Vermeer D60x90 Navigator User manual

D60x90 Navigator®
Horizontal Directional Drill
D60x90_m1_04
Serial No. 101 -
Order No. 105400BQ9
Maintenance
Manual

D60x90 Navigator HDD Maintenance
Introduction
This manual explains the proper operation of your machine. Study and understand these instructions thoroughly before operating or
maintaining the machine. Failure to do so could result in personal injury or equipment damage. Consult your Vermeer dealer if you
do not understand the instructions in this manual, or need additional information.
The instructions, illustrations, and specifications in this manual are based on the latest information available at time of publication.
Your machine may have pro d u c t improvements and features not yet contained in this manual.
The maintenance intervals are based on normal operating conditions. When operating under severe conditions, the maintenance
intervals should be shortened.
To provide a better view, some photographs or illustrations in the maintenance sections may show the machine shields removed.
Never operate the machine with the shields removed - keep all shields in place. If removing a shield is necessary, return it
to its operating position before operating the machine.
Vermeer Corporation reserves the right to make changes at any time without notice or obligation.
This manual is supplied with each machine. Refer to it for all lubrication and maintenance procedures. Keep this manual with the
machine for ready reference. Store it in a protected location when not in use.
Additional copies of the manuals, and Operations and Safety video, are available from your dealer. Use the reorder numbers on the
front cover to order additional manuals.
Copies of this manual, and the Operations and Safety video, are available in Spanish from your dealer.
Su distribuidor dispone de ejemplares en español de este manual y del vídeo de Operaciones y Seguridad.
NOTICE TO OWNER
Replacement manuals are free of charge by registering your used Vermeer machine. Your machine’s Operator’s, Maintenance and
Parts Manuals may be available online at www.myvermeer.com. For questions about online or printed manuals, or to register a used
machine, contact the Customer Data Department by telephone: [phone] or 641-628-3141; email: [e-mail];
internet: www.vermeer.com or www.myvermeer.com; or, letter: Customer Data Dept., Vermeer Corporation, PO Box 200, Pella IA
50219 USA.

D60x90 Navigator HDD Maintenance
SERVICE
Service instructions are contained in a separate service manual. Service manuals can be obtained by contacting your Vermeer dealer.
If you are considering servicing the machine without the assistance of a Vermeer dealer, remember this is a complex machine which
often involves complex service procedures.
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 accurately and safely with proper tools and equipment. If you encounter a problem that you do not
understand or cannot solve, contact your Vermeer dealer.
TRADEMARKS
VERMEER, VERMEER Logo, and NAVIGATOR are trademarks of Vermeer Manufacturing Company.
JOHN DEERE is a trademark of Deere & Company.
CHEVRON and DELO are trademarks of Chevron Intellectual Property LLC.
MOBIL and DELVAC are trademarks of Exxon Mobil Corporation.
SHELL and ROTELLA are trademarks of Shell Trademark Management B.V.

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D60x90 Navigator HDD Maintenance Table of Contents i
Table of Contents
Safety Messages. . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Safety Symbol Explanation . . . . . . . . . . . . . . . . . . . . . . . . . .10-1
Welding Precautions . . . . . . . . . . . . . . . . . . . . . 11-1
Welding Alert - Electronic Components . . . . . . . . . . . . . . . . . 11-1
Shutdown Procedure . . . . . . . . . . . . . . . . . . . . . 12-1
Grease Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1
Maintenance - 10 Service Hours or Daily . . . . . 20-1
Machine - Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1
Machine Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1
Engine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1
Fluid Levels - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1
Fuel Tank - Fill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-2
Fuel/Water Separators - Check/Drain. . . . . . . . . . . . . . . 20-3
Hydraulic Fluid Level - Check . . . . . . . . . . . . . . . . . . . . . 20-4
Engine Crankcase Oil - Check/Fill . . . . . . . . . . . . . . . . . 20-4
Coolant Level - Check/Fill. . . . . . . . . . . . . . . . . . . . . . . . 20-5
Air Cleaner Restriction Indicator - Check. . . . . . . . . . . . . . . . 20-6
Air Intake Screen - Check/Clean . . . . . . . . . . . . . . . . . . 20-6
Dust Discharge Valve - Empty . . . . . . . . . . . . . . . . . . . . 20-7
Accumulator Pressure - Check . . . . . . . . . . . . . . . . . . . . . . . 20-7
Auto Greaser - Check/Refill . . . . . . . . . . . . . . . . . . . . . . . . . . 20-8
Piston Wash Water Tank - Drain/Clean/Refill . . . . . . . . . . . . 20-8
Rotation Gearbox Oil - Check . . . . . . . . . . . . . . . . . . . . . . . . 20-9
Drill Rod Care and Inspection . . . . . . . . . . . . . . . . . . . . . . . . 20-9
Water Swivel - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10
Greasing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10
Packing Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10
Vise Dies - Inspect/Clean . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10
Vises - Grease. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-11
Front Roller Guides - Grease . . . . . . . . . . . . . . . . . . . . . . . 20-11
Maintenance - 50 Service Hours or Weekly . . . 25-1
Rack Frame Pivot - Grease. . . . . . . . . . . . . . . . . . . . . . . . . . 25-1
Rack Frame Pivot Cylinders - Grease. . . . . . . . . . . . . . . . . . 25-1
Gearbox Slide - Grease. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-2
Rear Outriggers - Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-2
Drilling Fluid Pump Crankcase Oil Level - Check . . . . . . . . . 25-3
Track Planetary Gearbox Oil Level - Check . . . . . . . . . . . . . 25-3
Bolts - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-4
Maintenance - 100 Service Hours . . . . . . . . . . . 30-1
Engine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-1
Engine Oil and Filter - Initial Change/Replacement . . . . 30-1
Radiator and Oil Cooler - Clean . . . . . . . . . . . . . . . . . . . . . . 30-2
Battery Voltage - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-2
Safety Signs Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . 30-2
Overall Machine - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-3
Backup Alarm - Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-4
Hydraulic System - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-4
Hydraulic Enable - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-5
Operator Presence System - Check . . . . . . . . . . . . . . . . . . . 30-6

ii Table of Contents D60x90 Navigator HDD Maintenance
Neutral Start Interlock - Check . . . . . . . . . . . . . . . . . . . . . . . 30-7
Drilling Fluid System - Check . . . . . . . . . . . . . . . . . . . . . . . . 30-7
Ground Drive System - Inspect. . . . . . . . . . . . . . . . . . . . . . . 30-8
Track Tension - Check . . . . . . . . . . . . . . . . . . . . . . . . . . 30-8
Maintenance - 250 Service Hours . . . . . . . . . . . 35-1
Hydraulic Fluid Filters - Initial Replacement . . . . . . . . . . . . . 35-1
Hydraulic Fluid Flow Direction . . . . . . . . . . . . . . . . . . . . . 35-2
Maintenance - 500 Service Hours or Yearly . . . 40-1
Engine Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-1
Fuel Filters - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-2
Engine Oil and Filter - Change/Replace . . . . . . . . . . . . . 40-3
Battery Terminals - Check . . . . . . . . . . . . . . . . . . . . . . . . . . 40-4
Battery Terminals - Clean . . . . . . . . . . . . . . . . . . . . . . . . 40-5
Hydraulic Fluid Filters - Replace. . . . . . . . . . . . . . . . . . . . . . 40-6
Drilling Fluid Pump Crankcase - Initial Oil Change. . . . . . . . 40-6
Maintenance - 1000 Service Hours . . . . . . . . . . 45-1
Track Gearbox Oil - Change. . . . . . . . . . . . . . . . . . . . . . . . . 45-1
Hydraulic Fluid - Change . . . . . . . . . . . . . . . . . . . . . . . . . . . 45-2
Hydraulic Fluid - Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . 45-2
Strainer - Clean and Inspect . . . . . . . . . . . . . . . . . . . . . . 45-3
Tank - Fill. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45-3
Drilling Fluid Pump Crankcase Oil - Change . . . . . . . . . . . . 45-4
Maintenance - 3000 Service Hours . . . . . . . . . . 50-1
Engine Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-1
Cooling System - Drain and Clean . . . . . . . . . . . . . . . . . . . . 50-2
Cooling System - Refill . . . . . . . . . . . . . . . . . . . . . . . . . . 50-3
Maintenance - 4500 Hours . . . . . . . . . . . . . . . . . 55-1
Diesel Particulate Filter (DPF) - Forced Regeneration. . . . . .55-1
Maintenance As Required. . . . . . . . . . . . . . . . . . 60-1
Engine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-1
Engine Compartment - Clean . . . . . . . . . . . . . . . . . . . . . 60-1
Engine Cooling Compartment - Clean Out . . . . . . . . . . . 60-1
Battery - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-2
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-4
Behind Seat in Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-4
On Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-5
Air Cleaner Element - Replace. . . . . . . . . . . . . . . . . . . . . . . .60-6
Rack and Pinion - Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-7
Rod Guide Rollers - Replace . . . . . . . . . . . . . . . . . . . . . . . . .60-8
Vise Die Grips - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-8
Track Tension - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-9
Track Tension - Increase . . . . . . . . . . . . . . . . . . . . . . . . 60-9
Track Tension - Decrease. . . . . . . . . . . . . . . . . . . . . . . . 60-9
Gearbox Guides - Replace. . . . . . . . . . . . . . . . . . . . . . . . . .60-10
Gearbox Guides - Adjust. . . . . . . . . . . . . . . . . . . . . . . . 60-10
Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-11
Preparing for Storage . . . . . . . . . . . . . . . . . . . . . . . . . . 60-11
Removing from Storage . . . . . . . . . . . . . . . . . . . . . . . . 60-12
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . 70-1
Engine System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-1
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-1
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-2

D60x90 Navigator HDD Maintenance Table of Contents iii
Drilling Fluid System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-3
Strike Alert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-4
Remote Lockout System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-5
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-1
Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-1
Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-2
Machine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-3

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D60x90 Navigator HDD Maintenance Safety Messages 10-1
Section 10: Safety Messages
General safety messages appear in this Safety Messages section. Specific safety messages are located in
appropriate 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.
SAFETY SYMBOL EXPLANATION
DANGER Indicates a hazardous situation that, if not avoided, will result in death or serious injury.
WARNING Indicates a hazardous situation that, if not avoided, could result in death or serious injury.
CAUTION Indicates a hazardous situation that, if not avoided, could result in minor or moderate injury.
NOTICE Indicates information considered important, but not hazard-related.
This is the safety alert symbol. This symbol is used in combination with an exclamation mark or
other symbols to alert you to the potential for bodily injury or death.
WARNING: Read Operator’s Manual and safety signs, and watch the operations and safety
video, before operating machine.

10-2 Safety Messages D60x90 Navigator HDD Maintenance
WARNING: Wear personal protective equipment. Wear close-fitting clothing and confine
long hair. Always wear a hard hat, safety glasses, and safety shoes.
WARNING: Keep spectators away.
WARNING: Exhaust fumes can be fatal.
If operating in an enclosed area, remove exhaust fumes with an exhaust pipe extension to
the outside.
DANGER: Rotating drill string or cutters can kill.
Stay away from rotating drill rod and cutting tool.

D60x90 Navigator HDD Maintenance Safety Messages 10-3
DANGER: Rotating drill string can kill. Unexpected start-up possible.
Lock out before working on drill string.
WARNING: Keep hands, feet, and clothing away from power-driven parts. Keep shields
in place and properly secured.
WARNING: Use Shutdown Procedure before servicing, cleaning, repairing or
transporting machine. Follow Shutdown Procedure, page 12-1.
WARNING: Make no modifications to this equipment unless specifically recommended by Vermeer
Corporation.
WARNING: Be sure that all safety devices, including shields, are installed and functioning properly
after servicing the machine.

10-4 Safety Messages D60x90 Navigator HDD Maintenance
WARNING: When HEST (High Exhaust System Temperature) Light is displayed, the
exhaust gas temperature could exceed 1100°F (600°C) during regeneration. High
temperature may cause in fire, burn, or explosion hazards, which may result in personal
injury or death. Do not expose flammable material or explosive atmospheres to exhaust
gas or to exhaust system components during regeneration.
WARNING: To prevent fires, routinely clear any combustible material from the engine
exhaust system. Tier 4 Interim / Stage IIIB emission compliant exhaust systems use
extreme high temperature that can ignite combustible material.
WARNING: Servicing machine during DPF regeneration can result in serious personal
injury. Avoid exposure and skin contact with hot exhaust gases and hot exhaust system
components.
WARNING: If regeneration is performed within any indoor service/maintenance facility, ensure the
exhaust removal system is capable of withstanding temperatures exceeding 1100°F (600°C).
WARNING: Failure to follow any of the preceding safety instructions or those that follow within this manual,
could result in serious injury or death. This machine is to be used only for those purposes for which it was
intended as explained in the Operator’s Manual.

D60x90 Navigator HDD Maintenance Welding Precautions 11-1
Section 11: Welding Precautions
WELDING ALERT - ELECTRONIC COMPONENTS
NOTICE: Electronic modules and controllers will be damaged from
stray voltages and currents generated during welding if not
unplugged before welding.
To prevent extensive and costly damage to the electrical
components:
Step 1: Turn Battery Disconnect Switch (1) to DISCONNECT.
NOTICE: Disconnecting the battery ground with the battery
disconnect switch will not prevent damage to the electronic
components during welding. Each of the modules must have the
electrical connector unplugged from the module.
Step 2: Unplug Strike Alert (2) and pump controller (POM) modules (3).
Step 3: Unplug three engine ECUs (4).
2
1
3
4

11-2 Welding Precautions D60x90 Navigator HDD Maintenance
Step 4: Under the seat, unplug three connectors, to the cab controller (5), the
Remote Lockout (RLC) module (6) and the DCIM module (7).
In cab machine, access through foot panel in front of operator seat; in non-
cab machine, tip seat forward and lift panel.
Step 5: Unplug carriage controller (CCU) (8), rack controller (ROM) (9), and vise controller (VOM) (10).
5
6
7
8
9
10

D60x90 Navigator HDD Maintenance Shutdown Procedure 12-1
Section 12: Shutdown Procedure
Step 1: Shut off drilling fluid pump.
Step 2: Reduce engine speed to idle.
Step 3: Wait 2 minutes to shut off engine when shutting down after operating at full power.
Step 4: Shut off engine and remove key.
For your safety and the safety of others, use the 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 Lockout Procedure
- With Remote Lockout or the Lockout Procedure - Without Remote Lockout System in the Overview Section of the
Operator’s Manual.
A variation of the above procedure may be used if instructed within this manual or if an emergency requires it.

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D60x90 Navigator HDD Maintenance Grease Chart 15-1
Section 15: Grease Chart
50h
10h
2
4
700IF752 Rev A
24
50h
10h
1
1
92
4
2
5
2
Outriggers
Gearbox slide
Rack pivot cylinder
Rack pivot
Vises
Roller
guides

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D60x90 Navigator HDD Maintenance 10 Service Hours or Daily 20-1
Section 20: Maintenance - 10 Service Hours or Daily
MACHINE - GREASE
As a general rule, grease machine after it is shut down for the day. This protects the metal under the seals from
corrosion caused by condensation as the temperature drops.
Ensure all fittings and grease applicator nozzle are clean before applying grease. If any grease fittings are
missing, replace them immediately.
MACHINE INSPECTION
•Inspectmachinedailyandcheckforleaksbeforestarting.
•Ifstabilizerorrackhydrauliccylindersdrift,contactyourVermeerdealerforrepair.
•Checkvisediesdailyandremoveaccumulated debris or dirt. Clean with a wire brush.
ENGINE MAINTENANCE
Visually inspect engine daily and make any necessary adjustments and repairs before starting.
Refer to the Engine Operation Manual supplied with each machine for complete instructions.
FLUID LEVELS - CHECK
Check fluid levels daily before operating the machine. Refer to the Engine Operation Manual.

20-2 10 Service Hours or Daily D60x90 Navigator HDD Maintenance
Fuel Tank - Fill
Fill tank before raising rack.
Fill fuel tank at the end of each day to prevent condensation. Do not fill to the very
top, leave room for expansion.
(1) Fill Cap
(2) Fuel Gauge
To meet government emission requirements use diesel fuel with a low or ultra low
sulfur content, less than 15 ppm or 0.0015% (15 mg/kg).
NOTICE: Use of higher content sulfur fuel will cause engine damage and void engine warranty.
WARNING: Fuel and fumes can explode and burn.
Shut off engine before refueling. No flame. No smoking.
1
2
2
15 mg/kg
S