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.