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D20x22 Series IINavigator® Horizontal Directional Drill

D20x22_Series_ii_m2_01Serial No. 1001 -Order No. 105400CD5

Maintenance Manual

D20x22 Series II HDD Maintenance

IntroductionThis 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 product 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. Reorder numbers are listed on the front covers of the manuals and on the video..

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

You are requested to notify Vermeer Corporation when you have purchased a used Vermeer machine. Notify the Customer Data Department by telephone: 800-829-0051 or 641-628-3141; email: [email protected]; internet: www.vermeer.com or www.vermeerag.com; or letter: Customer Data Dept., Vermeer Corporation, PO Box 200, Pella IA 50219 USA. Upon request, an owner of a used Vermeer machine will receive one free set of Operator’s, Maintenance and Parts manuals.


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, NAVIGATOR and BIOSTICK are trademarks of Vermeer Manufacturing Company.MERCON is a trademark of Ford Motor Company.DEXRON is a trademark of General Motors Corporation.KUBOTA is a trademark of Kubota, Ltd.FLEETGUARD is a trademark of Fleetguard, Inc.

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D20x22 Series II HDD Maintenance Table of Contents i

Table of ContentsSafety Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

Safety Symbol Explanation . . . . . . . . . . . . . . . . . . . . . . . . . .10-1

Shutdown Procedure . . . . . . . . . . . . . . . . . . . . . . . . . 11-1

Welding Precautions . . . . . . . . . . . . . . . . . . . . . . . . . 12-1Welding Alert - Electronic Components . . . . . . . . . . . . . . . .12-1

Maintenance - 10 Service Hours or Daily . . . . . . . . . 20-1Machine - Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-1Engine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-1Fluid Levels - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-1

Engine Oil Level - Check . . . . . . . . . . . . . . . . . . . . . . . . 20-1Hydraulic Fluid Level - Check . . . . . . . . . . . . . . . . . . . . . 20-2Coolant Level - Check . . . . . . . . . . . . . . . . . . . . . . . . . . 20-3Fuel Tank - Fill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-4

Air Cleaner Restriction Indicator - Check . . . . . . . . . . . . . . .20-5Drill Rod Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-5Auto Greaser - Adjust/Check/Refill . . . . . . . . . . . . . . . . . . . .20-6R.A.T.T. Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-7

Tool - Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-7Rotation Sensor Phase - Verify . . . . . . . . . . . . . . . . . . . 20-8

Maintenance - 50 Service Hours or Weekly . . . . . . . 25-1Fuel/Water Separator - Drain . . . . . . . . . . . . . . . . . . . . . . . .25-1Engine Oil and Filter - Initial Change . . . . . . . . . . . . . . . . . .25-1Control Levers Linkage - Oil . . . . . . . . . . . . . . . . . . . . . . . . .25-2Track Gearbox Oil Level - Check . . . . . . . . . . . . . . . . . . . . .25-2

Drilling Fluid Pump Crankcase Oil Level - Check . . . . . . . . . 25-3Rotation Gearbox Oil - Check . . . . . . . . . . . . . . . . . . . . . . . 25-3Power Vise - Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-4

Maintenance - 100 Service Hours . . . . . . . . . . . . . . . 30-1Cooling System - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-1Drilling Fluid System - Check . . . . . . . . . . . . . . . . . . . . . . . . 30-1Drilling Fluid Pump Oil - Initial Change . . . . . . . . . . . . . . . . . 30-1Control Levers - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-1Overall Machine - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-2Safety Signs Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 30-2Indicator Lights - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-3Emergency Stop Switch - Check . . . . . . . . . . . . . . . . . . . . . 30-3Neutral Start Interlock - Check . . . . . . . . . . . . . . . . . . . . . . . 30-3Operator Presence System - Check . . . . . . . . . . . . . . . . . . . 30-4Hydraulic System - Check . . . . . . . . . . . . . . . . . . . . . . . . . . 30-5Ground Drive System - Inspect . . . . . . . . . . . . . . . . . . . . . . 30-6

Track Chain Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-6

Maintenance - 250 Service Hours . . . . . . . . . . . . . . . 35-1Engine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-1Cooling System Additive - Add . . . . . . . . . . . . . . . . . . . . . . . 35-1Hydraulic Fluid Filter - Initial Replacement . . . . . . . . . . . . . . 35-2R,A.T.T. Tool Oil - Change . . . . . . . . . . . . . . . . . . . . . . . . . . 35-2

Maintenance - 500 Service Hours . . . . . . . . . . . . . . . 40-1Engine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-1Fuel Tank - Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-1

ii Table of Contents D20x22 Series II HDD Maintenance

Fuel Filters - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-2Engine Oil and Filter - Change . . . . . . . . . . . . . . . . . . . . . . 40-3Battery Electrolyte Level and Terminals - Check/Clean . . . 40-4

Battery Terminals - Clean/Check Electrolyte Level . . . . . 40-5Ground Drive Speed - Check . . . . . . . . . . . . . . . . . . . . . . . . 40-6Park Brake - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-6Hydraulic Fluid Filter - Replace . . . . . . . . . . . . . . . . . . . . . . 40-7

Hydraulic Fluid Flow Direction . . . . . . . . . . . . . . . . . . . . . 40-8Drilling Fluid Pump Oil - Change . . . . . . . . . . . . . . . . . . . . . 40-8

Maintenance - 1000 Service Hours . . . . . . . . . . . . . . .45-1Engine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45-1Planetary Gearbox Oil - Change . . . . . . . . . . . . . . . . . . . . . 45-1Cooling System - Drain and Clean . . . . . . . . . . . . . . . . . . . 45-2

Cooling System - Refill . . . . . . . . . . . . . . . . . . . . . . . . . . 45-3Hydraulic Fluid - Change . . . . . . . . . . . . . . . . . . . . . . . . . . . 45-4

Hydraulic Fluid - Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . 45-4Strainer - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45-4Strainer - Clean and Inspect . . . . . . . . . . . . . . . . . . . . . . 45-5Strainer - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45-5Tank - Fill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45-5

Additional Periodic Maintenance . . . . . . . . . . . . . . . .46-1Engine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46-1

2000 Service Hours or Yearly . . . . . . . . . . . . . . . . . . . . . 46-12000 Service Hours or 2 Years . . . . . . . . . . . . . . . . . . . . 46-13000 Service Hours or 2 Years . . . . . . . . . . . . . . . . . . . . 46-16000 Service Hours or 6 Years . . . . . . . . . . . . . . . . . . . . 46-1

Maintenance As Required . . . . . . . . . . . . . . . . . . . . . .50-1

Engine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-1Engine Compartment - Clean . . . . . . . . . . . . . . . . . . . . . . . .50-1Battery - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-1Air Cleaner Elements - Replace . . . . . . . . . . . . . . . . . . . . . .50-3Track Tension - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-4Rod Guide Plate - Replace . . . . . . . . . . . . . . . . . . . . . . . . . .50-5Vise Dies - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-6

Front Vise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-6Rear Vise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-7

Stakedown Drivers - Remove/Install . . . . . . . . . . . . . . . . . . .50-9Rotation Sensor Phase - Adjust . . . . . . . . . . . . . . . . . . . . .50-10Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-12

Preparing for Storage . . . . . . . . . . . . . . . . . . . . . . . . . . 50-12Removing from Storage . . . . . . . . . . . . . . . . . . . . . . . . 50-12

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-1Engine System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-1Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-1Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-2Drilling Fluid System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-3Strike Alert System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-4Remote Lockout System . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-5

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65-1Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65-1Machine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65-3

D20x22 Series II HDD Maintenance Safety Messages 10-1

Section 10: Safety MessagesGeneral 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.

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 D20x22 Series II 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.

D20x22 Series II HDD Maintenance Safety Messages 10-3

WARNING: 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. Refer to page 11-1.

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 D20x22 Series II HDD Maintenance

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.

D20x22 Series II HDD Maintenance Shutdown Procedure 11-1

Section 11: Shutdown ProcedureStep 1: Shut off drilling fluid pump.

Step 2: Reduce engine speed to idle.

Step 3: Wait two 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 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 “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.

D20x22 Series II HDD Maintenance Welding Precautions 12-1

Section 12: Welding PrecautionsWELDING 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 controller (2).

Step 3: Unplug Remote Lockout (RLO) module (3) (in compartment to the left of seat), Strike Alert module (4) and DP10 display (5) (in right hand control panel).

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12-2 Welding Precautions D20x22 Series II HDD Maintenance

Step 4: Unplug Tethered Transport Control (6).

Step 5: Tier 4 Interim/Stage IIIB engine: unplug engine ECU (7), located on left side of engine.

Step 6: Connect welding ground as close to work as possible.

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D20x22 Series II HDD Maintenance 10 Service Hours or Daily 20-1

Section 20: Maintenance - 10 Service Hours or DailyMACHINE - 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.

ENGINE MAINTENANCE• Check fluid levels.

• Check air cleaner indicator.

• Perform walk-around inspection.

Refer to the Engine Operation Manual supplied with the machine for engine maintenance information.

FLUID LEVELS - CHECKCheck fluid levels daily before operating the machine. Also, inspect machine and make any necessary adjustments and repairs before starting the engine. Refer to the Engine Operation Manual.

Engine Oil Level - CheckWith engine level, fill to full mark on dipstick. Do not overfill.

(1) Oil Fill Cap

(2) Oil Dipstick1

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20-2 10 Service Hours or Daily D20x22 Series II HDD Maintenance

Hydraulic Fluid Level - CheckClean hydraulic fluid is very important. Do not spill dirt or other contaminants into the tank. Filter all hydraulic fluid through a 5-micron filter before adding it to the tank.

Keep tank filled to sight gauge level. Machine must be level and in transport position. Refer to “Lubricants,” page 65-1.

Step 1: Remove fill cap (1).

Step 2: Fill to upper half of sight gauge level (2).

Step 3: Install fill cap.

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Coolant Level - Check

Fill to within 1/2˝ (13 mm) of bottom of fill pipe with a low-silicate (ethylene glycol) antifreeze and clean water mixture.

NOTICE: Never add pure antifreeze to a cooling system. We recommend using a 50/50 mixture. Never use high-silicate antifreeze or antifreeze that is higher than a 60/40 mixture.

(1) Fill Cap

(2) Overflow Bottle

WARNING: Hot fluid under pressure can scald.

Allow engine to cool before opening radiator cap.

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Fuel Tank - Fill

Fill fuel tank at the end of each day to reduce condensation. Do not fill to the very top; leave room for expansion.

Fuel Capacity: 25 gal (95 L)

Refer to the Engine Operation Manual for engine service requirements.

(1) Fill Cap

(2) Fuel Level (on display)

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.

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15 mg/kgS

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AIR CLEANER RESTRICTION INDICATOR - CHECKWhen yellow indicator reaches the red area on indicator (1), replace air cleaner filter element. Push button (2) to reset indicator.

• Do not remove element until the indicator shows it needs to be replaced.

• Do not wash or blow out element; it must be replaced.

NOTICE: The air restriction indicator will not function properly if:

• Element is damaged or not seated properly in housing.

• Air cleaner element body is damaged. If so, unfiltered air may be entering engine.

• Air transfer duct between air cleaner and engine is damaged or its clamps are loose.

• Air duct between air cleaner and restriction indicator is damaged or pinched.

DRILL ROD CAREInspect drill rod before and during each use.

• Remove any rod from drill string with damaged or worn ends.

• Remove any bent rod from drill string.

• Use proper thread or profile gauge to check for damaged thread.

• After rods are coupled together, check for fluid leakage at the joint.

• Leaking drill rod joints indicate damaged shoulders, which will not torque properly.

• Check shoulders for dents, gouges, or high spots.

• Dress damaged shoulders with a file.

Do not exceed bend radius of the drill rod. Doing so will cause premature failure of the drill rod.

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AUTO GREASER - ADJUST/CHECK/REFILLCheck the level of grease each day at start-up. Refill as needed.

• To refill, release latches (1) to lift pump and hoses and replace bucket.

• To fill and prime, use power greaser at fitting (2).

• To adjust amount of grease dispensed, remove plug (3) at top of tube with Allen wrench to remove top cap and turn screw:

clockwise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . increase grease

counterclockwise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .decrease grease

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R.A.T.T. TOOLTool - Oil

Oil tool daily or after every bore. Use DEXRON III or MERCON automatic transmission fluid.

Step 1: Elevate fill vent plug (1) end of tool at a minimum angle of 10°.

Step 2: Remove vent plug and fill cap (2).

Step 3: Use oil gun (3) provided to fill tool. The attached pressure gauge will read around 50 psi (3.5 bar).

Step 4: As soon as the ATF flows out of the vent hole, install plug (1).

Step 5: Continue to fill the tool until the gauge reads approximately 70 psi (4.8 bar). Replace fill cap.

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.

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Rotation Sensor Phase - Verify

Verify Rotation Sensor Phase is calibrated correctly.

Step 1: Press Service Screen Key (1).

Step 2: Use Increase/Decrease Keys to scroll to “RCKCAL”.

Step 3: Move Rotation Handle out of NEUTRAL.

Display (2) should read a positive 85–90°.

Refer to “Rotation Sensor Phase - Adjust,” page 50-10.

VISES - INSPECT/CLEANInspect vise dies and remove debris with a wire brush.

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D20x22 Series II HDD Maintenance 50 Service Hours or Weekly 25-1

Section 25: Maintenance - 50 Service Hours or WeeklyFUEL/WATER SEPARATOR - DRAIN

Tier 4/Stage IIIB engine only

Refer to the Engine Operation Manual supplied with each machine for instructions.

Drain fuel/water separator (1) weekly.

Do not spill fuel. Catch expelled fuel in an appropriate container.

ENGINE OIL AND FILTER - INITIAL CHANGEChange engine oil and replace filter after the first 50 service hours, and then every 500 service hours.

Refer to “Engine Oil and Filter - Change,” page 40-3.

WARNING: Fuel and fumes can catch fire or explode, resulting in serious burns or death.

Shut off engine before refueling. Never work around fuel while smoking or near an open flame.

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25-2 50 Service Hours or Weekly D20x22 Series II HDD Maintenance

CONTROL LEVERS LINKAGE - OIL(1) Control Levers Linkage

Apply a light coating of oil on linkage attachment points.

TRACK GEARBOX OIL LEVEL - CHECKOil requirements are listed in the Specifications section “Lubricants.” Refer to page 65-1.

Check oil level with plug at 3:00 or 9:00 position. Fill to check plug level.

(1) Fill/Check Plug

(2) Drain Plug

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D20x22 Series II HDD Maintenance 50 Service Hours or Weekly 25-3

DRILLING FLUID PUMP CRANKCASE OIL LEVEL - CHECK(1) Fill/Check Plug

Maintain fill/check plug level. Refer to “Lubricants,” page 65-1.

ROTATION GEARBOX OIL - CHECK

Check oil level in rotation gearbox at check plug (1).

Remove six bolts (2) and top shield (3) and fill gearbox with lube oil until oil seeps out of check plug.

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25-4 50 Service Hours or Weekly D20x22 Series II HDD Maintenance

POWER VISE - GREASE(1) Clamping Cylinders

Two shots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . four fittings

(2) Guide Bushing

Two shots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . one fitting

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D20x22 Series II HDD Maintenance 100 Service Hours 30-1

Section 30: Maintenance - 100 Service HoursCOOLING SYSTEM - CHECK

• Inspect hose clamps and overflow tube.

• Check for dirt and debris in radiator fins. Clean fins with water or air pressure. Partially blocked fins will increase engine coolant and/or hydraulic oil operating temperature.

• Check fan for cracks, loose rivets, and bent or loose blades.

DRILLING FLUID SYSTEM - CHECKCheck drilling fluid system for leaks, kinked or collapsed hoses, and hoses or other parts that rub against each other.

DRILLING FLUID PUMP OIL - INITIAL CHANGEChange oil after the first 100 service hours and every 500 hours thereafter. Refer to “Drilling Fluid Pump Oil - Change,” page 40-8.

CONTROL LEVERS - CHECKCheck control levers for freedom of movement.

Check that levers spring-return to NEUTRAL.

30-2 100 Service Hours D20x22 Series II HDD Maintenance

OVERALL MACHINE - CHECKShields and Guards – Check that all shields and guards are installed and are fastened securely to machine. Replace and repair any shields or guards that are damaged or have missing parts.

Hardware – Check machine for loose, worn, or missing parts and hardware. Tighten any loose parts and replace any worn or missing parts. Refer to the Parts Manual for replacement parts.

Frame – Check machine frame and contact Vermeer dealer immediately if you notice any bending or cracking.

Fire Prevention – Keep engine compartment, battery, hydraulic lines, fuel tank and operator’s station clean of accumulated trash, grease, and debris.

Electrical Harness – Check that electrical harness and all wires are properly supported and not rubbing on any sharp corners. Support any loose wires hanging under machine frame.

SAFETY SIGNS MAINTENANCESafety signs located on your machine contain important and useful information that will help you operate your equipment safely and correctly. Refer to the Parts Manual for identification and location of safety signs.

To assure that all safety signs remain in place and in good condition, follow the instructions given below:

• Keep safety signs clean. Use soap and water - not mineral spirits, abrasive cleaners, or other similar cleaners that will damage the sign.

• Replace any damaged or missing safety signs. When attaching safety signs, the temperature of the mounting surface must be at least 40°F (5°C). The mounting surface must be clean and dry.

• When replacing a machine component with a safety sign attached, replace the safety sign also.

Replacement safety signs can be purchased from your Vermeer equipment dealer.


INDICATOR LIGHTS - CHECKCheck indicator light operation. Turn key counterclockwise to test bulbs. All indicator cluster lights should light. If any bulbs do not light, check bulb and replace if necessary.

EMERGENCY STOP SWITCH - CHECKPress red Emergency Stop Button while engine is running. Engine must stop.

With red button depressed, try starting engine. Engine must not start.

NEUTRAL START INTERLOCK - CHECKStep 1: Move and hold Thrust Control Handle out of NEUTRAL position.

Step 2: Attempt to start the engine. Engine must not start. Display will instruct operator to return handle to NEUTRAL.

Step 3: Return handle to NEUTRAL.

Step 4: Move and hold Rotation Control Handle out of NEUTRAL position.

Step 5: Attempt to start the engine. Engine must not start. Display will instruct operator to return handle to NEUTRAL.

Step 6: Return handle to NEUTRAL.

Step 7: Increase engine speed to full RPM. Rotation, thrust and ground drive must not move with controls in NEUTRAL and engine at full RPM with operator seated at the controls.


OPERATOR PRESENCE SYSTEM - CHECKThe machine is equipped with an Operator Presence system. The rod thrust and rotation drive will not function if operator is not seated at the controls. This system is intended for operator safety and must be maintained in good functional condition.

Step 1: Sit in operator’s seat and start engine.

Step 2: Press and hold Run Button on remote lockout transmitter for two seconds to enter remote lockout RUN mode.

Step 3: Push Thrust Control Handle forward. The gearbox should move forward.

Step 4: While gearbox is moving, partially stand to remove your weight from the seat. The gearbox must stop moving.

Step 5: While still holding Thrust Control Handle in FORWARD, sit in operator’s seat. The gearbox must not resume motion.

Step 6: Return Thrust Control Handle to NEUTRAL.

Step 7: Push Rotation Control Handle forward to rotate drill rod.

Step 8: While rod is rotating, partially stand to remove your weight from the seat. Rod rotation must stop.

Step 9: While still holding Rotation Control Handle in FORWARD, sit in operator’s seat. The rod rotation must not resume motion.

Step 10: With operator in seat, have an assistant move Propel Handles out of NEUTRAL. The tracks must not move.

NOTICE: Contact a Vermeer dealer if Operator Presence system does not work properly.


HYDRAULIC SYSTEM - CHECK

• Ensure all connections are tight and hoses are in good condition before applying pressure to the system.• Check hydraulic cylinders for leaks and damage. Repair or replace as required.• Examine condition of hoses. Check for leaking hoses, kinked hoses, and for hoses that rub against each

other or other parts of the machine.• Replace all deteriorated or damaged hoses. When a hose with a protective sleeve is replaced, always

install a protective sleeve over the new hose.

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.


GROUND DRIVE SYSTEM - INSPECTCheck condition of wear plates. Replace if missing or if thickness is less than 1/16˝ (1.6 mm).

(1) Upper Track Wear PlatesTwo on each side

(2) Track Drive RollersFour rollers on each side—located on inside of shield (3) at bolts (4). Replace rollers if broken or excessively worn.

Track Chain Tension Refer to “Track Tension - Adjust,” page 50-4.

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Section 35: Maintenance - 250 Service HoursENGINE MAINTENANCE

Obtain engine oil sample.


COOLING SYSTEM ADDITIVE - ADD

Add 6.5 oz (192 ml) of Fleetguard DCA4 to cooling system to restore corrosion inhibitors.




HYDRAULIC FLUID FILTER - INITIAL REPLACEMENTReplace hydraulic filter (1):

• after the first 250 hours; every 500 service hours thereafter• each time hydraulic fluid is changedRefer to “Hydraulic Fluid Filter - Replace,” page 40-7.

R.A.T.T. TOOL OIL - CHANGEStep 1: Elevate fill vent plug (2) end of tool at a minimum angle of 10°.

Step 2: Remove vent plug and fill cap (1) and drain oil.

Step 3: Use oil gun provided to fill tool. The attached pressure gauge will read around 50 psi (3.5 bar).

Step 4: As soon as the ATF flows out of the vent hole, install plug (2).

Step 5: Continue to fill the tool until the gauge reads approximately 70 psi (4.8 bar). Replace fill cap.

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• Check/adjust/replace alternator and fan belts.

• Check engine protective devices.

• Clean fuel transfer pump strainer.

• Check/replace hoses and clamps.


FUEL TANK - DRAINDrain fuel tank water and sediment at fitting (1).


1


FUEL FILTERS - REPLACERefer to the Engine Operation Manual supplied with each machine for instructions.

(1) Fuel Filter

(2) Fuel Filter with Fuel/Water Separator

(3) Secondary Fuel Filter (on left side of engine)

WARNING: Fuel and fumes can explode and burn.

Shut off engine before refueling. No flame. No smoking. Clean up any spilled fuel.

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Tier 3/Stage IIIA engine

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3

Tier 4/Stage IIIB engine


ENGINE OIL AND FILTER - CHANGE

Refer to the Engine Operation Manual supplied with each machine for instructions.

(1) Drain Plug

(2) Engine Oil Filter (on left side of engine)

(3) Dipstick

(4) Oil Fill Cap

NOTICE: After refilling oil, force oil into all vital parts of the engine by turning engine over for 15 seconds without allowing engine to start.

Step 1: To prevent starting, disconnect wire to fuel shutoff solenoid (5).

Step 2: Crank engine for 15 seconds.

Step 3: After correct oil pressure is reached, stop cranking and connect wire to fuel shutoff solenoid.

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BATTERY ELECTROLYTE LEVEL AND TERMINALS - CHECK/CLEAN

• Use a flashlight to check electrolyte level.

• Work in a well-ventilated area.

• Avoid breathing fumes from battery.

• Avoid contact with skin, eyes, or clothing.

• Keep flame and sparks away, and do not smoke.

• Keep out of reach of children.

• Do not short across battery terminals or allow tools to short from battery terminals to frame.

• Do not jump-start or charge a battery with frozen electrolyte.

In case of acid contact:

External: Flush with plenty of water. If eyes have been exposed, flush with water for 15 minutes and get prompt medical attention.

Internal: Drink large quantities of water or milk, follow with milk of magnesia, beaten egg, or vegetable oil. Call a physician immediately.

WARNING: Battery fumes are flammable and can explode. Keep all burning materials away from battery. Battery explosion can blind. Acid can blind and burn. Tools and cable clamps can make sparks.

Do not smoke. Shield eyes and face. Read instructions.


Battery Terminals - Clean/Check Electrolyte Level

Step 1: Disconnect battery using Battery Disconnect Switch (1).

Step 2: Remove bolts and battery access shield (2).

Step 3: Remove negative (-) cable (3), then positive (+) cable (4).

Step 4: Clean terminals and clamps with a stiff wire brush. Apply a light coating of petroleum jelly around the base of each terminal.

Step 5: If equipped, remove cell caps. Fill each cell with distilled water (never add acid) so the top of the plates are covered.

WARNING: Battery posts, terminals, and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm.

Wash hands after handling.

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NOTICE: If battery is underfilled, electrolyte will be too concentrated, causing plates to deteriorate more rapidly. Do not overfill. In freezing weather, run engine for a few minutes immediately after filling battery, to allow proper mixing of water and electrolyte. If battery uses too much water, check system for overcharging.

Step 6: Install cell caps.

Step 7: Spray terminals with a battery terminal sealer and install cables.

Step 8: Install access shield and bolts.

Step 9: Connect battery using Battery Disconnect Switch.

GROUND DRIVE SPEED - CHECKCheck that reverse speed does not exceed 132 ft/min (40.2 m/min). Contact your Vermeer dealer for assistance to correct the problem.

PARK BRAKE - CHECKPark machine on at least a 15 percent incline. With the engine off and the propel levers in neutral, the machine must not move. Contact your Vermeer dealer for assistance to correct the problem.


HYDRAULIC FLUID FILTER - REPLACEReplace hydraulic fluid filter (1):

• after initial 250 hours service and every 500 service hours thereafter

• each time hydraulic fluid is changed

Step 1: Follow Shutdown Procedure, page11-1.

Step 2: Thoroughly clean area around filter to keep contaminants out of hydraulic system.

Step 3: Use a filter wrench to turn filter body counterclockwise to remove filter.

Step 4: Carefully clean and inspect mating surfaces of filter head. Look for cracks or pitting in filter head. If needed, replace filter head. Refer to “Hydraulic Fluid Flow Direction,” page 40-8.

Step 5: Apply a thin film of oil to gasket of new filter.

Step 6: Thread filter to filter head and tighten it by hand until snug.

Step 7: Use a filter wrench to tighten filter an additional 1/10 turn. Do not overtighten.

Step 8: Start engine and allow it to idle for 1 minute.

Step 9: After one minute, move machine. Shut down and check hydraulic fluid level. Check for leaks around filter.

If leaks are found, tighten filters only enough to stop the leak.

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Hydraulic Fluid Flow DirectionWhen replacing a filter head, note that IN (1) and OUT (2) are stamped above the ports, with an arrow to indicate direction of flow through the filter head.

The filter head has a built-in relief, which will open and bypass the filter element if hydraulic fluid is cold or if filter is dirty or clogged.

If filter head is installed backwards, the relief will not function; and cold fluid or a clogged filter can damage hydraulic system.

DRILLING FLUID PUMP OIL - CHANGE(1) Drain Plug (not visible)

(2) Fill/Check Plug

Maintain fill/check plug level. Refer to “Lubricants,” page 65-1.

If oil appears milky, contact your Vermeer dealer. Water may be seeping past plunger rod seals.

Totank

Fromvalve

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• Check/adjust engine valve lash.


PLANETARY GEARBOX OIL - CHANGEEnsure drain plug is on bottom when draining oil.

Oil requirements are listed in the Specifications section. Refer to “Lubricants,” page 65-1.

Fill to check plug level with plug at 3:00 or 9:00 position.

(1) Fill/Check

(2) Drain Plug1

2


COOLING SYSTEM - DRAIN AND CLEAN

Step 1: Follow Shutdown Procedure, page11-1. Allow system to cool, then remove radiator cap.

Step 2: Drain old coolant from system by opening petcock (1) on radiator. The system holds approximately 21.4 qt (20.3 L).

Step 3: Close petcock.Step 4: Fill radiator with clean water. Check for signs of rust and add a cooling

system cleaner to water if necessary.Step 5: Install radiator cap. Run engine long enough to ensure thermostat has

opened, allowing engine and radiator to receive fresh water. Step 6: Shut off engine. Allow system to cool, then remove radiator cap and open

petcock to drain water.



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Cooling System - RefillStep 1: Close petcock. Use 2.9 gal (11 L) each of low-silicate ethylene glycol antifreeze and clean water to

prepare a 50/50 water/antifreeze mixture. Add most but not all of mixture to radiator. Do not fill it completely.

Step 2: Run engine until mixture has circulated through system.

Step 3: Add 14 oz (414 ml) of Fleetguard DCA4. Finish filling radiator with 50/50 water/antifreeze mixture. Install radiator cap.

Step 4: Check radiator after engine has cooled overnight. As air works out of system, you may need to add more water/antifreeze mixture to keep radiator full. Continue checking before starting each day until radiator remains full.


HYDRAULIC FLUID - CHANGE

Hydraulic Fluid - DrainNOTICE: If fluid smells burnt, contains air bubbles, or appears contaminated, contact your Vermeer dealer immediately.

Step 1: Run engine until hydraulic fluid is warm.

Step 2: Follow Shutdown Procedure, page11-1.

Step 3: Remove fill cap (1).

Step 4: Remove drain plug (2) from bottom of hydraulic tank and drain fluid into a suitable container, 40 gal (151 L) capacity minimum.

Step 5: Clean, inspect, and install drain plug.

Step 6: Replace hydraulic filter. Refer to “Hydraulic Fluid Filter - Replace,” page 40-7.

Strainer - RemoveStep 1: Disconnect hoses and drain any oil into a suitable container.

Step 2: Remove fitting at location (3) and remove strainer from inside of tank.

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Strainer - Clean and InspectClean strainer with a petroleum-based paint thinner or other good cleaning solvent. Scrub strainer with a soft-bristled brush.

Inspect strainer; contact your Vermeer dealer if you find any of the following:

• lacquers which may have formed as a result of hot spots in the hydraulic system

• an extremely dirty strainer that will not come clean

• metallic particles on the screen mesh

• any evidence of hydraulic system failure

• any evidence of holes or other damage that would allow unfiltered oil to circulate in the hydraulic system

Strainer - InstallStep 1: Apply a suitable thread sealant to strainer and fitting threads.

Step 2: Install strainers and fittings.

Step 3: Connect and tighten hoses.

Tank - FillStep 4: Fill hydraulic fluid tank. Refer to “Lubricants,” page 65-1.

Step 5: Install and tighten fill cap.

Step 6: Start engine, and operate the hydraulic system.

Step 7: Check hydraulic fluid level. The fluid level must be within the upper half of sight gauge (4).

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D20x22 Series II HDD Maintenance Additional Periodic Maintenance 46-1

Section 46: Additional Periodic MaintenanceENGINE MAINTENANCE


2000 Service Hours or Yearly• Inspect alternator.• Inspect crankshaft vibration damper.• Inspect engine mounts.• Test/exchange fuel injection nozzles.

2000 Service Hours or 2 Years• Add cooling system coolant extender (ELC).

3000 Service Hours or 2 Years• Change cooling system coolant (DEAC).• Replace cooling system coolant temperature regulator.• Inspect starting motor.• Inspect water pump.

6000 Service Hours or 6 Years• Change cooling system coolant (ELC).

D20x22 Series II HDD Maintenance Maintenance As Required 50-1

Section 50: Maintenance As RequiredENGINE MAINTENANCE

• Clean engine crankcase breather.

• Prime fuel system.


ENGINE COMPARTMENT - CLEANInspect and clean engine compartment frequently to prevent engine compartment fires. Always clean up spilled fuels and lubricants, including any debris that is fuel or oil contaminated. Use appropriate methods to dispose of contaminated materials.

BATTERY - REPLACEReplacement batteries must meet standard battery specifications provided in “Machine Specifications.” Refer to page 65-3.

WARNING: Battery fumes are flammable and can explode. Keep all burning materials away from battery. Battery explosion can blind. Acid can blind and burn. Tools and cable clamps can make sparks.

Do not smoke. Shield eyes and face. Read instructions.

50-2 Maintenance As Required D20x22 Series II HDD Maintenance

Step 1: Disconnect battery using Battery Disconnect Switch (1).

Step 2: Remove bolts and battery access shield (2).

Step 3: Remove negative (-) cable (3), then positive (+) cable (4).

Step 4: Remove battery and install new battery.

Step 5: Spray cable clamps and terminals with a battery terminal sealer.

Step 6: Install positive (+) cable (4), then install negative (-) cable (3).

Step 7: Install red plastic cap over positive cable.

Step 8: Install battery access shield and bolts.

Step 9: Connect battery using Battery Disconnect Switch.

WARNING: Battery posts, terminals, and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm.

Wash hands after handling.

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AIR CLEANER ELEMENTS - REPLACE

When air cleaner restriction indicator shows the colored band (1) (usually red), the air cleaner element must be replaced.

NOTICE: Do not attempt to clean and return a used element to service.

To replace element:

Step 1: Unlatch end cover of air cleaner assembly and remove cover (2).

Step 2: Remove dirty primary element.

Step 3: Unscrew wing nut holding secondary element in place. Inspect secondary element; replace it if it is dirty or damaged.

Refer to the Engine Operation Manual supplied with the machine to determine make and number of correct replacement filter(s).

Step 4: Check replacement air cleaner element(s) for damage.

Step 5: Install replacement air cleaner element(s). Ensure end of primary element with gasket is installed against closed end of air cleaner assembly, and is seated properly.

Step 6: Install end of air cleaner assembly; ensure all fasteners and/or clamps are tight.

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TRACK TENSION - ADJUST

Before starting adjustment procedures, ensure tracks are clean and free of dirt and mud.

Step 1: Remove access cover.

Step 2: Tighten bolt inside spring to increase tension; loosen bolt to decrease tension.

Step 3: Measure distance (1) from stop plate (2) to end of spring (3). Measurement should read 7.40–7.50" (18.8–19.0 cm) for a new track.

You may need a flashlight to see spring inside track assembly.

Step 4: Drive machine forward approximately 30 ft (10 m) and reverse 30 ft (10 m).

Step 5: Tighten bolt further until distance (1) is 7.40–7.50" (18.8–19.0 cm).

Step 6: Replace access cover.

Discard track when lugs are worn off or when no further bolt adjustment is possible.

WARNING: The track tensioning system is under high tension and may cause personal injury if tension is not released according to the instructions given below.

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ROD GUIDE PLATE - REPLACEReplace rod guide plate (1) when worn. Rod guide plate wear is identified when rods begin to show wear from vise jaws, indicating that rod is no longer being centered by rod guide.

To replace:

Step 1: Remove bolts (2), washers (3), and rod guide plate (1).

Step 2: Install new plate, washers, and bolts.

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VISE DIES - REPLACE

Front ViseStep 1: Start engine and close vise pressing top of

Front Vise Switch (1). Shut off engine.

Step 2: Manually slide vise (2) toward rod box (3) if pin (4) is under cross bar.

Step 3: Remove pin (4) from cylinder die.

Step 4: Start engine, open vise and shut off engine.

Step 5: Slide moveable die (5) out.

WARNING: Pinch points in vise can crush.

Keep hands away, unless engine is shut off.

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Step 6: Remove bolt (6) and stationary die (7).

Step 7: Install new stationary die and keeper bolt. Torque bolt to 35 ft-lb (47 Nm).

Step 8: Slide moveable die onto cylinder rod; start engine and close vise.

Step 9: Shut off engine.

Step 10: Insert pin.

Rear ViseStep 1: Start engine.

Step 2: Close vise by pressing top of Rear Vise Switch (1). Shut off engine.

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Step 3: Insert punch (2) through hole and push out vise die keeper pin.

Step 4: With operator seated at the controls, start engine and open rear vise by pressing bottom of Rear Vise Switch (1). Shut off engine.

Step 5: Remove moveable vise die (3).

Step 6: Install new stationary die and keeper bolt. Torque keeper bolt to 35 ft-lb (47 Nm).

Step 7: Remove rear vise blocking. Connect rotation cylinder to vise assembly.

Step 8: Place new moveable vise die on the stationary die. Align die so the cylinder push rod will enter the die pocket when the vise is closed.

Step 9: Return to operator station and start engine.

Step 10: Extend cylinder to close rear vise by pressing top of Rear Vise Switch (1).

Step 11: Shut off engine.

Step 12: Install vise die keeper pin with punch (2).

WARNING: A rotated rear vise will move down when the engine is shut off. Serious injury and loss of fingers or hand can result if fingers or hand is in or under vise when engine is shut off. Always rotate vise back to home position before shutting off engine.

WARNING: Do not hold vise die in vise assembly to guide cylinder rod into vise die socket. Serious injury or loss of fingers or hand can result.

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STAKEDOWN DRIVERS - REMOVE/INSTALLStep 1: Remove pins (1) at top and bottom of shield to open shield.

Step 2: Roll rubber O-ring (2) out of groove.

Step 3: Support stake while removing pin (3).

Step 4: Remove stake.

Step 5: Reverse procedure to install stake.

Step 6: Close shield and replace pins.

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ROTATION SENSOR PHASE - ADJUST

This procedure requires two people.

Step 1: Disable R.A.T.T. mode. Lights (1), (2) and (3) will be OFF.

Step 2: Disconnect drill string from drive chuck.

Step 3: Position carriage at most rearward position on rack.

Step 4: With the drive chuck stopped, loosen sensor jam nut (4) and rotate sensor (5) clockwise until it touches the metal pulse ring (6).

NOTICE: Do not rotate the drive chuck with the sensor in contact with the pulse ring. The pulse ring can be damaged from the sensor rubbing on it.

Step 5: Rotate sensor 1/8 turn counterclockwise, away from pulse ring.

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. Adjust sensor only when the shaft is rotating slowly. Never place fingers between sensor mounting plate and the rotating shaft when adjusting the sensor.

AUTO

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Step 6: Press Service Screen Key (8) to access Options Menu (9). Using the Increase/Decrease Keys (10), scroll down to RATT option (11).

Step 7: Use Increase/Decrease Keys (10) again to scroll to “RCKCAL” (12).

Step 8: Rotate console so that technician adjusting the phase sensor can see the phase angle display (13).

Step 9: The technician in the seat begins rotating the drive chuck slowly in forward drilling direction.

Step 10: The second technician slowly rotates the sensor counterclockwise until phase angle at display reads a positive 85–95°.

Step 11: Stop drive chuck rotation.

Step 12: Tighten jam nut.

Step 13: Verify that phase is in correct range.

Step 14: To test: press R.A.T.T. Mode Button and pull on Rotation Handle. Drive chuck will oscillate.

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STORAGE

Preparing for Storage

• Store machine inside or under cover.

• Clean off foreign material and wash machine. Repaint bare metal to inhibit rust.

• Repair or replace worn or broken parts or damaged decals.

• Refer to the Engine Operation Manual for engine storage instructions.

• Disconnect battery cables or remove battery. Refer to “Battery Electrolyte Level and Terminals - Check/Clean,” page 40-4. Check fluid level and charge fully; recheck every 30 days and charge if necessary.

• Remove Remote Lockout system batteries from remote transmitter and charging compartment. Unplug docking station.

Removing from Storage• Remove all protective coverings.

• Drain any water and sediment from fuel tank that may have built up during storage. Fill fuel tank.

• Check battery fluid level. Charge battery and install in machine if removed or reconnect cables.

• Plug in Remote Lockout system docking station. Charge batteries fully. Install charged battery in remote transmitter.

• Refer to the Engine Operation Manual instructions for restoring engine to operation.

• Disable fuel system and crank engine to provide crankshaft lubrication.

WARNING: Use Shutdown Procedure when preparing the machine for storage. Follow Shutdown Procedure, page11-1.

D20x22 Series II HDD Maintenance Troubleshooting 60-1

Section 60: TroubleshootingENGINE SYSTEM

Refer to the Engine Operation Manual supplied with each machine for troubleshooting procedures.

ELECTRICAL SYSTEMProblem Cause SolutionLow battery output Low water level Add water.

Loose alternator belt Tighten belt.Defective alternator Replace alternator.Corroded or loose battery cable Clean and tighten battery cables.Defective battery cell Replace battery.Cracked battery case or broken terminal Replace battery.Dirty or wet battery top, causing discharge Clean battery top.

Battery uses too much water Cracked battery case Replace battery.Overcharged battery See your Vermeer dealer.

Low battery charge Alternator not charging See your Vermeer dealer.Corroded or loose battery cable Clean and tighten battery cables.Poor wiring connections in battery charging circuit

Check wiring connections.

Defective battery cell Replace battery.Faulty regulator Replace regulator.Excessive engine idling Reduce engine idle.Continuous drain on battery—dirty battery top or electrical components shorted or grounded

Clean battery top.

60-2 Troubleshooting D20x22 Series II HDD Maintenance

HYDRAULIC SYSTEMProblem Cause Solution

No hydraulic power Operator not in seat when using drilling functions Sit in the operator’s seat.

No hydraulic fluid Fill with fluid.

Battery voltage too low to shift the solenoid Check battery, alternator and charging circuit.

Damaged or worn hydraulic pump See your Vermeer dealer.Relief valve damaged See your Vermeer dealer.Remote Lockout system in LOCKOUT mode. Put Remote Lockout system in RUN mode.

Slow hydraulic power Low hydraulic fluid level Add hydraulic fluid.Plugged hydraulic filter Replace filter.Plugged hydraulic strainer Clean strainer.Worn pump See your Vermeer dealer.Improper pressure relief setting See your Vermeer dealer.Hydraulic fluid cold Let machine warm up and operate hydraulic

system.Noisy hydraulic pump Cold hydraulic fluid Warm up machine at reduced engine speed.Hydraulic power loss Low hydraulic fluid Add hydraulic fluid.

Plugged hydraulic filter Replace filter.Plugged hydraulic strainer Clean strainer.Wrong viscosity of hydraulic oil Change hydraulic fluid to correct viscosity.Worn pump or motor See your Vermeer dealer.Improper pressure relief setting See your Vermeer dealer.Poor engine performance Check engine.

(Sheet 1 of 2)


Oil foams Low hydraulic fluid Add hydraulic fluid.Water in hydraulic fluid Change fluid.Air leak between tank and pump Repair leak.

DRILLING FLUID SYSTEMProblem Cause SolutionNo hydraulic power No hydraulic fluid Fill with fluid.

Damaged or worn hydraulic pump See your Vermeer dealer.Relief valve damaged See your Vermeer dealer.

Slow hydraulic power Low hydraulic fluid level Add hydraulic fluid.Plugged hydraulic filter Replace filter.Plugged hydraulic strainer Clean strainer.Worn pump See your Vermeer dealer.Improper pressure relief setting See your Vermeer dealer.

Noisy hydraulic pump Hydraulic fluid cold Let machine warm up and operate hydraulic system.Warm up machine at reduced engine speed.

HYDRAULIC SYSTEM (CONTINUED)Problem Cause Solution

(Sheet 2 of 2)

60-4 Troubleshooting D20x22 Series II HDD Maintenance

The alarm will sound briefly when the Test Button is pressed. A successful test is indicated when the green light remains steady ON after the test button is released.

If there is a flashing green light after releasing the test button, the Strike Alert system is not functioning correctly. Confirm voltage stake is fully inserted into the ground. The soil at the stake may need to be moistened to improve conductivity of the earth. Retest the system. If the test fails to pass, contact your Vermeer dealer.

The Strike Alert system automatically runs a system check whenever the machine is powered up (ignition key turned from OFF to RUN). The alarm does not sound during the power-up system check.

STRIKE ALERT SYSTEMINDICATOR INDICATION SIGNIFICANCE

Two-Tone HornOn Electrical strike occurred or Test Button pressedSilent No voltage detected above threshold.

Green Light

Off Test in progress, light burned out, or wiring harness problem

Flashing Ground Stake is not in the ground.

Double Flashing Current Sensor failed.

Triple FlashingGround Stake wiring problem

On Power-up check or Test passed. System is ready.CONTROL FUNCTIONAlarm Cancel Button Turns alarm off (only when an external voltage and current are not present)Test Button Tests sensors, controller, and alarm


The Remote Lockout system controls thrust, rotation, and fluid functions together. If one function is working and the others are not, then the Remote Lockout system is not the source of the problem. The Remote Lockout system cannot disable one function independent of the others.

Contact your Vermeer dealer for troubleshooting assistance.

REMOTE LOCKOUT SYSTEMProblem Cause SolutionRemote Lockout system not responding

Operator not in seat when system is turned ON

Sit in seat and select RUN or LOCKOUT mode.

Cold weather operation causing greater hydraulic oil viscosity, preventing pressure switches from confirming lockout

To achieve lockout confirmation, move throttle to its lowest setting.

Lockout not confirmed due to machine in Transport mode

To achieve lockout confirmation, change from Transport mode to Drill mode.

Out of range Move into range.Low battery Replace battery.

D20x22 Series II HDD Maintenance Specifications 65-1

Section 65: Specifications LUBRICANTS

Lubricant Capacity Specifications / Notes

Engine Oil Refer to engine specifications

An Engine Operation Manual is supplied with each machine. Refer to the manual for engine service requirements.

Hydraulic FluidVermeer HyPower 46 orVermeer HyPower 68 orVermeer HyPower 100

Hydraulic system: 40 gal (151 L)Tank: 29 gal (110 L)

ISO 46: -13° to 86°F (-25° to 30°C)ISO 68: -4° to 104°F (-20° to 40°C)ISO 100: 14° to 122°F (-10° to 50°C)Use caution not to get dirt or other contaminants into the system(s). Filter all fluid through a 5-micron filter before adding to tank.NOTICE: Use of any oils other than those recommended without written factory approval will jeopardize warranty.

All-Purpose Gear Lube Maintain check plug level in rotation gearbox

Oils must conform to API GL5 or MIL-L-2105D specifications.-20° to 100°F (-30° to 40°C): 80W-90 20° to 120°F (-10° to 50°C): 85W-140

General Lubricating OilVermeer Ultra Gold 10W30

As required SAE10W30

GreaseVermeer Ultra LC Grease

As required Lithium complex, extreme pressure NLGI Grade 2To 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.

65-2 Specifications D20x22 Series II HDD Maintenance

Lubricant Capacity Specifications / Notes

Drilling Fluid Pump CrankcaseVermeer Ultra Gold 40

1 qt (1 L) SAE- 40 non-detergent(Classification MM or better)

Drill Rod Thread Compound

As required BioStick thread lubricant (P/N 296337339)

Drive Chain LubeVermeer Chain Lube

As required (P/N 117442-001)

D20x22 Series II HDD Maintenance Specifications 65-3

MACHINE SPECIFICATIONSEngine Kubota V3800DI-T Tier 3/Stage IIIAMaximum power 83 hp (62 kW) SAE gross at 2200 rpm Model Tier 4 Interim/Stage IIIBMaximum power 83 hp (62 kW) SAE gross at 2200 rpm Fuel capacity 25 gal (95 L)Oil capacity 1.85 gal (7 L)Maximum engine inclination 30°Cooling medium Mixture of 50% water and 50% ethylene glycol-base

antifreeze to -34°F (-37°C) protectionEngine coolant capacity 2.7 gal (10.3 L)Electrical system 12-voltAlternator 90 AmpBatteryRequired 1BCI group size 31Cold Cranking Amps (CCA) 950 cold cranking amps, 30 seconds,

0°F (-18°C)Reserve capacity 185 min, 25 amp output at 80°F (27°C)Length 13˝ (33 cm)Width 6-3/4˝ (17 cm)Height 9-3/8˝ (24 cm)

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65-4 Specifications D20x22 Series II HDD Maintenance

Hydraulic Systems Pressure SettingsRotation pump flow 33 gpm (125 L/min) @2400 rpmSystem pressure 3335 psi (230 bar) reliefCharge pressure relief 313 psi (21.5 bar)Ground drive pressure 3100 psi (214 bar)Thrust/pullback 3045 psi (210 bar)Hydraulic tank capacity 23 gal (87 L)General, Basic Machine DimensionsWeight empty (no rod) 8600 lb (3900 kg)Weight w/ rod box 10,600 lb (4808 kg)Overall length 17 ft 2˝ (5.2 m)Overall width 50.5˝ (128 cm)Overall height (at top of muffler) 75˝ (191 cm)Drilling Fluid System Pressure SettingsAuxiliary pump flow 25 gpm (95 L/min)System pressure 1600 psi (110 bar)Vise/stakedown/rod loader pressure 3300 psi (227 bar)

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Index2000 Service Hours or 2 Years, 46-12000 Service Hours or Yearly, 46-13000 Service Hours or 2 Years, 46-16000 Service Hours or 6 Years, 46-1

AAdditional Periodic Maintenance, 46-1Air Cleaner Elements - Replace, 50-3Air Cleaner Restriction Indicator - Check, 20-5Auto Greaser - Adjust/Check/Refill, 20-6

BBattery - Replace, 50-1Battery Electrolyte Level and Terminals - Check/Clean, 40-4Battery Terminals - Clean/Check Electrolyte Level, 40-5

CControl Levers - Check, 30-1Control Levers Linkage - Oil, 25-2Coolant Level - Check, 20-3Cooling System - Check, 30-1Cooling System - Drain and Clean, 45-2Cooling System - Refill, 45-3Cooling System Additive - Add, 35-1

DDrill Rod Care, 20-5Drilling Fluid Pump Crankcase Oil Level - Check, 25-3

Drilling Fluid Pump Oil - Change, 40-8Drilling Fluid Pump Oil - Initial Change, 30-1Drilling Fluid System - Check, 30-1Drilling Fluid System, 60-3

EElectrical System, 60-1Emergency Stop Switch - Check, 30-3Engine Compartment - Clean, 50-1Engine Maintenance, 20-1, 35-1, 40-1, 45-1, 46-1, 50-1Engine Oil and Filter - Change, 40-3Engine Oil and Filter - Initial Change, 25-1Engine Oil Level - Check, 20-1Engine System, 60-1

FFluid Levels - Check, 20-1Front Vise, 50-6Fuel Filters - Replace, 40-2Fuel Tank - Drain, 40-1Fuel Tank - Fill, 20-4Fuel/Water Separator - Drain, 25-1

GGround Drive Speed - Check, 40-6Ground Drive System - Inspect, 30-6


HHydraulic Fluid - Change, 45-4Hydraulic Fluid - Drain, 45-4Hydraulic Fluid Filter - Initial Replacement, 35-2Hydraulic Fluid Filter - Replace, 40-7Hydraulic Fluid Flow Direction, 40-8Hydraulic Fluid Level - Check, 20-2Hydraulic System - Check, 30-5Hydraulic System, 60-2

IIndicator Lights - Check, 30-3

JKLLubricants, 65-1

MMachine - Grease, 20-1Machine Specifications, 65-3Maintenance - 10 Service Hours or Daily, 20-1Maintenance - 100 Service Hours, 30-1Maintenance - 1000 Service Hours, 45-1Maintenance - 250 Service Hours, 35-1Maintenance - 50 Service Hours or Weekly, 25-1Maintenance - 500 Service Hours, 40-1Maintenance As Required, 50-1

NNeutral Start Interlock - Check, 30-3

OOperator Presence System - Check, 30-4Overall Machine - Check, 30-2

PPark Brake - Check, 40-6Planetary Gearbox Oil - Change, 45-1Power Vise - Grease, 25-4Preparing for Storage, 50-12

QRR.A.T.T. Tool, 20-7R.A.T.T. Tool Oil - Change, 35-2Rear Vise, 50-7Remote Lockout System, 60-5Removing from Storage, 50-12Rod Guide Plate - Replace, 50-5Rotation Gearbox Oil - Check, 25-3Rotation Sensor Phase - Adjust, 50-10Rotation Sensor Phase - Verify, 20-8

SSafety Messages, 10-1Safety Signs Maintenance, 30-2Safety Symbol Explanation, 10-1Shutdown Procedure, 11-1Specifications, 65-1Stakedown Drivers - Remove/Install, 50-9Storage, 50-12Strainer - Clean and Inspect, 45-5


Strainer - Install, 45-5Strainer - Remove, 45-4Strike Alert System, 60-4

TTank - Fill, 45-5Tool - Oil, 20-7Track Chain Tension, 30-6Track Gearbox Oil Level - Check, 25-2Track Tension - Adjust, 50-4Troubleshooting, 60-1

UVVise Dies - Replace, 50-6

WWelding Alert - Electronic Components, 12-1Welding Precautions, 12-1


Revision HistoryRevision Date Page(s) Descriptiontm1_00 07/07 All Temporary Maintenance Manual released.tm1_01 09/07 All D20x22 Series II added; other updates.m1_00 09/07 All First edition Maintenance Manual released.

m1_01 08/08 Sections 20, 25, 45, 50, 65Hydraulic sight gauge and filter access cover; rotation gearbox oil check; track tension adjustment; new vise die replacement steps; Tier 3 engine

m1_02 09/09Introduction, Sections 10,12, 20, 30, 40, 45, 50, 65

DVD language; safety definitions; safety messages; welding precautions; auto greaser; battery voltage check removed; battery warning; track tension adjustment; checks for ground speed and park brake; oil changing procedure; drilling fluid crankcase capacity.

m1_03 05/11 Sections 25, 50, 65 Clarifications, new style joystick, BioStick grease

m2_00 04/12 All Tier 4 Interim/Stage IIIB Engine and other updatesm2_01 10/12 Sections 20, 35 R.A.T.T. pressure correction

Copyright 2012 All rights reserved.Vermeer Corporation

1210 Vermeer Road East, P.O. Box 200Pella, Iowa 50219-0200

WARNINGThe engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

CALIFORNIAProposition 65 Warning

Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

When operated in California, any off-road diesel vehicle may be subject to the California Air Resources Board In-Use Off-Road Diesel Vehicle Regulation. It therefore could be subject to retrofit or accelerated turnover requirements to reduce emissions of air pollutants. For more information, please visit the California Air Resources Board website at http://www.arb.ca.gov/msprog/ordiesel/ordiesel.htm.

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