8-17
HE1, 4-13, 4-35 Return Valve, 4-24
K15, 15-7 Right Brake Manifold A29, 7-1
K8, 15-8 Right Joystick Assembly A30, 14-1
L10, 15-9 Right Joystick Control A15, 8-1
L13, 14-9 Right Stakedown Cylinder CY10, 12-8
L14, 11-14 Right Stakedown Motor MH10, 12-4
L33, 14-9 Right Track Brake Valve DV32, 7-1
D36x50 Series II Navigator HDD Service Index

Right Track Control Valve DV11, 7-1 Shutoff Cylinder Control Valve DV23, 14-2
Right Track Motor MH6, 7-1 Slowdown/Anti-crash Module, 6-3, 6-19
ROCKFIRE, 6-21 Solenoid Coil L21, 15-2
RockFire, 6-3, 6-21 Solenoid L13, 10-1
Rod Box, 8-42 Solenoid L14, 10-1
Rod greaser, 13-1 Solenoid L16, 10-1
Rod Greaser Valve, 13-11 Solenoid L21, 10-1
Rod Lift Cylinder CY1, 8-1 Solenoid L26, 9-1
Rod Lift Cylinder CY2, 8-1 Solenoid L34, 13-1, 13-6
Rod Lift Cylinders, 8-26 solenoid valve DV14, 12-4
Rod Lift Switch S37, 8-1, 8-13, 8-18, 8-22 SP/FMI Code Identification, 3-27
Rod Loader Flow Divider Valve FV10, 8-1 Specifications, 2-4
Rod Loader Lift Control Valve DV12, 8-1 Drilling Fluid, 14-2
Rod Loader Lift Control Valve Solenoid L5, 8-1 Ground drive, 7-29
Rod Loader Motor, 8-28 Hydraulic Fluid Distribution, 4-14
Rod Loader Motor Control Valve DV13, 8-1 Rack lift, 11-14
Rod Loader Motor Control Valve Solenoid L32, 8-1 Rod greaser, 13-10
Rod Loader Motor Control Valve Solenoid L33, 8-1 Rod Loader, 8-23
Rod Loader Motor MH7, 8-1 Stakedown, 12-19
Rod Loader Performance, 2-20 Vises, 10-22
Rod Loader Power Valve DV9, 8-1 Stabilizer Function Performance, 2-27
Rod Loader Power Valve Solenoid L6, 8-1, 8-22 Stakedown Cylinder Control Valve DV16, 12-8
Rod Loader Valve, 8-24 Stakedown Cylinder Lower Solenoid L10, 12-8
Rod Loader Valve A6, 8-1 Stakedown Cylinder Orifice FV17, 12-8
Rod Loader Valve Manifold A6, 8-24 Stakedown Cylinder Select Solenoid L7, 12-8
Rod Selector Extend Switch S38, 8-1 Stakedown Cylinder Select Valve DV14, 12-8
Rod Selector Retract Switch S39, 8-1 Stakedown Cylinders, 12-25
Rotation Motor, 5-15 Stakedown Cylinders Up Solenoid L9, 12-8
Rotation Pump, 4-7 Stakedown Manifold A7, 12-4
Rotation Pump EDC, 6-16 Stakedown Motors, 12-22
Rotation Pump PMP1, 4-1, 4-7, 4-13 Stakedown Performance, 2-23
Rotation Sampling, 4-22 Stakedown Switch S32, 12-8
Run, 15-12 Stakedown Valve, 12-20
Starter Relay K2, 3-37
S Starter Solenoid L38, 3-3
Sample Collection Points, 4-22 Starting Shutdown, EDC Controller Power Input Relay
Sampling, 4-20 K11, 15-2
Schematic Starting the Engine, 2-2
Drilling Fluid, 14-7, 14-8 Strike alert, 16-1
Hydraulic Fluid Distribution, 4-4 Strike alert circuits, 16-5
Rack lift, 11-4 Strike Alert Coil A30, 16-2
Remote Lockout, 15-5, 15-6 Strike Alert Module A17, 16-2
Rod greaser, 13-4 Strike alert test, 16-4, 16-7
Strike alert, 16-5 Suction Screen FL5, 4-1
Water, 14-7, 14-8 Suction Strainer FL5, 4-16
Seat Switch Relay K7, 7-1, 7-7, 8-11, 10-9 Suction Valve, 14-46
Seat Switch S26, 6-16, 7-1, 7-7, 8-11 Switch S34, 10-10
Seat Switch S6, 6-23
Selector Switch S31, 12-8 T
Sending Unit B2, 3-13 Temp Gauge GA4, 3-12
Shaft Replacement, 4-31 Terminology, 1-6
Shaft Seal Replacement, 4-31 Test Switch S12, 16-2
Shutdown Procedure, 2-1 Testing for Continuity, 1-19
Shutoff Cylinder Control Solenoid L17, 14-2 Testing Ground Drive, 7-26
Index
Testing Joysticks, 6-38
Testing Proximity Switches, 6-39
Testing Rack Angle, 11-11
Testing Rod Loader, 8-18
Testing Stakedown, 12-15
Testing Vise, 10-18
Testing Water Shutoff, 14-14
Thermal Breaker F8, 3-18
Thermal Breakers, 3-7
Three Position Switch S42, 5-14
Three Speed Switch S42, 5-14
Throttle Actuator Motor M1, 3-39
Throttle Decrease Switch S15, 3-15
Throttle Increase Switch S14, 3-15
Throttle Switch S25, 3-40
Thrown Wrench, 1-4
Thrust Limiter Manifold A11, 6-3
Thrust Motors MH3 and MH4, 4-12
Thrust Pump, 4-10
Thrust Pump PMP2, 4-1, 4-10, 4-13
Thrust sampling, 4-22
Thrust/Pullback Charge Pump, 6-9
Thrust/Pullback Operation, 2-14
Thrust/Pullback Performance, 2-15
Timing the motor, 7-42
Tools
Motor, 7-35, 14-51
Planetary, 7-50
Pump, 14-38, 14-46
Towing, 5-23
Track Brake Solenoid L4, 10-9
Track chain, 7-45
Track Motors, 7-35
Track Tension
Adjustment, 7-48
Tightener, 7-47
Track/Drill Solenoid L24, 7-7
Transducer, 15-7
Transport Valve A5, 4-16
Transport/Rack Valve, 11-15
Transport/RackValve, 7-30
TRIHAWK, 6-21
Troubleshooting
Drilling Fluid, 14-10
Hydraulic Fluid Distribution, 4-15
Rack lift, 11-8
Strike alert, 16-7
Transport/Rack Valve, 7-28
Vises, 10-14
D36x50 Series II Navigator HDD Service
Troubleshooting Rod Lift, 8-22
Troubleshooting Rod Loader Select, 8-20
Troubleshooting Transport/Rack Valve, 11-14
Troubleshooting/Testing Auto Greaser, 13-9
Troubleshooting/Testing Drilling Fluid, 14-15
Troubleshooting/Testing Fluid Control Module, 14-18
Troubleshooting/Testing Ground Drive, 7-27
Troubleshooting/Testing Oil Cooler, 4-20
Troubleshooting/Testing PFC Pump, 4-18
Troubleshooting/Testing Rack Lift, 11-12
Troubleshooting/Testing Remote Lockout, 15-18
Troubleshooting/Testing Stakedown, 12-17
Troubleshooting/Testing Vise, 10-19
Turbocharger/Intake, 3-30
V
Valve Assembly A8, 7-29
Valve Bank Assembly A5, 11-1
Valve DV24, 9-1
Valve Manifold A9, 7-9
Verify Software, 15-19
Vermeer Warranty, 1-2
Vise Performance, 2-22
Vise Rotate Cylinder CY16, 10-13
Vise Rotate CylinderReference Designator
CY7, 10-27
Vise Valve, 10-23
Vise Valve Assembly A8, 10-1
Voltage, 16-4
Voltage Stake E1, 16-2
Voltage strike, 16-6
W
Warning Light DS13, 3-12
Warranty, 1-2
Wash Wand, 14-10
Water Control Solenoid L23, 14-1
Water Flow Control Solenoid L22, 14-1
Water Off, 14-10
Water On, 14-9
Water Pump, 14-33
Water Shutoff Cylinder, 14-29
Water Shutoff Valve Performance, 2-29
Water Valve, 14-25, 14-27
Z
Zap alert
Alert, 16-1
D36x50 Series II Navigator HDD Service

Revision History
Revision Date Page(s) Description
S1_00 9/06 All 1st edition manual released.
S1_01 1/07 Chapter 17,TOC,Index 2nd revision manual released.
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