Vermeer руководство по эксплуатации

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  504/604 PRO Baler Operator’s and Maintenance Manual 504PRO_604PRO_o-m2_00 — Serial No. 504PR Serial No. 8001 — 604PR Serial No. 101 — Order No. 105400EC2 Cabled Assembly Order No. 510520026 https://tractormanualz.com…
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  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.
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  • Any defect which was caused (in Vermeer’s sole judgment) by other than normal use and service of the Agricultural Equipment, or by any of the following: (i) accident; (ii) misuse or negligence; (iii) overloading; (iv) lack of reasonable and proper maintenance; (v)improper repair or installation;…
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  Transportation costs, if any, of transporting to the Vermeer dealer. • The travel time and expenses of the Vermeer dealer’s service personnel to make a repair on the retail purchaser’s site or other location. • In no event shall Vermeer’s liability exceed the purchase price of the product.
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  EXCLUSIONS OF WARRANTIES: UNLESS OTHERWISE REQUIRED BY LAW, AND EXCEPT FOR THE WARRANTIES EXPRESSLY AND SPECIFICALLY MADE HEREIN, VERMEER MAKES NO OTHER WARRANTIES, AND ANY POSSIBLE LIABILITY OF VERMEER HEREIN UNDER IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESS, IMPLIED, OR STATUTORY, INCLUDING, BUT NOT LIMITED TO, ANY WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.
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  RECEIVING AND DELIVERY REPORT Refer to applicable sections of this manual as needed and check or perform the following items: Receiving Check that all loose items (controller, driveline, controller mount, tractor harness, manuals, gauge wheels, any optional kits, and all hardware) •…
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  Dealer/Owner Information Receiving and Delivery Report ii 504/604 PRO Baler https://tractormanualz.com…
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  Identification Numbers – Record The serial number is shown on data plate on the right side of machine, as shown right. Warranty claims and queries cannot be dealt with unless the serial number is stated. Please enter this number here immediately after delivery: Machine Model # …………
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  • Inspect tires and rims for damage. • Check that highway lights operate correctly. • Check all chains for proper adjustment. • Check the controllers for proper function and for visual damage. • Check drivelines for proper installation. • Ensure slow-moving vehicle sign is installed. •…

• Page 10: Table Of Contents

  Table of Contents TYPE OVERVIEW …………1-1 Field Statistics Page ……… . . 5-14 Tasks Page .

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  Cutting Device ……….7-27 10.4 Stopping the Machine in the Field .
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  12.3 Coupling the Cam-Type Cut-Out Clutch ….12-3 INDEX TECHNICAL DATA ………… 13-1 REVISION HISTORY ……….. 14-1 13.1 Overview …………13-1 13.2 Dimensions .

• Page 13: Type Overview

  1 TYPE OVERVIEW Drawbar D11 – US-Version Pick-up width 6.6 / 7.4 / 7.9 ft (2.00 / 2.25 / 2.40 m) Roller lubrication manual roller lubrication Chain lubrication automatic chain lubrication Cutting device Xtra Cut 17 (with 17 knives) Rotor ring type rotor (for 17 knives) net wrap Wrapping…

• Page 14: Safety Messages

  2 SAFETY MESSAGES General 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»…

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  Wear personal protective equipment. Dress properly. Keep spectators away. Follow Shutdown Procedure before servicing, cleaning, repairing or transporting machine. Pressurized fluid can penetrate body tissue and result in death or serious injury. Leaks can be invisible. Keep away from any suspected leak.

• Page 16: Safety Instructions

  Safety Instructions WARNING: Even when all instructions have been read and understood there are potential hazards with the machine. Always handle the machine with care to avoid injury to yourself and others! WARNING: Do not do work on the magnets of the blade holders if you have a cardiac pacemaker or other implant that can be impaired by magnetic fields.

• Page 17: Machine Decals

  • Do not step onto the drawbar or other parts of the machine, when the machine is in operation. Keep sufficient distance to baler (pick-up, running gear, bale unloading area). • Before threading the net wrapping material: Follow Shutdown Procedure on page 6-1 All protection devices must be mounted to the baler and must be in correct state.

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  Decal Explanation The two lift eyes at the upper cross bar are indicated by this symbol. Other fastening points are not permitted for crane suspension. Tie down points. Three points at the machine are indicated by this symbol: Two points on the axle and one on the drawbar.
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  Tailgate locking device If the lever is positioned perpendicular to the flow direction, the tailgate is secured against lowering. Lubrication Once a day: check lubrication and relubricate if necessary. Lubrication Check lubrication and relubricate if necessary. Necessary driveline speed: 540 rpm Thread scheme for net wrapping 2-6 Safety Messages 504/604 PRO Baler…

• Page 20: Safety Signs

  • When replacing a machine component with a sign attached, replace sign also. • Replacement signs can be purchased from your Vermeer equipment dealer. Decal Explanation DANGER: Baler intake can pull you in, resulting in death or serious injury.

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  • NEVER feed crop in by hand. • NEVER remove material from the baler intake while it is running. • NEVER try to unplug baler by hand while it is running. • ALWAYS disengage power takeoff, shut off tractor engine, set park brake, and remove key before working on baler for any reason including servicing, inspecting, or unplugging machine.
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  WARNING: Connect and use equipment highway lights. CAUTION: Oversized bales place excessive load on belts, rollers and bearings which could result in product or property damage and is a fire hazard. Do not overfill baler. WARNING: Read this Operator’s Manual and safety signs before operating machine.
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  WARNING: Riders are not allowed on the baler WARNING: Opening tailgate can crush, resulting in serious injury or injury. WARNING: Stay away from rear of baler. Warn others to stay away before raising tailgate. WARNING: A falling or closing tailgate can crush, resulting in serious or death.

• Page 24: Personal Protective Equipment

  The accumulator is under gas and oil pressure. Depressurize hydraulic system prior to disassembling or repair. Stepping or standing on some areas of machine may result in slipping or falling. Do not step on prohibited areas. DANGER: Entanglement in rotating driveline can result in death or serious injury.

• Page 25: Fire Prevention Baler

  Fire Prevention Baler Figure 1. Do not smoke in the vicinity of the machine. The harvested crop can easily ignite! To prevent fire: • Remove crop remains and oil leaks. • If any machine parts run hot: find and remove cause. •…

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  NOTICE Order fire extinguisher kit (part number AK01415) from your authorized Vermeer dealer. NOTICE Fire extinguisher is shipped empty and must be filled/charged prior to initial use. Fire extinguisher must also be refilled/ recharged after every subsequent use. To refill/recharge, use the following procedure: Figure 3.

• Page 27: Hydraulic System Baler

  Hydraulic System Baler WARNING: Pressurized fluid can penetrate body tissue and result in death or serious injury. 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.

• Page 28: Safety Devices

  • Depressurize hydraulic system as described in Shutdown procedure (see page 6-1). • Secure hydraulic operated parts (pick-up, cutting device) mechanically against unexpected movements. • If any short-time maintenance or assembly work is carried out with the tailgate open, the tailgate must be hydraulically secured against lowering: use the shut off valve (on the left side of machine).

• Page 29: Net Knife Safeguard

  2. Turn the hydraulic tailgate valve (1) (see Figure 4 on page 2-16) to the shut-off position (parallel to lines). Remove the tailgate safeguard 1. Turn the hydraulic tailgate valve to the operating position. 2. Close the tailgate. Figure 4. Tailgate hydraulic valve 2.7.2 Net knife safeguard WARNING: Risk of cutting! During work in the vicinity of the net knife: fit net knife safeguard.

• Page 30: Pick-Up Safeguard

  Figure 5. Secure the net knife KEY: 1. Handle net knife carrier — 2. Safety chain — 3. Spring clip 2.7.3 Pick-up Safeguard The pick-up safeguard is a safety chain (2) (see Figure 6 on page 2-18) that sets the height of the pick-up and protects it from falling if the hydraulic pressure should drop during driving.

• Page 31: Side Covers

  Figure 6. Pick-up safeguard KEY: 1. Hook — 2. Chain Side Covers WARNING: Risk of cutting injury from moving parts. Never operate the machine with open shields! WARNING: Risk of injury from swiveling shields. After unlocking, the shields swivel automatically up operated by pneumatic pressure.

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  Figure 7. Shields When the on the left and right side are open some parts are easier to reach. Open the cover 1. Turn the lever (1) (see Figure 8 on page 2-20) 504/604 PRO Baler Safety Messages 2-19 https://tractormanualz.com…
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  2. Use the lock (2) to open the cover. The cover will turn up. Close the cover 1. Push the cover down until first the lock and then the lever engage. Figure 8. Open the side cover KEY: 1. Lever — 2. Lock 2-20 Safety Messages 504/604 PRO Baler https://tractormanualz.com…

• Page 34: Intended Use

  3 INTENDED USE Vermeer round balers are designed solely for use in baling agricultural crop material. Always use the machine in accordance with the instructions contained in this Operator’s Manual, safety signs on the machine, and other material provided by Vermeer Corporation.

• Page 35: Overview Of The Machine

  The baler has a wide pick-up max. 7.9 ft (2.40 m) and can produce round bales with a width of 4.0 ft (1.23 m) and a diameter from: • 504 PRO 3.3 – 5.2 ft (1.00 –1.60 m). • 604 PRO 3.3 – 5.9 ft (1.00 –1.80 m).

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  Figure 9. General overview KEY: 1. Controller — 2. Tying unit — 3. Bale chamber — 4. Tailgate — 5. Bale ejector — 6. Feed channel floor — 7. Cutting unit — 8. Feed rotor — 9. Pick-up unit — 10. Draw bar 4-2 Overview of the Machine 504/604 PRO Baler https://tractormanualz.com…

• Page 37: Controls And Adjustments

  5 CONTROLS AND ADJUSTMENTS Control The baler is operated from the tractor by the PTO shaft, the hydraulic single and double acting valves and by the user interfaces E-Link Pro For more information about how to operate the user interface, see the software description (see page 5-7). The has a touch screen, but can also be operated using the buttons on the side.

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  Figure 10. E-link Pro buttons A. ON/OFF 1. Start 6. Home Push ON/OFF to switch the monitor On or Off Push Start to start or restart a net wrap cycle Push Home to activate the home page B. Escape 2. Manual/Automatic 7.

• Page 39: Setup The E-Link Pro Display

  D. OK (Enter) 4. Hydroflex floor 9. Task Push OK to accept the active selection Push Hydroflex floor to switch the function of Push Task to activate the page for entering (selected with the Up or Down button) the double acting valve in the tractor to lift/ tasks lower the Hydroflex floor.

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  Setup Display and Sound 1. Push [ ] (F6) (see page 5-2) on a configuration page. The page «Display/Sound Configuration» appears. 2. Push the line «Brightness». 3. Push the button [ ] or [ ] to increase or decrease the brightness of the display. 4.
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  11.Push [OK] to confirm the setting and toggle between Hour and Minute. 12.Push the button [ ] to confirm the time. 13.Push the line «Daylight Saving» to switch between daylight saving or “standard time”. Virtual Terminal 1. Push the button [ ] on a configuration page.

• Page 42: Software Description

  Software Description Figure 11. E-Link Pro Software KEY: 1. Home page (see page 5-7) — 2. Bale setup (see page 5-12) — 3. Field statistics (see page 5-14) — 4. Tasks (see page 5-15) — 5. Advanced 5-6 Controls and Adjustments 504/604 PRO Baler https://tractormanualz.com…

• Page 43: Home Page E-Link Pro

  Home Page E-Link Pro Figure 12. Home page The home page of the E-Link Pro display is divided into 6 sections: • Sections [A and E] have control buttons. • Sections [B, D and F] give information. • Section [C] has a button to view the field name and other information. 504/604 PRO Baler Controls and Adjustments 5-7 https://tractormanualz.com…

• Page 44: Bale Settings Page

  [A] Buttons on the left to go to another page Home page Bale settings page Statistics/field data page Tasks page Advanced settings page [B] Information about the current bale 1. Bale size indicator (Inch) 2. Target bale size (Inch) 3. Bale size indicator (graphic) 4.

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  Figure 13. Colour of the bale size indicator 1. Green, bale in progress 2. Yellow, bale nearly at target, only appears when «Near full alert” feature is activated (see page 5-23) At this point an audio signal is generated. 3. Red, bale is at the target size 4.
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  [E] Buttons on the right to start or change the operation of the baler The buttons start the following: Start to wrap the bale (Manual wrapping) Switch from manual to automatic wrap or from automatic to manual wrap. In automatic mode, the wrapping starts automatically, in manual mode you must push the start button to start the wrap process The selected mode is also visible on the display see [F].
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  [F] Baler equipment and operation status 1. The bale is wrapped manually 2. Number of Knives are inserted (green icon); if knives are not inserted this icon is black 3. Hydroflex floor is not lowered (black icon); if the Hydroflex floor is lowered this icon is red 4.
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  The settings are automatically saved when you go to another page, for example to the home page. Setting Machine type Unit Min — Max Default/Advised 504 PRO 35 – 63 Full bale size inch 604 PRO inch 35 – 71 The set diameter of the bale.
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  Net wraps number 1.5 – 10.0 The number of wraps around the bale. 0 – 10 Bale density Level The level that indicates if the bale must be more dense or less dense. — Soft core On/Off Selection for making bales with a soft core or not. –…

• Page 50: Field Statistics Page

  Field Statistics Page Figure 15. Field statistics page This page shows information about the number of bales and hours worked on the field. The name of the selected field is shown in the title bar. Information of up to 20 fields can be stored. The name of the field can be entered on this page. Push the buttons up or down to select a field.

• Page 51: Tasks Page

  3. Push OK to save the name. 4. Push to return to the field statistics page or to go to the home page. • Push to delete the data of the field. Push to confirm. Tasks Page Figure 16. Tasks Depending on the available options on your baler like the tying system and knife groups, this page shows entries for wizards to make changes.

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  1. Push to start the wizard. 2. Select the new number of knives. The selected number is shown grey and the icon «Disengage” starts blinking. 3. Use the double acting valve in the tractor to disengage the knives. The icon «Engage” starts blinking after the knives are lowered. 4.

• Page 53: Advanced Menu

  Advanced Menu Figure 17. Advanced menu structure KEY: 1. Advanced user interface — 2. Calibration (see page 5-19) — 3. Diagnostics (see page 5-22) — 4. Advanced Baler setup — 5. Administrator Menu — 6. Advanced baler setup — 7. Tuning 504/604 PRO Baler Controls and Adjustments 5-17 https://tractormanualz.com…

• Page 54: Advanced User Interface

  Figure 18. Advanced menu Push the button on the line you want to use. 5.8.1 Advanced User Interface Figure 19. Advanced user interface On this page you can change the shown information on the home page as follows: 5-18 Controls and Adjustments 504/604 PRO Baler https://tractormanualz.com…

• Page 55: Calibration

  1. Push the button right on the line «Info boxes set-up”. 2. The display shows: Figure 20. Info box setup 3. Use the arrow buttons arrow up or down to select the information box you want to change. 4. Use the arrow buttons left or right to select the information you want to display on the home page.

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  On this page you can start the calibration of the bale diameter. Do this if the size of the bale deviates from the set bale size. Before you start the calibration you must know how much the deviation is (See example below). Calibrate as follows: 1.
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  Example Measure the distances A, B, C and D (= horizontal and vertical distance on both sides of the bale) and calculate the average bale size: (A+B+C+D)/ 4. For example: The set bale diameter = 49.5 Inch but it is a bit too small: (48.5 + 48 + 49.5 + 48)/4 = (194)/4 = 48.5 In this example the average bale size is 1 inch too small so the {bale offset} must be increased.

• Page 58: Diagnostics

  «System information»: Displays the software version, the model, serial number and the total number of bales and hours. • «Administration»: This is only available for Vermeer technicians and requires a password. • 5-22 Controls and Adjustments 504/604 PRO Baler https://tractormanualz.com…

• Page 59: Advanced Baler Setup (504/604 Pro Baler)

  5.8.4 Advanced Baler Setup (504/604 PRO Baler) Figure 23. Advanced Baler Setup Model Setup 504/604 PRO Baler Controls and Adjustments 5-23 https://tractormanualz.com…

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  Figure 24. Advanced Baler Setup 1. Settings for the number of available knives or the wrapping method can be changed by pushing the arrow up or down 2. Push to return to the «Adv. menu» or to go to the home page. The selection is automatically saved when you leave the page.
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  – Soft core bale size [%] 0 – 100 Size of the soft core, this is a percentage of the of the normal bale. Switch the soft core on or off on the page: «Bale set-up” (see page 5-12) – Net delay 0.0 –…

• Page 62: Shutdown Procedures

  6 SHUTDOWN PROCEDURES Shutdown Procedure Service and Maintenance When stopping the machine, use the following shutdown procedure: • Ensure bale chamber is empty. Do not leave bale or partial bale in bale chamber. • Reduce engine speed to idle and switch off driveline. •…

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  • Secure hydraulic operated parts (pick-up, cutting device) mechanically against unexpected movements. 6-2 Shutdown Procedures 504/604 PRO Baler https://tractormanualz.com…

• Page 64: Preparing The Equipment Baler

  7 PREPARING THE EQUIPMENT BALER WARNING: Crushing can occur! During handling in the area of the drawbar ensure that the machine is secured against moving. Do not raise the tongue jack before the baler has been safely coupled to the tractor. Do not uncouple the baler, unless: •…

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  • To move the tongue jack slowly, you must push the crank handle into the tongue jack up to the stop. • Up: Turn the crank handle counter clockwise. • Down: Turn the crank handle clockwise. Figure 25. Tongue jack KEY: 1.

• Page 66: Adjust The Height Of The Drawbar

  4. Insert the safety bolt. 5. Position the tongue jack under the draw bar of the baler. 6. Turn the crank until the tongue jack is extended. Remove the support foot: 1. Turn the crank (1) until the support foot (4) has retracted and there is sufficient free space. 2.

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  11.Adjust the bolt (8) until the draw bar head is in a horizontal position. 12.Tighten the bolts (9). 13.Connect the drawbar of the baler to the tractor. CAUTION: Observe the torques on the decal! . Whenever the safety nuts and bolts (9) have been loosened they must be replaced by new ones 7-4 Preparing the Equipment Baler 504/604 PRO Baler…
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  Figure 26. Adjust the drawbar KEY: 1. Bolts — 2. Bolts — 3. Locking plate — 4. Hole — 5. Toothed flange — 6. Pin — 7. Pin — 8. Bolt — 9. Bolts 10. Strap A, B, C, types of drawbar heads 504/604 PRO Baler Preparing the Equipment Baler 7-5 https://tractormanualz.com…

• Page 69: Tow Hitch Version

  Figure 27. Torques Tow Hitch Version • Adjust drawbar per ASABE standards as shown. Failure to adjust the drawbar properly may result in driveline damage. 7-6 Preparing the Equipment Baler 504/604 PRO Baler https://tractormanualz.com…

• Page 70: Driveline Baler

  Figure 28. Type I Driveline (power take-off) Speed 540 rpm Diameter 1-3/8 in. (35 mm) # of Splines Dimension A 7.9–11.8 in. (20–30 cm) Dimension B 13.0–19.7 in. (33–56 cm) Dimension C 13.8 in. (35 cm) Driveline Baler Danger: Entanglement in rotating driveline [4] can result in death or serious injury.

• Page 71
  Keep driveline shields in place at all times. Ensure shields turn and telescope freely. Wear close-fitting clothing and confine long hair. Figure 29. Rotating driveline WARNING: During operation there is potential of the driveline slipping off the tractor power take-off and causing injuries and/or damages.

• Page 72: Driveline — Couple To Tractor

  Figure 30. Angle of driveline Only the driveline prescribed by the manufacturer may be used! A key-type overrunning clutch as integrated part of the driveline protects the machine drive. Figure 31. Driveline WARNING: Injury may occur. (see page 7-9) Protective tube and guard cone of the driveline and power take-off protection must be fitted and be in proper condition.

• Page 73: Driveline — Uncouple From Tractor

  • Lift driveline [4] from holder [3](see Figure 32 on page 7-10). • Align splines and push driveline onto tractor PTO shaft. • Pull back on collar [6], push driveline onto tractor shaft, and release collar (see Figure 33 on page 7-10). Push onto tractor shaft until collar snaps into locked position.

• Page 74: Attach Baler

  • Install and lower tractor PTO shield [5] (see Figure 33 on page 7-10). Figure 34. Anti-rotation chain Attach Baler WARNING: Use Shutdown Procedure before attaching implement to the tractor.(see page 6-1) For trouble-free operation of the baler correct coupling of the machine and adjustment of the driveline is important. •…

• Page 75: Electrical System

  Figure 35. Attach baler NOTICE Order safety chain (part number AK01332) from your authorized Vermeer dealer. Electrical System 7.6.1 Lighting Set To connect the lighting system, insert the 7-pin plug into the corresponding socket on the tractor. Before traveling on the roads, check that the lighting system functions correctly (also at daylight).

• Page 76
  Figure 36. Controller Figure 37. E-Link PRO display Figure 38. Monitor mounting system 504/604 PRO Baler Preparing the Equipment Baler 7-13 https://tractormanualz.com…
• Page 77
  • Install the Monitor mounting system (see Figure 38 on page 7-13) on tractor at a location convenient for the operator. • To connect the controller, insert the 9-pin plug into the corresponding socket on the E-LINK PRO tractor harness. After connecting the plug supply voltage is available.

• Page 78: Net Wrapping

  Net Wrapping Figure 39. Open the top cover and secure the net knife KEY: 1. Handle net knife carrier — 2. Safety chain — 3. Spring clip — 4. Top cover 504/604 PRO Baler Preparing the Equipment Baler 7-15 https://tractormanualz.com…

• Page 79
  Figure 40. Covers KEY: 1. Side cover — 2. Top cover — 3. Bar 7-16 Preparing the Equipment Baler 504/604 PRO Baler https://tractormanualz.com…
• Page 80
  Figure 41. Prepare for a Net Roll KEY: 1. Crank handle — 2. Safety chain on the net roll holder 504/604 PRO Baler Preparing the Equipment Baler 7-17 https://tractormanualz.com…

• Page 81: Insert The Net

  7.7.1 Insert the Net 1. Push the new net roll (1) (see Figure 42 on page 7-19) into the holder. 2. Connect the safety chain (2). 3. Tilt the holder (3) and net into the net roll holder. 4. Turn the crank handle into the sleeve of the net roll up to the stop, and than 1/8 of a turn backward. This ensures that the roll can rotate freely.

• Page 82
  Figure 42. Insert the net roll KEY: 1. Net roll — 2. Safety chain — 3. Net roll holder 504/604 PRO Baler Preparing the Equipment Baler 7-19 https://tractormanualz.com…
• Page 83
  Figure 43. Check distance core position KEY: 1. Extruder bearing — 2. Inner washer — A. Distance between 3/8 and 1/2” 7-20 Preparing the Equipment Baler 504/604 PRO Baler https://tractormanualz.com…
• Page 84
  Figure 44. Check the position of the Spindles KEY: 1. Spindle — 2. Spindle 504/604 PRO Baler Preparing the Equipment Baler 7-21 https://tractormanualz.com…

• Page 85: Adjust The Net Roll Holder

  Figure 45. Feed the Net KEY: 1. Net roll — 2. Upper guide tube — 3. Net tightener — 4. Expanding device — 5. Rubber roll — 6. Steel roll 7.7.2 Adjust the Net Roll Holder Net rolls are available in several widths and net lengths. Depending on the length of the net you want to use and the width of the net some adjustments must be made.

• Page 86: Netwrap Roller Position

  2. Pull the handle (1) of the net knife carrier to the front and hold it. 3. Attach the safety chain (2) and secure it with the clip (3). 4. If you use a net length of 2000 m do the following on both sides: 1.

• Page 87
  When netwrap roller valve (6)(see page 7-23) is turned to the operating position, netwrap roller (3) performs the following functions: • During wrap cycle Roller (3) is in rearward position(see page 7-25). • Roller (3) is belt-driven from roller (1) and rotates •…
• Page 88
  Figure 49. D Figure 48. C • At start of wrap cycle • Tractor hydraulic valve operating tailgate circuit must be in float position to allow cylinder (4) to retract. • A solenoid valve opens when wrap cycle begins. This allows cylinder (4) to retract by means of spring pressure, moving roller (3) rearward. (see page 7-25) Roller (3) begins rotating when netwrap feed clutch engages.

• Page 89: Reset Net Knife

  To disable roller (3) movement: 1. Make a bale and start wrap cycle. 2. Disengage PTO immediately after wrap cycle starts. 3. Follow Shutdown Procedure,(see page 6-1) 4. Ensure roller (3) is in rear position and move valve (6) to shut-off position. This will lock roller (3) in rear position at all times. 5.

• Page 90: Cutting Device

  Cutting Device 7.8.1 Insert a Net Roll WARNING: Before you do work near the net knife, insert the net knife safeguard and secure the net knife. CAUTION: Always wear safety gloves when doing work near the net knife and with the net. CAUTION: Be aware that a net roll of 3000 m with a width of more than 1.23 m can be heavy (>…

• Page 91
  1. Press softkey (E) to enable the Hydroflex control bottom door circuit. 2. Using tractor hydraulic control for remote valve connected to the electric control valve on the baler, fully lower (open) bottom door. As bottom door lowers, knives automatically disengage. 3.
• Page 92
  4. Press softkey (D) to enable the cutting device circuit. 5. Press softkeys (A), (G), and (H) to select desired knife group. 6. Move tractor hydraulic control in the opposite direction that lowered the bottom door in Step 2. • The selected knife group raises into cutting position through bottom door.

• Page 93: Brittle Crop Material

  High-Pressure Override Procedure 11.Repeat Steps 1–5. 12.Press and hold softkey (K). Holding softkey (K) allows knives to be raised at full tractor pressure — up to 2610 psi (180 bar) or higher — rather than the 580 psi (40 bar) limit of normal operation. 13.After icons (I) indicate knives fully raised, immediately repeat Steps 1–8 to ensure correct accumulator pressure.

• Page 94: Assembly And Disassembly Of The Cutting Device Knives

  Figure 51. Cutting knive 7.8.5 Assembly and Disassembly of the Cutting Device Knives NOTICE By removing individual knives the cut length of the baling material can be changed. If no cutting function is desired for a longer period of time, all knives can be removed and replaced by blank knives. WARNING: Injury may occur.

• Page 95
  • Using pliers withdraw the knives rearward, then diagonally upwards from the knife axle and remove them from the knife slots. Figure 52. Knive axle lever NOTICE Removed knives should be replaced by blank knives (part no. 1724551237W) to prevent plugging of the knife slots. Both blank and removed knives can be stored and secured with a cotter pin on the maintenance platform (see Figure 53 on page 7-33).

• Page 96: Regrinding The Cutting Device Knives

  Figure 53. Mowing cutting device Figure 54. Replacing blank knives 7.8.6 Regrinding the Cutting Device Knives To provide the best crop throughput it is recommended to regrind the cutting device knives at least after cutting of 500 bales. Dependent on the working conditions sharpening may be necessary earlier.

• Page 97: Close Up And Shutdown Procedure On The Field

  WARNING: Injury may occur when working near the magnets [1] of the knife holders! The function of cardiac pacemakers can be interrupted by magnetic fields. Potential of injury by sharp edges: Never strike against the installed knives from the bottom with a striking tool — this may damage the magnets! (see page 7-34) •…

• Page 98
  8. Remove the spring clips (3) from the pick-up guide wheels. 9. Lift the guide wheels and hook them on the left and right side of the baler in the drive position (2) . 10.Secure the guide wheels with the spring clip (3). 11.Push in the bale ejector tubes (1) and secure with the cotter pin.

• Page 99: Transporting The Machine

  8 TRANSPORTING THE MACHINE Tractor (towing vehicle) Requirements for Baler Minimum weight/transport speed (per ASABE standard, “Safety for Agricultural Equipment”): WARNING: Loss of steering or braking control can result in death or serious injury. Use a tractor that is large enough for sufficient steering and braking control.

• Page 100
  Hydraulic system • Minimum number of remote valves with FLOAT function one single acting and one double acting • Minimum flow rate 13 gpm (50 L/min) • Minimum pressure recommended 2600 psi (180 bar) • Maximum pressure 3045 psi (210 bar) NOTICE Some tractors have detents which will not allow the tractor hydraulic control to return to NEUTRAL on its…

• Page 101: Minimum Weight/Transport Speed (Per Asabe Standard, «Safety For Agricultural Equipment»)

  Figure 56. Tractor wheels Minimum weight/transport speed (per ASABE standard, “Safety for Agricultural Equipment”) WARNING: Maximum towing speed: 20 mph (32 km/h). Loss of steering or braking control can result in death or serious injury. Use a tractor that is large enough for sufficient steering and braking control. Do not tow equipment that does not have brakes at speeds over 20 mph (32 km/h).

• Page 102
  Ensure slow-moving vehicle (SMV) sign [1] is installed with orange and red reflective surfaces facing rearward as shown. (see Figure 59 on page 8-5) Install optional highway safety towing chain (minimum 10,000 lb / 4540 kg capacity), Vermeer part number AK01332. •…
• Page 103
  Figure 59. Slow-moving vehicle 504/604 PRO Baler Transporting the Machine 8-5 https://tractormanualz.com…

• Page 104: Operating The Machine Baler

  9 OPERATING THE MACHINE BALER WARNING: Death or serious injury may occur The machine may only be operated by persons who are familiar with the operating instructions and the safety instructions. Never remove any harvested crop material from the machine while the drive is running. Prior to work: Switch off driveline, switch off tractor engine, remove ignition key and disconnect driveline from power take-off.

• Page 105: Laying Swaths (Windrows)

  WARNING: Injury may occur. Never leave tractor controls unattended while the implement is operating. When carrying out work on the opened tailgate: Follow Shutdown Procedure (see page 6-1), and use appropriate safeguards when working on or around machine. WARNING: Injury may occur. Contact with baler or bales can result in death or serious injury. Keep all spectators and other workers away from baler and work area while in operation.

• Page 106: Pick-Up Gauge Wheels

  • Lift and lower the pick-up by means of the tractor’s hydraulic control. Figure 61. Shutoff valve Figure 62. Screen NOTICE The valves of the hydraulic switch will not be activated when the [1] pick-up is selected. This setting has to be preferred to minimize the power consumption and to avoid unnecessary heating of the valve coils.

• Page 107: Wind Guard

  • Set the safeguard safety chain to the desired position. • Always select the same adjustment on both sides of the pick-up. Figure 63. Pick-up gauge wheel 9.3.2 Wind guard The wind guard (see figure on page 9-5) is mounted movable – hanging above the pick-up. •…

• Page 108: Driveline Speed

  Figure 64. The wind guard WARNING: Injury may occur at the pick-up. Both pick-up gauge wheels cover the circular path of the tines laterally and are therefore part of the safety equipment. When using the baler both gauge wheels must always be attached. Driveline Speed Operate baler at power take-off standard speed of 540 rpm.

• Page 109: Driving Style

  CAUTION: Damage may occur. Only the driveline prescribed by the manufacturer may be used! WARNING: Injury may occur. Protective tube and guard cone of the driveline and the power take-off protection, must be fitted and be in proper condition. Always ensure that the driveline is installed and secured correctly: Secure the driveline safeguard against revolving by fitting the chain.

• Page 110: Adjust Baler Settings On The Control

  Adjust Baler Settings on the Control On the controller in the tractor set the following: 1. Push the button to go to the Bale settings page. (Or on the home page of the E-link Control push 2. Make all the settings (see page 5-12). 3.

• Page 111
  9.7.1 Open and close tailgate The tailgate is opened and closed by means of the tractor’s hydraulic control (distribution valve for the tailgate): Tailgate must be properly closed: • Before beginning to pick up the crop material. After each bale ejection. •…
• Page 112
  Figure 66. Locking hook 504/604 PRO Baler Operating the Machine Baler 9-9 https://tractormanualz.com…

• Page 113: Operation Instructions

  10 OPERATION INSTRUCTIONS 10.1 Start Baling You can start baling when the baler is prepared according to the previous paragraphs: • Net or twine is inserted • Baler is adjusted to the field • Knives are set You know how to drive •…

• Page 114: Eject A Bale

  Make 2 or 3 smaller bales at the end of the field Do this for the last 2 or 3 bales on the field: 1. Stop the tractor when the bale is at the size you want to make it. 2.

• Page 115: Disconnect The Baler From The Tractor

  2. Use the single acting valve in the tractor to open the tailgate. The bale leaves the chamber and an arrow appears in the display. 3. Move the single acting valve in the tractor to ‘float’ to lower the tailgate completely. This ensures that •…

• Page 116: Stopping The Machine In The Field

  8. Switch off the tractor engine and remove the key. Disconnect the Baler 1. Install the tongue jack(see page 7-1). 2. Disconnect the cables of electrical power supply, lighting and control panel and store in storage slots. 3. Disconnect the hydraulic hoses and connect them to the dummies and store in storage slots. 4.

• Page 117: Maintenance/Setting

  11 MAINTENANCE/SETTING WARNING: Use Shutdown Procedure before servicing, cleaning, repairing or transporting machine (see page 6-1). 11.1 Tires on Baler WARNING: Tire explosion can result if the following procedures are not followed: Maintain correct tire pressure. Do not inflate tire above recommended pressure (see page 11-3). •…

• Page 118
  Figure 67. Baler wheels Figure 68. Gauge wheel 11-2 Maintenance/Setting 504/604 PRO Baler https://tractormanualz.com…

• Page 119: Tires And Tire Pressure

  11.1.1 Tires and tire pressure Tire Pressure Lug nut torque Retorque 2 tires types: – 14L, 30 psi 244 ft-lb after first 10 hours – 14L 16.1 (330 Nm) of operation, – 21.5L 16.1 – 21.5L, 16 psi then at 50-hour intervals 29 psi 2 pick-up gauge wheels: 16 ×…

• Page 120: Safety Signs And Labels

  Replace any damaged or missing signs. When attaching signs, the temperature of the mounting surface must be at least 40°F (5°C). The mounting surface must also be clean and dry. • When replacing a machine component with a sign attached, replace sign also. • Replacement signs can be purchased from your Vermeer equipment dealer. 11.4 Environment/Disposal 11.4.1 Lubricants •…

• Page 121: Tying Unit Maintenance

  11.5 Tying Unit Maintenance 11.5.1 Adjust the Disk Brake of the Net Tying Unit To prevent free-wheeling of the net roll the disc brake must be adjusted in such a way that the brake disc can no longer be turned by hand when the lever (1) (see Figure 70 on page 11-6) points upwards.

• Page 122: Adjust The Shock Absorbers

  Figure 70. Adjust the disk brake of the net tying unit KEY: 1. Lever — 2. Bolt — 3. Milled nut 11.5.2 Adjust the Shock Absorbers On the left side of the baler the movements of the net tensioner (1) are damped by a shock absorber. Two wing nuts push the friction linings against the net tensioner from both sides.

• Page 123
  2. Move the net tensioner (3) (see Figure 71 on page 11-7) to the top end position and hold it. 3. Tighten both wing nuts (1) and (2) finger tight. 4. Move the net tensioner to the bottom end position, if it is just possible to move it by hand the wing nuts are correctly tightened. Otherwise tighten the wing nuts further.

• Page 124: Components For E-Link Pro

  11.6 Components for E-LINK PRO 11.6.1 Controller and Display 11-8 Maintenance/Setting 504/604 PRO Baler https://tractormanualz.com…

• Page 125
  (Explanation for Figure on previous page) Item Item controller «E-LINK PRO» net knife tripping device USB port hydraulic switch B1 sensor cutting device (knife group 1) hydraulic switch B2 hydraulic switch B3 sensor cutting device (knife group 2) sensor bale ramp hydraulic switch B4 and B5 sensor tailgate locking pressure control valve…
• Page 126
  3× Sensor M30 • Locking device, right • Locking device, left ∅ 1.18 in. (30 mm) • Net knife 11-10 Maintenance/Setting 504/604 PRO Baler https://tractormanualz.com…

• Page 127: Chain Lubrication System Maintenance

  If adjustment is required, only a trained service technician is allowed to make the change on the basis of the service information provided by Vermeer. Procedure 1.

• Page 128
  Test during the first few hours after filling 1. Check the oil level every 2 hours after filling the oil container. If necessary fill the oil container again. Figure 73. Lubrication oil container and pump KEY: 1. Cap — 2. Oil container — 3. Cap of the pump — 4. Oil pump — 5. Tubes NOTICE Change oil annually after the end of the season.

• Page 129: Maintenance Procedures

  • Replace drain plug [12] and refill gearbox [10] through check/fill hole [11]. Figure 74. Gearbox NOTICE Gearbox capacity is 57.5 oz (1.7 L). Use SAE-90 gear oil meeting API-GL5 specifications. Check filling level with dip stick weekly: Oil level must be between min. and max. mark. •…

• Page 130: Lubrication Chart

  • Lubricate the knife lever only on balers with cutting device XtraCut 17(see page 11-14). Maintenance after Every 500 Bales or more often, in sandy conditions twice per day Sharpen or replace the knives • Lubricate several parts of the baler (see page 11-14) •…

• Page 131
  Lubricant Specifications Multipurpose grease NLGI 2 extreme pressure grease, e.g. VERMEER LC Ultra or SHELL Alvania EP2 Always apply 2 strokes with a manual grease gun Chain Lubrication SAE 30 motor oil (do not use waste oil)) 504/604 PRO Baler Maintenance/Setting 11-15 https://tractormanualz.com…
• Page 132
  Lubricant Specifications Transmission oil SAE 90 transmission oil Machine oil Multifunctional oil After 500 bales after the first use Note Position in Baler part Lubricant figure Only balers with cutting device XtraCut 17: 500 bales after first use, then once per season grease knife lever After every 500 bales (or daily) Position in…
• Page 133
  After every 500 bales (or daily) Lubricant metering device (roller lubrication) on both sides Tailgate roller (at the lower edge of the on both sides, open and fix the tailgate 1/4 (see page 11-23) tailgate) Tailgate roller (at the lower edge of the on both sides, open and fix the tailgate 1/4 (see page 11-23) tailgate) Roller on locking device…

• Page 134: Clean The Baler

  At the end of the season annually (in case of special operating conditions also weekly) Star ratchet in pick-up drive left baler side Bearing on pick-up on both sides Applies to camless pickup: left and right grease nipple can only be seen after removal of the side covers Main gear unit Oil change…

• Page 135: Grind The Cutting Unit Knives

  11.8.4 Grind the Cutting Unit Knives WARNING: Chopper knives can cut fingers and hands. WARNING: Wear gloves and use suitable tool when handling chopper knives. WARNING: Do not do work on the magnets of the blade holders if you have a cardiac pacemaker or other implant that can be impaired by magnetic fields.

• Page 136
  6. Find the lever of the knife axle (see Figure 75 on page 11-20) on the feed channel housing in front of the tire on the right side. Swivel the lever down through 90° as far as the stop. 7. Go inside the bale chamber and use pliers to remove the knives •…

• Page 137: Replace Knives With Blind Knives

  11.8.5 Replace Knives with Blind Knives WARNING: Do not do work on the magnets of the blade holders if you have a cardiac pacemaker or other implant that can be impaired by magnetic fields. CAUTION: Do not hit the knives with any kind of tool from the bottom. This may damage the magnets and splinters may brake loose and cause injury.

• Page 138
  Figure 76. Knife storage KEY: 1. Knives or blind knives — 2. Cotter pin Install the blind knives 1. Go inside the baler and push the blind knives diagonally down onto the knife axle. 2. Swivel the lever of the knife axle up. 3.

• Page 139: Lubricate The Tailgate And Tensioning Arm Rollers

  11.9 Lubricate the Tailgate and Tensioning Arm Rollers Loosen the belts 1. Shut off the tractor and remove the key. 2. Pull the wire (1) (see Figure 77 on page 11-24) behind the hook (2) to lock the rocker arm. 3.

• Page 140: Adjusting The Scraper Plate

  Figure 77. Rocker arm KEY: 1. Wire — 2. Hook 11.10 Adjusting the Scraper Plate Correct adjustment of the two scraper plates [1] reduces the effect of jamming the two pick-up augers and optimizes the crop-flow (see Figure 78 on page 11-25). Adjust the scraper to auger clearance using the screws [2]: •…

• Page 141: Tensioning The Hydroflexcontrol

  Figure 78. Auger scraper 11.11 Tensioning the Hydroflexcontrol • Adjust the distance between top and bottom disc of the HYDROFLEX rubber spring: 2 in. (50 mm)(see Figure 79 on page 11-26). 504/604 PRO Baler Maintenance/Setting 11-25 https://tractormanualz.com…

• Page 142
  Figure 79. Hydroflex rubber spring 11-26 Maintenance/Setting 504/604 PRO Baler https://tractormanualz.com…

• Page 143: Assembly Procedures

  12 ASSEMBLY PROCEDURES 12.1 Driveline – Uncouple from Machine Before road transport: • Disconnect anti-rotation chain [1] from baler(see Figure 80 on page 12-1). • Open access cover of the guard cone [2](see Figure 81 on page 12-2). • Rotate gearbox shaft manually as needed to loosen and remove tapered pin [3] from clutch(see Figure 82 on page 12-3). Replace access cover of the guard cone [2](see Figure 81 on page 12-2).

• Page 144: Driveline — Couple To Machine

  Figure 81. Guard cone 12.2 Driveline – couple to machine Slide driveline onto gearbox shaft(see Figure 80 on page 12-1). • Open access cover [2] of the guard cone(see Figure 81 on page 12-2). • Rotate gearbox shaft manually as needed to install tapered pin [3] to clutch(see Figure 82 on page 12-3). •…

• Page 145: Coupling The Cam-Type Cut-Out Clutch

  Figure 82. Gearbox 12.3 Coupling the Cam-Type Cut-Out Clutch A driveline with automatic overload clutch (cam-type cut-out clutch) is installed. Clean and grease the profile of the machine sided connecting shaft prior to assembling. • • Loosen and turn out tapered pin [1]. •…

• Page 146
  Figure 83. Grease Figure 84. Cut-out clutch installation 12-4 Assembly Procedures 504/604 PRO Baler https://tractormanualz.com…

• Page 147: Technical Data

  13 TECHNICAL DATA 13.1 Overview 504/604 PRO Capprox. 60 in. × 48.4 in. (152 cm × 123 cm) Net wrapping unit with quality round bale net Length: 6,560 ft or 9,840 ft / width: max: 4.27 ft (Length: 2,000 or 3,000 m / width: max: 130 cm) center net roll tube inside diameter min.

• Page 148: Dimensions

  Speed of driveline 540 rpm Electrical connections Connection for lighting system 12 V (7-pole) Connection for control Connect to battery Length with closed tailgate [m] 16 ft 5” (5.0 m) Length with open tailgate 17 ft 7” (5.4 m) Width without gauge wheels 96”…

• Page 149
  Figure 85. Baler dimensions 504/604 PRO Baler Technical Data 13-3 https://tractormanualz.com…
• Page 150
  INTENTIONALLY BLANK Technical Data 504/604 PRO Baler https://tractormanualz.com…
• Page 151
  Index Advanced User Interface …………..5-18 Revision number …………….14-1 Calibration………………5-20 Safety signs………………2-7 Chain Lubrication …………….11-11 Serial number ………………iii side covers ………………2-19 Depressurize ………………10-3 Disposal ……………….11-4 Drawbar ………………..7-3 E-link pro……………….5-1 Eject a Bale ………………10-2 Field statistics page …………….5-14 Lubrication chart …………….11-14 Net tying ………………7-27 Pick-up Safeguard…………….2-17 PTO shaft……………….7-9…
• Page 152
  14 REVISION HISTORY Date Revision Page(s) Description o-m2_00 08/16 Second edition Operator’s and maintenance Manual released. 504/604 PRO Baler Revision History 14-1 https://tractormanualz.com…
• Page 153
  https://tractormanualz.com…

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• Page 1
  D60x90 Navigator ® Horizontal Directional Drill Operator’s Manual D60x90_o1_06 Serial No. 101 — Order No. 105400BQ7 Cabled Assembly No. 296338880…
• Page 2
  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.
• Page 3
  Orientation: Right and left sides of the machine are determined by facing the power vises while seated at the controls. RADEMARKS VERMEER, VERMEER Logo, NAVIGATOR, and ARMOR are trademarks of Vermeer Manufacturing Company. JOHN DEERE is a trademark of Deere and Company.
• Page 4
  Vermeer’s option without charge by any authorized independent Vermeer dealer. The warranty repair or replacement must be made by a Vermeer independent authorized dealer at the dealer’s location. Vermeer will pay for replacement parts and such authorized dealer’s labor in accordance with Vermeer’s labor reimbursement policy. Vermeer reserves the right to supply remanufactured replacement parts as it deems appropriate.
• Page 5
  (7) Transportation costs, if any, of transporting to the Vermeer dealer. Freight costs, if any, of transporting replacement parts to the Vermeer dealer. (8) The travel time of the Vermeer dealer’s service personnel to make a repair on the retail purchaser’s site or other location (9) In no event shall Vermeer’s liability exceed the purchase price of the product, (10) Vermeer shall not be liable to any person under any circumstances for any incidental or consequential damages (including but not limited to, loss of profits, out of service time) occurring for any reason at any time.
• Page 6
  (12) Depreciation damage caused by normal wear, lack of reasonable and proper maintenance, failure to follow operating instructions, misuse, lack of proper protection during storage. (13) Accessory systems and electronics not of Vermeer’s manufacture are warranted only to the extent of such manufacturer’s respective Limited Warranty if any.
• Page 7
  NO DEALER WARRANTY. The selling dealer makes no warranty of its own and the dealer has no authority to make any representation or promise on behalf of Vermeer or to modify the terms or limitations of this warranty in any way.
• Page 8
  Equipment Limited Warranty (the “Standard Limited Warranty”) for the Covered Components of the Specified Models of New Vermeer Industrial Equipment for the Lifetime of the Equipment provided that such Equipment is operated and maintained in accordance with the directions and instructions set forth in the Operator’s and Maintenance Manuals. All conditions, exclusions and limitations of the Standard Limited Warranty apply.
• Page 9
  Receiving and Delivery Report EALER Check or perform the following: ___ Check for shipping damage or shortage. ___ Check that work area cones are supplied with the machine. ___ Check that certificates for electrically insulated gloves (1 pair) and boots (2 pairs) are supplied with the machine.

• Page 10: Engine

  Engine ___ Check engine oil level. ___ Check condition of air cleaner. ___ Check air intake clamps. ___ Check battery charge and electrolyte level. ___ Check belts for correct tension. ___ Check coolant level and antifreeze concentration. ___ Check radiator hose clamps. ___ Check engine for correct operation.

• Page 11: Delivery

  ELIVERY Check and perform with the customer: ___ Review contents of the HDD Resource Library • Review the DVD on Horizontal Directional Drilling ___ Review all sections of the Operator’s Manual. ___ Grease or oil all lubrication points. Review and demonstrate with the customer the various aspects of Navigator HDD: ___ overall explanation of how the machine works ___ directional drilling safety ___ preparing the Navigator HDD for operation…

• Page 12: Dealer/Owner Information

  EALER WNER NFORMATION dealer owner address address city city state / province state / province zip / postal code zip / postal code country country phone number phone number email address email address iv Receiving and Delivery Report D60x90 Navigator HDD…

• Page 13
  ACHINE DENTIFICATION UMBER ECORD Model Number Serial Number ACHINE DENTIFICATION ECAL This decal provides identification of the model and 17-digit identification number. The barcode contains the machine’s VIN number and can be scanned with any barcode reading device. D60x90 Navigator HDD Receiving and Delivery Report v…
• Page 14
  NGINE DENTIFICATION UMBER ECORD On top of engine Engine Model Number Engine Serial Number NGINE ONTROL DENTIFICATION UMBER ECORD Model Number Serial Number vi Receiving and Delivery Report D60x90 Navigator HDD…
• Page 15
  RILLING LUID DENTIFICATION UMBER ECORD Model Number Serial Number D60x90 Navigator HDD Receiving and Delivery Report vii…
• Page 16
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• Page 17: Table Of Contents

  Table of Contents Receiving and Delivery Report …..i Remote Control ……..20-5 Tethered Secondary Remote Control (S/N 138 -) .

• Page 18
  Remote Control Operating Range ….20-30 Step — Non-Cab Operator Station…..20-64 Transport Controls .
• Page 19
  Locating Screens ……25-4 Lockout Procedure — Without Remote Lockout System 30-19 Version Screen .
• Page 20
  AutoDrill — Pause/Resume ….. . . 30-36 Range — Test ……. . . 40-14 Front Vise Function in Resuming AutoDrill .
• Page 21
  Driving Machine with Tethered Secondary During the Bore……..50-31 Remote Control .
• Page 22
  Drill Rods — Clean and Store ….. 50-55 Maintenance Intervals ……60-3 Flushing Bentonite/Polymers from Drilling Fluid System 50-55 Machine — Wash.

• Page 23: Safety Messages

  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”…

• Page 24
  WARNING: Check machine before operating. Machine must be in good operating condition and all safety equipment installed and functioning properly. WARNING: Wear personal protective equipment. Dress properly. Refer to “Personal Protection,” page 40-5. WARNING: Keep spectators away. WARNING: Engine exhaust can asphyxiate. Operate only outdoors. WARNING: Use before servicing, cleaning, repairing or transporting Shutdown Procedure…
• Page 25
  WARNING: Pressurized fluid can penetrate body tissue and result in serious injury or death. Leaks can be invisible. Keep away from any suspected leaks. Relieve pressure in the hydraulic system before searching for leaks, disconnecting hoses, or performing any other work on the system.

• Page 26: Fire Extinguisher

  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 result 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.

• Page 27: Welding Precautions

  Section 11: Welding Precautions ELDING LERT LECTRONIC OMPONENTS 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: Turn Battery Disconnect Switch (1) to DISCONNECT. Step 1: NOTICE: Disconnecting the battery ground with the battery disconnect switch will not prevent damage to the electronic…

• Page 28
  Under the seat, unplug three connectors, to the cab controller (5), the Step 4: Remote Lockout Controller (RLC) (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. Unplug carriage control unit (CCU) (8), rack output controller (ROM) (9), and vise controller (VOM) (10).

• Page 29: Intended Use

  Section 15: Intended Use The Vermeer D60x90 Navigator Horizontal Directional Drill is designed solely to create horizontal bores through the earth. Utilities are typically installed in these underground bores during pullback. Always use the machine in accordance with the instructions contained in this Operator’s Manual, safety signs on the machine, and other material provided by Vermeer Corporation.

• Page 30
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• Page 31: Controls

  Section 20: Controls Controls Locations ANEL ONTROL Strike Alert Indicator Light page 20-10 Remote Lockout LOCKOUT Mode Light (red) page 20-15 Remote Lockout Processing Light (yellow) page 20-15 Remote Lockout Run Mode Light (green) page 20-15 Wash Wand/Drill Fluid Selector Switch page 20-54 Strike Alert Switch page 20-9…

• Page 32: Left Panel Controls

  ANEL ONTROLS Horn Key Drill/Transport Mode Indicator page 20-33 Rotation Brake Key page 20-40 3-Speed Rotation Gearbox Key page 20-39 Left Stabilizer Lower Key page 20-35 Right Stabilizer Lower Key page 20-35 Left Stabilizer Lift Key page 20-35 Right Stabilizer Lift Key page 20-35 Rack Tilt Switch page 20-36…

• Page 33: Right Panel Controls

  IGHT ANEL ONTROLS AutoDrill Resume and Mode Select page 20-43 Remote Lockout Alarm Cancel page 20-18 Hydraulic Enable page 20-24 Rod Row Positioner page 20-46 Drilling Fluid Pump Increase/Decrease page 20-53 2-Speed Thrust/Pullback page 20-41 AutoDrill Rotation and Thrust Increase/Decrease page 20-44 D60x90 Navigator HDD…

• Page 34: Right Joystick

  IGHT OYSTICK Thrust Joystick page 20-41 Rear Vise page 20-51 Vise Rotation page 20-51 Rod Lower page 20-46 Front Vise page 20-51 Rod Lift page 20-46 Rod Transfer Arms Retract page 20-45 Rod Transfer Arms Extend page 20-45 OYSTICK Rotation Joystick page 20-38 Drilling Fluid On/Off page 20-52…

• Page 35: Remote Control

  EMOTE ONTROL Left Track Joystick page 20-31 Right Track Joystick page 20-31 Ground Drive Trim Switches page 20-31 Remote Power page 20-26 Hydraulic Enable page 20-24 Display Screen page 20-26 Remote Control Engine Stop page 20-22 Horn page 20-31 Ground Drive Calibrate page 20-32 Throttle Increase/Decrease (10)

• Page 36: Tethered Secondary Remote Control (S/N 138 -)

  (S/N 138 -) ETHERED ECONDARY EMOTE ONTROL Stop Button Press to stop machine. Rotate to pull button out and turn to ON. Signal Strength Status Off/On Left Track Forward Left Track Reverse Rack Tilt Right Track Forward Right Track Reverse Rack Level The tethered remote works only when an operator is not in the seat.

• Page 37: Remote Lockout Transmitter

  EMOTE OCKOUT RANSMITTER Power Button page 20-13 Lockout Button page 20-13 Run Button page 20-13 Yellow Processing Light page 20-14 Green RUN Mode Light page 20-14 Blue Low Battery Light page 20-14 Red LOCKOUT Mode Light page 20-14 TART UTTONS Engine Stop Button page 20-22 Start Button…

• Page 38: Local Lockout Buttons

  OCAL OCKOUT UTTONS Vise Local Lockout Carriage Local Lockout Button 20-8 Controls D60x90 Navigator HDD…

• Page 39: Strike Alert Controls

  Strike Alert Controls Strike Alert Test Switch Push top … .to test voltage and current sensing circuits. Alarm on drill unit must sound. NOTICE: If the alarm sounds when the key is pressed, it means the system is working correctly.

• Page 40
  Green Indicator Light ON ……Strike Alert system test passed FLASHING ……. . . sensor failure, ground stake not in ground or ground stake wiring problem OFF .

• Page 41: Strike Alert — Indicators And Controls

  Strike Alert — Indicators and Controls INDICATOR INDICATION SIGNIFICANCE Electrical strike occurred or Test Key pressed Two-Tone Horn Silent No voltage detected above threshold Test in progress, light burned out, or wiring harness problem Flashing Voltage stake is not in the ground Double Flashing Green Light Current sensor failed…

• Page 42
  Strike Alert Horn When alarm sounds, the drill may have contacted an electrical line. Alarm and machine horn will sound while the Test Key is pushed. Cab Machine Non-Cab Machine 20-12 Controls D60x90 Navigator HDD…

• Page 43: Remote Lockout Controls

  Remote Lockout Controls EMOTE RANSMITTER ONTROLS In order for the remote transmitter to function, machine ignition key must be ON. (1) Power Button (black) Press and hold until yellow light flashes ……. . ON Then green light illuminates solid.

• Page 44: Indicator Lights

  Indicator Lights Flashing or steady lights indicate various operating conditions (1) LOCKOUT Mode Light Red steady ….drill rotation, thrust/pullback, and fluid locked out (2) RUN Mode Light Green steady .

• Page 45: Remote Lockout Machine Controls

  EMOTE OCKOUT ACHINE ONTROLS Indicator Lights on Control Panel Flashing or steady lights indicate various operating conditions. RUN Mode Light Green steady ….drill control returned to operator Green flashing .

• Page 46: Indicator Lights On Display Screen

  Indicator Lights on Display Screen Flashing or steady light (4) indicates various operating conditions. Refer to next page. RUN Mode Light Green steady….drill control returned to operator Green flashing .

• Page 47: Remote Lockout Indicators

  Remote Lockout Indicators Transmitter Indicators Indication Function/Status Green RUN Light Steady RUN mode. Machine not locked out. Flashing Lockout requested; waiting for confirmation. Red LOCKOUT Light Steady LOCKOUT mode. Machine is locked out. Yellow Light Flashing No radio communication between transmitter and machine. Double flashing Remote is in Registration mode.

• Page 48
  Alarm Cancel Key Press to cancel continuously sounding alarm (5) when radio communication is not established. If alarm does not stop sounding, assume a strike has occurred. Alarm Non-Cab Machine Cab Machine Alarm sounds with a series of beeps or continuous tone to indicate various operating and Remote Lockout system conditions.

• Page 49: Remote Lockout Battery Charger

  EMOTE OCKOUT ATTERY HARGER Non-Cab Machine Tip seat (1) forward, then lift panel (2) to access. Insert battery into charger (3). Plug battery charger cord into one of the 12-volt 150-watt electrical accessory outlets (4) on operator console. Amber light on battery flashes when battery is fully charged.

• Page 50: Cab Machine

  Cab Machine Battery Charger Plug battery charger cord into 12-volt 150-watt electrical accessory outlet 20-20 Controls D60x90 Navigator HDD…

• Page 51: Engine Controls

  Engine Controls NGINE PERATION ONTROLS Keyswitch Vertical position ……. . engine stop 1st position clockwise .

• Page 52
  Start Button — Cab Machine For use only when keyswitch is not accessible. Press to start engine. Keyswitch inside cab must be turned to ON position. Buttons (2) and (3) are located inside storage box on outside front of cab. Engine Stop Button — Cab Machine Press to shut off engine.
• Page 53
  Battery Disconnect Switch Rotate key counterclockwise ….disconnect ground Rotate key clockwise ……connect ground D60x90 Navigator HDD Controls 20-23…
• Page 54
  Hydraulic Enable Key After starting, press key to enable the hydraulics for the rod loader, power vise circuits, and accessory circuits. WARNING: Pressing Hydraulic Enable Key will result in vise movement if the vise control switch positions were changed while the engine was off. Crushing injury may result.
• Page 55
  Throttle Increase Button — Drill Station, Rotation Joystick Press ……. . . increase engine RPM Throttle Decrease Button — Drill Station, Rotation Joystick Press .

• Page 56: Transport Controls

  Transport Controls RANSPORT EMOTE ONTROL Remote Control is disabled if operator is seated at controls. Remote Power Key Press for 3 seconds ..to turn Remote Control ON and OFF “Remote On” message appears on display screen. Release key;…

• Page 57: Contrast

  Contrast Press and hold (3), briefly press (1) ..increase Press and hold (4), briefly press (1) ..decrease Backlight Press and hold (2), then briefly press (1) ..on Press and hold (5), then briefly press (1) .

• Page 58: Remote Registration

  Remote Registration Turn on keyswitch. Engine need not be running. Step 1: Wait 5 seconds, then remove 2-pin Deutsch “Registration/Country” jumper Step 2: (7) from wire harness. Wait 3 seconds, then install jumper. Step 3: In 3 more seconds, light B (8) on the base controller double flashes red. Base controller is in registration mode.

• Page 59
  Non-Cab Machine Remote Control Transmitter Storage Bracket Remote Control Battery Charger Plug connecting cord into transmitter and charger. Cab Machine 12-volt 150-watt electrical accessory outlets Plug connecting cord into transmitter and charger. Remote Control Transmitter Storage Bracket Remote Control Transmitter Transport Container — on front of cab Computer Plug-In…

• Page 60: Remote Control Operating Range

  Remote Control Operating Range The following operating ranges assume the remote control system, including transmitter, batteries, and receiver, are in correct operating condition. Normal Range: within 100 ft (30 m) Maximum Recommended Range: up to 300 ft (91 m) • Check range before operating machine.

• Page 61: Transport Controls

  RANSPORT ONTROLS Left Track Joystick Push……. . left track FORWARD Pull .

• Page 62
  Ground Drive Calibrate Key Press and hold until “Enabled Trim On” appears on display. If machine tracks to the left, press right trim switch while tracking until tracking is correct. If machine is tracking to the right, press left trim switch until tracking is correct.
• Page 63
  Drill/Transport Mode Indicator ……Mode automatically changes to Drill when operator is in seat. Track Mode Indicator Light Comes on when operator is out of the seat and the remote is ON.

• Page 64: Transport With Tethered Remote (S/N 138 -)

  Transport with Tethered Remote (S/N 138 -) Left Track Forward Left Track Reverse Right Track Forward Right Track Reverse 20-34 Controls D60x90 Navigator HDD…

• Page 65: Setup Controls

  Setup Controls TABILIZER ONTROLS ONSOLE Three lights on keys come on while pressing key. Left Stabilizer Lower Key ……. Lift left rear of machine.

• Page 66: Rotary Stakedown Controls — Left Console

  OTARY TAKEDOWN ONTROLS ONSOLE Rack Tilt Switch Press……….tilt rack Rack Level Switch Press.

• Page 67: Rack And Stabilizer Controls — Remote Controls

  ACK AND TABILIZER ONTROLS EMOTE ONTROLS Rack Tilt Keys Press upper key ……..tilt rack Press lower key.

• Page 68: Drilling Controls

  Drilling Controls RILLING ONTROLS OTATION Drill Rotation Joystick (self-centering) Push ……rotate rod counterclockwise Use for uncoupling threaded drill rod.

• Page 69
  3-Speed Rotation Gearbox Key ……Controls drill rod rotation speed. Press to toggle through high, medium and low speeds. Rotation gearbox changes to LOW when front vise is on.
• Page 70
  Rotation Brake Key Default ……..off/disengaged Press once .

• Page 71: Drilling Controls — Thrust

  RILLING ONTROLS HRUST Thrust/Pullback Control Joystick (self-centering) Push ……..thrust drill forward Pull .

• Page 72
  Thrust/Pullback Pressure Gauge ……Thrust/Pullback Force in LB Actual Drilling Speed in FPM (M/MIN) 20-42 Controls D60x90 Navigator HDD…

• Page 73: Autodrill Controls

  RILL ONTROLS AutoDrill Set Button After pressing key (2) to select mode: AUTO Press and release ……activate AutoDrill Move either Rotation or Thrust/Pullback Joystick to pause AutoDrill mode.

• Page 74
  AutoDrill Rotation Pressure Increase Key In SPEED mode ……increases speed In ROTATION mode ….. . .increases pressure In DISABLE mode.

• Page 75: Rod Loader Controls

  OADER ONTROLS Right Rod Transfer Arms Retract Button (right joystick) Press trigger up ……… . .

• Page 76
  Rod Lift Button Press and hold ……lift rod to rod box Refer to “Rod Handling Components,” page 20-48.
• Page 77
  Anti-Crash Advisory Graphic turns orange to indicate carriage will not move because rod loader arms are extended. Rod Transfer Arm Barrier The barriers automatically move out (10) with the first movement of the rod loaders arms. Fold barriers back in manually before transporting.

• Page 78: Rod Handling Components

  Rod Handling Components Rod Lifter Rod Transfer Arm Rod Gripper Gripper is always closed unless trigger is activated. Top Rod Box Pin — keeps rod from being pushed out of box Center Rod Box Pin — keeps rod in removable rod box Bottom Rod Box Pin — keeps rod in fixed rod box Removable Rod Box Fixed Rod Box…

• Page 79
  Storage Position for Rod Box Pins Storage Position for Pins for Fixed Rod Box — keeps rods in fixed rod box (10) Install lock bar (11) on fixed rod box as needed. D60x90 Navigator HDD Controls 20-49…

• Page 80: Greaser

  REASER The greaser (1) lubricates drill rod threads. Press Grease Button (2) on left joystick to release grease. To adjust quantity of grease applied to threads, remove plug (3) at top of tube with Allen wrench, and rotate threaded screw inside in to decrease grease amount, or out to increase grease amount.

• Page 81: Power Vise Controls

  OWER ONTROLS Front Vise Switch Push up……. . clamp front drill rod Activating vise also opens gripper when rod loader is under selected row.

• Page 82: Drilling Fluid Controls

  RILLING LUID ONTROLS Fluid System ON/OFF Switch Push up ….. . .fluid system ON (variable flow) Pull down ……. . fluid system OFF Fluid Full Flow Button Press and hold .

• Page 83
  Drilling Fluid Pump Flow Increase Key Drilling Fluid Pump Flow Decrease Key Drilling Fluid Pump Flow Rate Display 0 ……….no flow 1 to maximum rated flow of pump .

• Page 84: Wash Wand Controls

  Wash Wand Controls Wash Wand/Drill Fluid Selector Switch Push top ……drilling fluid to drill rod Push bottom .

• Page 85
  Wash Wand Quick Coupler Antifreeze System Valve Rotate down (handle 90° to valve body) ….closed Rotate up (handle in-line with valve body) ….open Dump Valve Attach hose (not supplied) to release drilling fluid pressure in drill string.

• Page 86: Drill Station Controls

  Drill Station Controls PERATOR RESENCE ONTROLS Operator Presence Switch The machine is equipped with an Operator Presence system in the seat. The operator must be sitting in the seat for drill rotation and drill thrust to function. Seat Pivot Latch (Non-Cab Machine only) Lift rear lever or push front lever down to release seat pivot lock.

• Page 87: Work Lights

  IGHTS Light Switch Press top ……..work lights ON Press bottom .

• Page 88: Horn Keys

  Non-Cab Machine Remote Control Cab Machine NGINE OVER ATCHES Locking Push-Button Latch Releases T-Handles Push buttons (1) to open door. Turn handles (2) to open doors. To release latches (3) and close doors, pull bar (4) up. 20-58 Controls D60x90 Navigator HDD…

• Page 89: Radiator Grille Cover

  Radiator Grille Cover Remove three bolts (1) to swing cover up and open. Press yellow lock on prop bar (2) to close cover. D60x90 Navigator HDD Controls 20-59…

• Page 90: Auxiliary Outlets

  UXILIARY UTLETS 12-Volt Accessory Outlets Use connectors (1) to operate 12-volt 150-watt electrical accessories. A 15-amp breaker protects the circuit. Non-Cab Machine Cab Machine 20-60 Controls D60x90 Navigator HDD…

• Page 91: Cab Controls

  ONTROLS Door Latch Window Emergency Egress Hammer Cab Door Latch Cab door is held open by pressing metal loop (3) into latch (4). Pull latch release (5) to allow cab door to swing closed. D60x90 Navigator HDD Controls 20-61…

• Page 92
  Windshield Wiper Switch Top ……….high Middle.

• Page 93: Access

  CCESS Fuel Tank Handle Air Cleaner Access Door Radiator Access Door Use stepladder to access two doors on top of hood. D60x90 Navigator HDD Controls 20-63…

• Page 94: Step — Non-Cab Operator Station

  PERATOR TATION To install Operator Station Step: Remove retainer pin (1). Slide step from storage bin (2). Install step (3) in slots on operator platform. Install operator station step prior to stepping onto operator platform. To store Operator Station Step: Lift step (3) from slots on operator platform.

• Page 95: Console Display

  Section 21: Console Display This electronic system is designed to display various machine operating parameters. The system incorporates gauges and diagnostic indicators with an LCD (Liquid Crystal Display) of readings from which the operator may choose. Eight arrow buttons on either side of the display correspond to different functions on different screens.

• Page 96: Menu Screen

  CREEN Drilling Display next page Drill Setup page 21-12 Calibration page 21-16 Software Information page 21-19 Screen Brightness User Settings (Screen Brightness Setting) page 21-19 21-2 Console Display D60x90 Navigator HDD…

• Page 97: Drill Screen

  RILL CREEN This is the default screen at startup. Remote Lockout Status Green: Unlocked Yellow: No communication Red: Locked Strike Alert Status Green: Test passed, system ready Yellow: Stake not in ground, current sensor failure, or stake wiring problem Red: Strike has occurred. Rear Wireline Lockout page 55-11 Red: locked…

• Page 98
  Rotation Gauge Dial shows pressure in PSI, BAR or MPA or torque in FT-LB or NM. Green arc indicates current torque. Icon above and to the left of dial (A) shows High, Medium or Low Speed. Red arc shows adjustable rotation pressure or torque limit.
• Page 99
  Carriage Position Indicator (10) Anti-Crash Indicator (11) Graphic is in orange when anti-crash warning is in effect. Drilling Fluid Flow (12) Yellow triangle shows current set point. Drilling Fluid Pressure (13) Yellow triangle shows current set point. Hydraulic Fluid System Temperature (14) Fuel Gauge (15)

• Page 100: Autodrill Screens

  AutoDrill Screens Adjustment instructions are in the section. Refer to Overview “AutoDrill,” page 30-35. Symbol (A) turns green when mode is active, and turns black when AutoDrill is OFF. Abbreviation for mode appears above symbol. Red arcs (B) indicate adjustable maximum settings. AutoDrill Off AutoDrill cannot be SET or RESUMED.

• Page 101: Engine Screen

  NGINE CREEN Engine Oil Pressure Engine RPM Battery Voltage Press to access Drill Screen Engine Hours Coolant Temperature Normal operating range is from 170– 200°F (77–93°C). Fuel Level (when rack is level) Fuel Level Indicator Green: OK Yellow: Low, less than 20 percent Red: Empty, less than 10 percent Percent of Potential Engine Power Being Used…

• Page 102: Diesel Particulate Filter (Dpf)

  (DPF) IESEL ARTICULATE ILTER DPF Controls Diesel Particulate Filter Light Soot load indicates filter regeneration needed. Gray……… . .OK Yellow .

• Page 103
  Soot Percentage Indicator Request Forced DPF Regeneration Key Green for 5 seconds ….regeneration requested Gray ……cleaning not requested If filter does not need to be cleaned, pressing this key will not start cleaning process.

• Page 104: Forced Regeneration

  Forced Regeneration The DPF is self-cleaning and generally requires no operator action. Automatic regeneration is the standard mode. Regeneration should be disabled only if high exhaust temperatures pose a fire hazard, such as in confined spaces. However, if the Diesel Particulate Filter Light (1) is yellow, a forced regeneration may be required.

• Page 105: Auto Steer

  TEER Auto steering automates certain drill head motions. The operator sets and adjusts rotation duration and rotation direction. The bit rocks back and forth through an arc while maintaining a preset thrust pressure. Press Auto Steer Key (A) and hold for 3 seconds to access Auto Steer screens. Press key again to cycle through Auto Steer modes.

• Page 106: Drill Setup

  RILL ETUP Drilling Fluid This is the first screen displayed when Drill Setup Key is pressed. Icon (1) and top line (2) are highlighted. Press (3) or (4) to select parameter, which is then highlighted. Press (5) or 6) to increase or decrease a value. Parameters are: •…

• Page 107: Auto Stop

  Auto Stop This is the next drill setup screen. Icon (1) and top line (2) are highlighted. Press (3) or (4) to select parameter, which is then highlighted. Press (5) or (6) to increase or decrease a value. Parameters are: •…

• Page 108: Drilling Pressure

  Drilling Pressure This is the next drill setup screen. Icon (1) and top line (2) are highlighted. Press (3) or (4) to select parameter, which is then highlighted. Press (5) or (6) to increase or decrease a value. Parameters are: •…

• Page 109: Units

  Units Press (1) or (2) to select parameter, which is then highlighted. Press (3) or (4) to change units. All other parameters can be shown in metric or English units. • Rotation: torque or pressure • Thrust: pressure or force •…

• Page 110: Calibration Screens

  ALIBRATION CREENS Select carriage (1) and follow instructions on screen (2) to position carriage at front stop. Step 1: Press key (3) to re-zero carriage. Step 2: Select rod loader (4) and follow instructions on screen (5) to position rod loader at first row. Step 3: Press key (6) to re-zero rod arms.

• Page 111: Machine/Engine Diagnostics

  When the fault has been resolved, the message box border turns green, and the Hide Key changes to Recall to display messages again. For active faults or stop alerts, consult your Vermeer dealer. D60x90 Navigator HDD Console Display 21-17…

• Page 112
  Abbreviations and Acronyms in Fault Messages Cab Controller Cab Display Unit Power Distribution Module Pump Control Unit Pump Output Module Crane Controller Rack Control Unit Vise Output Module Carriage Control Unit Multi-Function Display Mud Pump Controller Reclaimer Control Unit Reclaimer Output Module Engine Control Unit (on engines) Left Joystick Right Joystick…

• Page 113: Screen Brightness Settings

  CREEN RIGHTNESS ETTINGS Press (1) or (2) to increase or decrease value. OFTWARE NFORMATION CREEN Displays part numbers and version numbers for software. D60x90 Navigator HDD Console Display 21-19…

• Page 114
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• Page 115: Digitrak Locating Program

  Section 25: DigiTrak Locating Program The DigiTrak Locating Program accepts telemetry signals from several systems. Refer to page 25-3. This section provides information on • how to set up the program to receive signals from your receiver • how to read the display screens. This program does not explain how to operate the locating systems;…

• Page 116: Navigation Screen

  AVIGATION CREEN This is the first screen in Target Steering mode when not using the SE locator program. Refer to your locator operator’s manual for details. Pitch Press to switch between angle and grade views. Sonde Temperature Press to switch between English and metric Drilling Fluid Pressure at drill head Press to switch between psi and bar…

• Page 117
  Locator Setup Screen Choose country. Options are: United States • United Kingdom • Australia • Switzerland • China • Netherlands • Choose DCI channel: 1–4. Choose type of device being communicated with: Eclipse A • Eclipse B • • • •…

• Page 118: Units Setup Screen

  Units Setup Screen Standard — choose English (U.S.) or metric Grade — percent/angle Radius — choose degrees or grade Locating Screens Image displayed when a locate point is taken with a DCI locator system Image displayed when a locate line is taken with a DCI locator system.

• Page 119: Version Screen

  Version Screen To access: Pressing Menu Key (1). Step 1: Press upper left key (2), which displays Locator Step 2: Setup Screen. Press key (2) again, which displays Version Step 3: Screen. D60x90 Navigator Directional Drill DigiTrak Locating Program 25-5…

• Page 120
  This page intentionally left blank.

• Page 121: Overview

  Section 30: Overview Remote Lockout Overview NOTICE: The Remote Lockout system is not intended to replace good spoken radio communication. Radio communication is essential to the Remote Lockout system process. Refer to “Radio Communication Requirements,” page 40-3. EMOTE OCKOUT YSTEM NTENDED The Remote Lockout system is a communication and control tool that allows a worker along bore path or at exit site to directly lock out:…

• Page 122
  NOTICE: Do not rely on the Remote Lockout system as an emergency stop. Even on successful remote lockout attempts, it is very unlikely that you could disable thrust and rotation quickly enough to prevent death or serious injury. Use the Remote Lockout system to lock out the machine before: •…

• Page 123: Remote Lockout System Component Identification

  EMOTE OCKOUT YSTEM OMPONENT DENTIFICATION Refer to “Remote Lockout Controls,” page 20-13. EMOTE RANSMITTER The remote transmitter (1) clips onto the user’s belt and has a range of 3300 ft (1 km). Range can decrease in some weather and environmental conditions, and in urban areas. The remote transmitter user can select either RUN or LOCKOUT mode, indicated by lights and buzzer.

• Page 124: Warning Alarm

  Warning Alarm If machine is not locked out, and if radio communication is not established within 10 seconds of entering Drill mode, a steady warning alarm sounds at the machine. If machine is locked out, the audible lockout horn (3) sounds and lockout symbol (4) is red.

• Page 125: Run Button

  Run Button The drill unit ignition key must be ON before the Remote Lockout system is turned on. If not, a loss of radio signal will be indicated at the remote transmitter. Refer to “Loss of Remote Transmitter Signal,” page 30-13. When transmitter is ON: Press green Run Button (3) and hold for 2 seconds to transfer control of drilling functions to the machine operator.

• Page 126: Remote Lockout Indicators

  If the remote transmitter is damaged and cannot be turned on, press Alarm Cancel Key (1). The yellow light will continue to flash, a reminder that the Remote Lockout is not functioning or communicating. Contact your Vermeer dealer for repair of the lockout system. Refer to “Troubleshooting” section in the for more information.

• Page 127: Hydraulic Lockout Or Engine Shutdown Option

  YDRAULIC OCKOUT OR NGINE HUTDOWN PTION The Remote Lockout system is equipped with an option to operate as either a Hydraulic Lockout (default) or an Engine Shutdown system. To change the system to engine shutdown: Move ignition key to OFF position. Step 1: Open right side access panel located beneath operator seat.

• Page 128: Auxiliary Engine Shutdown For Hydraulic Disable

  To change system back to hydraulic lockout: Move ignition key to OFF position. Step 1: Open rear access panel located beneath operator seat. Step 2: Remove jumper plug (1) from engine shutdown connector (3) (P131 black Step 3: and white wires), and attach to hydraulic connector (2) (P130 orange and white wires).

• Page 129: Remote Lockout Tests

  Test lockout of thrust and rotation by moving Thrust and Rotation Levers out of NEUTRAL. Thrust Step 6: and Rotation must not function. If Thrust or Rotation moves, contact your Vermeer dealer. After successful Lockout test, press and hold the green button (3) for 2 seconds to return to Drill mode.

• Page 130: Engine Shutdown Test

  Step 5: Machine is now in Lockout mode. Engine must shut down. If engine does not shut down, or if the engine can be restarted with Remote Lockout still in lockout mode, contact your Vermeer dealer immediately. After successful Lockout test, press and hold the green button (3) for 2 seconds to return to Drill mode.

• Page 131: Remote Lockout Transmitter Registration

  EMOTE OCKOUT RANSMITTER EGISTRATION If you replace the Remote Lockout system base or transmitter, register the two components. Turn Remote ON. Step 1: Push and hold black Power and red Lock buttons (1) simultaneously for 2 seconds Step 2: until yellow “No Communications” light (2) begins to double flash. Remote is in the Registration mode.

• Page 132
  In about 3 seconds Light B on the base controller (4) begins to double flash red. Base controller is in Registration mode. Yellow “No communications” lights on the remote (2) and machine (5) will flash Wait for registration results. Within 10 to Step 7: 30 seconds, the yellow “No communications”…

• Page 133: Loss Of Remote Transmitter Signal

  OSS OF EMOTE RANSMITTER IGNAL Loss of signal indicates that the remote transmitter and machine are not communicating with each other. Reasons for a loss of signal: • Remote transmitter is too far away from the machine. Range is up to 3300 ft (1 km). •…

• Page 134: Battery Condition

  ATTERY ONDITION Low Battery Low battery indication is only displayed on the remote transmitter. When approximately 10% of battery power is left, blue light (1) will flash. Discharged Battery If battery discharges and a loss of signal occurs in RUN mode, drilling will continue uninterrupted.

• Page 135: Remote Lockout System — Start

  Amber flashes slowly when battery is present but not charging. • Light is green and solid if charger has power (no battery present). More chargers are available from your Vermeer dealer for charging the battery in another vehicle. EMOTE OCKOUT…

• Page 136: Lockout Procedures

  OCKOUT ROCEDURES Lockout Procedure — With Remote Lockout System DANGER: Rotating drill string can kill. Unexpected start-up possible. Lock out before working on drill string. Lock out the machine before entering an exit pit, changing tools, repairing drill rod, manually adding or removing drill rod, or performing any other work on the drill string or tools.

• Page 137
  Drill mode, not Transport mode (operator seated at controls) • transmitter is within range. If the problem remains, contact your Vermeer dealer. When machine is successfully locked out, complete whatever work is required to change tools or repair Step 6: and replace drill rod or tooling.

• Page 138: Resuming Operation After Remote Lockout

  Resuming Operation after Remote Lockout Verify that drill rod and cutting tools are ready for operation. Step 1: Warn everyone who may be exposed to drill string or cutting tools that operation Step 2: will resume. Confirm that: Step 3: •…

• Page 139: Lockout Procedure — Without Remote Lockout System

  Lockout Procedure — Without Remote Lockout System DANGER: Rotating drill string can kill. Unexpected start-up possible. Lock out before working on drill string. Lock out the machine before entering an exit pit, changing tools, repairing drill rod, manually adding or removing drill rod, or performing any other work on the drill string or tools.

• Page 140: Drill Rod And Tools

  Death or serious injury will result. Use only drill rods, drilling tools, and breakout device described in this manual or approved by Vermeer Corporation. • Before using a new drill rod, tap drill rod against a hard surface, such as a wood block, to dislodge scale and rust inside.

• Page 141: Drill Tool Assemblies

  RILL SSEMBLIES Armor Drill Housing Assembly Attach housing (1) to drill string starter rod. Step 1: Follow instructions of transmitter for battery installation Step 2: and check function of transmitter. A variety of transmitters are available that fit inside the drill head cavity.

• Page 142
  Attach cover (5) with roll pin (6). Step 6: Install one socket head cap screw (7). Install O-rings (8), then bit (9) onto Step 7: housing. Insert solid cross pin (10) chamfer first. Hammer only on the rounded side of the pin. Install other socket head cap screw Step 8: (11).

• Page 143: Armor Multi-Tool

  Armor Multi-Tool Remove end cap (1) from handle of multi-tool and remove components. Screwdriver (2) — Used to scrape debris from holes in housing • and bit. • Hex Shaft (3) — Used to install and remove socket head cap screw that secures lid and bit cross pin.

• Page 144: Rotary Tooth Installation/Extraction — Gauntlet Bit

  Rotary Tooth Installation/Extraction — Gauntlet Bit Installation Align tooth shaft with mounting hole on bit. Place countersunk hole (6) over tooth. Hammer on back side of multi-tool, seating tooth fully. Extraction Using the 3/8˝ drive pin (5), push teeth out from the bit, fully exposing groove on tooth.

• Page 145: Locator System

  Reamer Carrier — Intended Use Vermeer reamer carriers are used to lift reamers weighing more than 50 lb (23 kg). The carrier allows you to install or remove reamers at the exit site while the machine is locked out. While holding the reamer with the carrier, you can turn the reamer by hand without rotating the drill string.

• Page 146: Reamer Carrier Styles

  Reamer Carrier Styles Vermeer Part Number Weight Limit Vermeer Part Number Weight Limit 296255-490 1000 lb (450 kg) 296260-037 2400 lb (1100 kg) Reamer Carrier Components The reamer carrier has a sliding frame (1) for adjustment to fit different size reamers and drill tools.

• Page 147: Reamer Carrier — Install/Remove

  Reamer Carrier — Install/Remove Using the reamer carrier requires two persons, one to attach and guide the carrier, and one to operate the lifting device. Use the correct reamer carrier connector for the reamer. Refer to previous page. To install the reamer carrier: Remove hairpin (1) and pin.

• Page 148: Turnbuckle — Adjust

  Turnbuckle — Adjust A turnbuckle (1) may be used for angular adjustment of reamer to drill string. Use appropriate- sized chain and turnbuckle for reamer and reamer carrier weight. WARNING: Do not lift a reamer that exceeds the weight limit of the carrier. WARNING: Falling load can injure you.

• Page 149: Reamer — Connect With Manually Threaded Joint And Collar

  Reamer — Connect with Manually Threaded Joint and Collar Lock out drill. Step 1: Clean all components. Step 2: Lubricate threaded end of reamer Step 3: (1). Align reamer with drill string and Step 4: manually turn reamer by hand until reamer is completely threaded onto drill string.

• Page 150: Pvc Pipe Pulling (Option)

  PVC P ULLING PTION The PVC puller assembly is used to pull PVC pipe back through the bored hole. Three different sizes of PVC pipe can be pulled by using the respective size pulling kits for 2˝, 3˝, or 4˝ PVC pipe. Assemble pipe lengths (if more than one) with the PVC puller (1).

• Page 151: Rod Loader Setup

  Rod Loader Setup WARNING: Falling load can crush. Never lift rod box over people. Do not stand or work under raised rod box. WARNING: Pinch points can result in serious crushing injuries. Keep hands and feet away from pinch points of rod loader. Keep red awareness bars lowered during rod loader operation.

• Page 152: Rod Box — Remove

  Rod Box — Remove Move rod loader to first row. Step 1: Fully retract rod transfer arm under rod box. Step 2: If removing rod box with rods, raise rod lifter to push rods into rod box. Step 3: Install two center rod support plates (2) and linch pins (3), one at each end Step 4: of rod box, to hold rod in rod box.

• Page 153: Rod Box — Install

  Rod Box — Install Lower rod lifters and shut off engine. Step 1: Connect hoist chain to lift eye (1). Step 2: NOTICE: Lift rod box by top lift eye only. Ensure male threads are at front of rod box. Step 3: If fixed rod box pin (2) was installed, remove it and place in storage Step 4:…

• Page 154: Rod Box — Prepare

  Rod Box — Prepare Push and hold up rods with Step 1: rod lifter. Remove two retainer pins (1) Step 2: and two rod box pins (2). Store rod support pins in Step 3: their storage location (3). Rod can now be added or removed from the rod box.

• Page 155: Automatic Functions

  Automatic Functions RILL AutoDrill acts as a cruise control by recording actual speeds and pressures when the AutoDrill Set Button (1) is pressed. This allows the operator to perform repetitive drilling functions automatically. AutoDrill — Set Press AutoDrill Resume/Mode Selection Key (2) to select the appropriate AutoDrill Step 1: mode.

• Page 156: Autodrill — Pause/Resume

  AutoDrill — Pause/Resume To pause AutoDrill, move either joystick out of center for at least 1/2 second. To resume: Press and hold AutoDrill Resume Key (2) for 3 seconds. Step 1: When rotation starts, release Resume Key. Step 2: Thrust/Pullback starts in 2–3 seconds, and AutoDrill is active. If thrust or rotation has not been active for 5 minutes, AutoDrill mode cannot be resumed, but must be reset.

• Page 157: Auto Steering

  TEERING Auto steering automates certain drill head motions. The operator sets and adjusts rotation duration and rotation direction. Two options are available: In Carve steering, the bit rocks back and forth through an arc while maintaining a preset thrust pressure. In Carve mode, the Rotation Joystick functions only as a switch to turn rocking motion on and off.

• Page 158: Carve Steering Setup

  Carve Steering Setup Use this procedure once at start-up. Rotate drill head to starting position, the center of the duration of Step 1: the sweep (1). Move both joysticks to NEUTRAL. Step 2: From Drill Screen, press Auto Steer Key (2) to access Steering Step 3: Setup Screen.

• Page 159: Zone Steering Setup

  Zone Steering Setup Use this procedure once at start-up. Rotate drill head to starting steering position, the center of the Step 1: duration of the sweep (1). Move both joysticks to NEUTRAL. Step 2: From Drill Screen, press Auto Steer Key (2) to access Steering Step 3: Setup Screen.

• Page 160
  When desired pressure is reached, AutoDrill function can be used. After pressing the Step 8: Left AutoDrill button, these actions should occur: Joystick a. Rotation will sweep to right side set point (end of sweep). b. Carriage will pull back the set distance. c.

• Page 161: Rod Wrap

  Rod Wrap As drilling distance increases and the drill string lengthens, the drill head rotates fewer degrees than the drive chuck. This is rod wrap. It varies with drilling conditions and drill pipe diameters. To compensate, increase angle with Increase/Decrease Keys (1). Failure to adjust may result in decreased productivity.

• Page 162: Vise Operating Guidelines

  PERATING UIDELINES WARNING: Pinch points in vise can crush. Keep hands away. DANGER: Wrench on rotating drill string can strike you. Death or serious injury will result. Always use the power vise to make or break joints at the machine. •…

• Page 163: Antifreeze — Add To Drilling Fluid System

  NTIFREEZE DD TO RILLING LUID YSTEM Store antifreeze in tank (1). It can be reused as necessary. Replace antifreeze when it is too diluted to protect system. Drain and flush drilling fluid hoses and water pump. Refer to “Flushing Step 1: Bentonite/Polymers from Drilling Fluid System,”…

• Page 164
  Select Wash Wand/Drill Switch (5) on control panel to WASH WAND Step 7: position. Start engine. Step 8: WARNING: High pressure water can penetrate skin. Serious injury possible. Fluid injected under the skin must be removed immediately by a surgeon familiar with this type of injury Keep nozzles away from body.

• Page 165: Preparation

  Section 40: Preparation Preparing Personnel PERATOR UALIFICATIONS WARNING: Read Operator’s Manual and safety signs, and watch the operations and safety video, before operating machine. Allow only responsible, correctly instructed individuals to operate machine. Become familiar with the controls, operation, and use of the machine under the supervision of a trained and experienced operator.

• Page 166: Training

  RAINING Before operating the drill unit, the operator and crew should be trained in the operation of horizontal directional drills. Initial training should be conducted at a site free of underground utilities and should cover: • all sections of this manual •…

• Page 167: Radio Communication Requirements

  ADIO OMMUNICATION EQUIREMENTS The Remote Lockout system is not intended to replace good verbal radio communication. Radio communication is essential to the Remote Lockout system process. WARNING: Proper communication is essential to prevent unplanned start-up of the drill string and/or tool. Serious injury or death could result. Always follow communication requirements as explained below.

• Page 168: Radio Communication To Stop Drilling Operation

  Radio Communication to Stop Drilling Operation When crew at the location of exposed drill rod or tool requests the operator to stop operation: The crew must communicate a stop command to the operator. Step 1: When stop command is received, the operator must immediately stop the machine. After machine has Step 2: stopped, the operator must return a message confirming that the message was received and understood.

• Page 169: Personal Protection

  ERSONAL ROTECTION WARNING: Wear personal protective equipment. To reduce the risk of being caught and entangled in moving components, wear close-fitting clothing and confine long hair. Do not wear jewelry, such as rings, wristwatches, necklaces, or bracelets. Working around the machine requires you to wear protective equipment. Always wear a hard hat, wraparound eye protection or goggles, and electrically insulated boots.

• Page 170: Sound And Vibration Levels

  Sound and Vibration Levels The stated sound levels are representative for a given operating condition. Operating conditions may vary at each jobsite. The actual sound levels for your application and operating conditions may be different. Equivalent Continuous A-Weighted Sound Pressure at Operator’s Ear as specified by directive 2000/14/EC, ISO 3744, and ISO 11201 .

• Page 171: Underground Utility Contact

  NDERGROUND TILITY ONTACT WARNING: Electricity or gas explosion can kill. Laser light in cut cable can result in eye damage. Locate utilities before drilling. Call 811 (U.S. only) or 1-888-258-0808 (U.S. or Canada) or local utility companies or national regulating authority. Before you start any digging project, do not forget to call the local One-Call system in your area and any utility company that does not subscribe to the One-Call system.

• Page 172: Electrical Shock Protection

  LECTRICAL HOCK ROTECTION DANGER: Electric shock can kill. If strike occurs, do not step off. DANGER: Contact with the drill rack, power supply, drilling fluid systems or operator station while standing on the ground could result in electrocution if an electrical strike occurs.

• Page 173: Electrocution Prevention

  Electrocution Prevention Electrocution is possible. Serious injury or death may result if the drilling tool strikes an energized power line. Refer to the operating instructions, and take the following precautions to prevent electrocution: • Call your One-Call system, and any utility company that does not subscribe to the One-Call system, before the start of your drilling project.

• Page 174: Electrically Insulated Gloves

  The ASTM In-Service specifications call for an electrical retest of gloves at a test lab every 6 months. This test is to recertify the non-conductivity of the gloves. Contact your Vermeer dealer for the location of the test lab in your area or a listing of the test labs.

• Page 175
  Electrically Insulated Gloves — Inspect Visually inspect insulated gloves and leather protectors before each use. • Check for signs of physical damage or chemical deterioration such as swelling, softness, hardening, stickiness, ozone deterioration, or sun-checking from prolonged exposure to sunlight. •…

• Page 176: Electrically Insulated Boots

  Electrically Insulated Boots If electrically insulated boots are not available locally, they can be obtained through Vermeer Corporation. A two-pair purchase voucher is supplied with the machine. Rubber electrically insulated boots, when in good condition and correctly used, also help protect the wearer from serious injury, death, and electrical burns.

• Page 177: Strike Alert System Functions

  Strike Alert System Functions The Strike Alert is only a warning device, not a protective device. The Strike Alert system detects voltage on the machine and/or current running through the drill string in the event of drill striking an underground power line. An alarm sounds alerting operator and other personnel of a potentially dangerous situation.

• Page 178: Preparing The Machine

  Preparing the Machine PERATOR RESENCE YSTEM The Operator Presence system prevents track drive function if the operator is seated at the controls. Thrust and rotation will not function if these controls are pushed when the operator is not in the seat. This system is intended for your safety and must be maintained in good functional condition.

• Page 179: Remote Lockout System — Test

  • Drill mode is active, with the operator seated at controls. If a problem remains, contact your Vermeer dealer, and use the “Lockout Procedure — Without Remote Lockout System” until the Remote Lockout system is repaired. Refer to page 30-19.

• Page 180: Preparing The Work Area

  Use information in this manual and your own good judgment to identify and prevent these hazards. Power Line Locator System A locator system to locate underground power lines is not included with the system but may be purchased from Vermeer dealerships. 40-16 Preparation D60x90 Navigator HDD…

• Page 181: Warning Cones

  Warning Cones Check that orange warning cones with warning safety signs are available for placement around drill unit work area. Four orange warning cones are provided. AWS AND EGULATIONS HECK Know and obey all federal, state, and local laws and regulations that apply to your work situation. LANNING THE WARNING: Electricity or gas explosion can kill.

• Page 182
  This page intentionally left blank.

• Page 183: Operation

  If pressure is too high, open the appropriate bleeder valve to reduce the pre-charge pressure. Close valve by turning clockwise before starting engine. Step 3: NOTICE: Operation of accumulator without sufficient pre-charge can cause bladder failure. Recharging Pressure Contact your Vermeer service dealer for recharging. D60x90 Navigator HDD Operation 50-1…

• Page 184: Starting The Engine

  TARTING THE NGINE Shut off drilling fluid pump. Step 1: Connect battery. Step 2: Put Rotation and Thrust/Pullback Joysticks in NEUTRAL. Step 3: Turn remote lockout transmitter on. Step 4: • The Remote Lockout system self-tests upon start-up, indicated by two short beeps. It then enters whatever mode it was in when the machine was shut down.

• Page 185: Cold Weather Starting

  • Slow down engine if hydraulic pump makes a high-pitched noise because it does not get enough oil. For frequent starts below 10°F (-12°C), consult your Vermeer dealer. Cold Weather Start System The engine is equipped with an engine block heater. Plug connector (1) into electrical source.

• Page 186: Shutdown Procedure

  Shutdown Procedure Shut off drilling fluid pump. Step 1: Reduce engine speed to idle. Step 2: Wait 2 minutes to shut off engine when shutting down after operating at full power. Step 3: Shut off engine and remove key. Step 4: 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.

• Page 187: Transporting The Machine

  Transporting the Machine RIVING THE ACHINE Survey area around machine for persons and obstacles before driving or moving machine. WARNING: Rollover possible. Be alert and use extreme caution when operating on hillsides, or near ditches, gullies, holes, or obstructions where rollover could occur. Serious injury or death can result if crushed under the machine.

• Page 188: Backup Warning Alarm

  Backup Warning Alarm WARNING: Before backing, clear area and warn others to stay away. Serious injury or death could result if a person is struck or run over by the machine. Have a spotter direct the operator while moving the machine. Whenever machine is in REVERSE, backup warning alarm will sound.

• Page 189: Safe Operating Slope

  Safe Operating Slope Safe operating slope depends on many factors, including: • Machine weight distribution, including front loading or absence of load • Height of load • Even or rough ground conditions • Potential for ground giving way, causing unplanned forward, reverse, or sideways tilt •…

• Page 190: Preparing For Transport

  REPARING FOR RANSPORT Store cable and voltage stake (1) on storage bracket at back of rack. • • Install rod retainers in top of rod box to prevent drill rods from coming out of rod box during trailering. • Put front rod box latch in locked position (2) to secure rod box to machine. •…

• Page 191: Driving Machine With Wireless Remote Control

  Driving Machine with Wireless Remote Control Turn ignition key to ON. Step 1: Raise rack to level position. Step 2: Press Remote Power Button (1). Step 3: Push Left Track Joystick (2) and Right Track Joystick (3) forward to drive Step 4: machine forward.

• Page 192: Driving Machine With Tethered Secondary Remote Control

  Driving Machine with Tethered Secondary Remote Control This control overrides Wireless Remote Control. Turn ignition key to ON. Step 1: Plug pendant connector in at toolbox. Step 2: Turn power button (1) to ON. Step 3: Press forward and reverse buttons as needed. Step 4: When finished, turn power button to OFF.

• Page 193: Trailering The Machine

  RAILERING THE ACHINE Loading/Unloading Before transporting machine on a truck or trailer, read truck or trailer manual for safety precautions and information. Clear trailer bed and ramps free of debris that will interfere with the loading process. WARNING: Machine may slide down loading ramps or off trailer deck. Serious injury or death can result if struck or crushed by machine.

• Page 194
  SLOWLY drive machine Step 3: squarely onto trailer. Stop machine when tie-down Step 4: position is reached. The tie- down position distributes machine weight on the trailer as recommended by trailer manufacturer. Lower rear stabilizers and Step 5: drill rack frame. Follow Step 6: Shutdown Procedure,…

• Page 195: Retrieval

  Disengage park brakes and bypass ground drive pump to allow hydraulic Step 2: fluid to circulate. Contact your Vermeer dealer for instructions. NOTICE: Towing device (chain, cable, or strap) must have a minimum working load of 150% of towing machine weight.

• Page 196: Setup

  Setup Walk the bore path and look for signs of utility lines, potential causes of locator interference, and general assessment. These signs could indicate presence of utility lines: • Ditch lines or depressions where the ground has settled from previous excavation. •…

• Page 197: Strike Alert System — Test

  TRIKE LERT YSTEM Test the Strike Alert system before operating the drill unit. Do not operate drill unless the Strike Alert test confirms the system is operational. Ensure current sensing coil (1) and coil connectors Step 1: are not damaged. Unwind voltage stake cable.

• Page 198
  Press top of Test Key (5). The Step 4: Strike Alert alarm (6) must sound. Press bottom of test key to silence alarm. The Strike Alert system is not functioning correctly if there is a flashing green light (3) after releasing the test key, or if icon (4) on screen turns yellow.

• Page 199: Machine — Anchor With Stakes

  Step 5: need to be moistened to improve conductivity of the earth. Retest the system. If the test fails again, contact your Vermeer dealer. Step 6: NOTICE: The Strike Alert system automatically runs a system check whenever the machine is powered up (ignition key turned from OFF to RUN).

• Page 200: Locating Equipment — Prepare

  OCATING QUIPMENT REPARE Fully charge locator batteries or install new batteries in the transmitter every day. Standard “C” batteries usually last up to 15 hours. Some locating systems require calibration before drilling. Failure to do so could result in inaccurate depth readings on the locator.

• Page 201: Rod Wiper — Install

  IPER NSTALL Use rod wiper (1) to clean drill rod when drilling. Install rod wiper into rod wiper holder (2). NTRANCE AND ITES REPARE WARNING: Do not work in trench with unstable sides which could cave in. Specific requirements for shoring or sloping trench walls are available from several sources, including federal and state O.S.H.A.

• Page 202: Warning Cones

  ARNING ONES Check that orange warning cones with warning safety signs are available for placement around drill unit work area. Four orange warning cones are provided. Set up orange cones around the machine with warning safety signs facing outward before starting operation. The safety sign warns unauthorized persons to stay away.

• Page 203: Safety Precautions

  AFETY RECAUTIONS DANGER: Contact with the drill unit while standing on the ground could result in electrocution if an electrical strike occurs. Do not touch the drill unit or remote fluid mixing system while drilling or after an electrical strike occurs. See other portions of this manual regarding procedures and personal protection equipment to avoid electrocution.

• Page 204
  DANGER: Electric shock can kill. Workers standing on the ground must not touch machine when alarm sounds. NOTICE: If a strike occurs, do not allow anyone to approach machine. The machine and ground will be electrically charged. If seated on the machine: •…

• Page 205: After Utility Company Has Shut Off The Power

  After Utility Company Has Shut Off the Power Press Strike Alert Alarm Cancel Key to shut off alarm. Step 1: Press Strike Alert Test Key to test Strike Alert system. If alarm sounds while key is pressed and green Step 2: light remains ON steady when the key is released, the Strike Alert system is undamaged.

• Page 206: Before The Bore

  Before the Bore WARNING: Keep spectators away. WARNING: Do not work in trench with unstable sides which could cave in. Specific requirements for shoring or sloping trench walls are available from several sources including federal and state O.S.H.A. offices. Be sure to contact suitable authorities for these requirements before working in the trench.

• Page 207: Diesel Particulate Filter (Dpf) Safety

  If the drill is starting at a shallow angle or the ground is hard, dig a small hole so drill bit can start drilling perpendicular to the soil. If drilling fluid additives are used, refer to manufacturer’s recommendations for handling precautions. (DPF) S IESEL ARTICULATE…

• Page 208
  WARNING: The DPF Light indicates a need for a forced regeneration, due to engine or operator conditions being outside the range for automatic regeneration. Move machine to a safe location and press Request Forced DPF Regeneration Key. After regeneration, follow these guidelines to reduce soot buildup in the DPF: •…
• Page 209
  WARNING: When DPF Light is red, machine operation has continued after DPF Light was yellow. Engine derates further, and may shut down. If this results in premature failure of exhaust system components, an engine service technician will be required to perform a service regeneration.

• Page 210: Drill Rod — Flush

  RILL LUSH If the drill rod has not been used within the last 24 hours, or if there is debris inside the drill rod, slowly rotate rod and flush it with drilling fluid before connecting it to the drill head. Move Wash Wand/Drill Rod Selector Switch (1) to Step 1: DRILL RODS.

• Page 211
  Use Drilling Fluid Increase/Decrease Keys (4) to increase or decrease Step 5: drilling fluid flow. Monitor drilling fluid flow rate on display (5). Monitor drilling fluid pressure on gauge (6). Step 6: If the drill becomes plugged: Step 7: • either dig down to the drill head, •…

• Page 212: Drill Rod — Lubricate

  RILL UBRICATE Press Grease Button (1) on left joystick to release grease. Refer to section “Lubricants” in the for specifications. Specifications Maintenance Manual Lubricate male rod threads and shoulders. Apply lubricant to clean, dry threads. NOTICE: Keep electrically insulated gloves from coming in contact with lubricant. Petroleum-based products will chemically damage gloves.

• Page 213: During The Bore

  During the Bore EGIN RILLING With bill at 6:00 position, thrust until drill rod just enters the ground. Step 1: Stop pushing Step 2: Rotate drill head until rod is centered in the rod guide rollers. Step 3: When centered, rotate and push remainder of drill rod into the ground. Step 4: •…

• Page 214: Drill Rods — Add To Drill String

  RILL DD TO RILL TRING (Step 1) Right Rows must be emptied sequentially, from first through last row, to prevent rods from being dumped out of the rod box. As each row is emptied, move the transfer arm to the next row. Press up and hold Rod Transfer Arm Retract Button (1) to Step 1: move rod transfer arm to the selected row for removing rod.

• Page 215
  Press down and hold Rod Transfer Arm Extend Button (4) Step 4: (Step 4) Right to move rod transfer arm to drill string. Release button (2) to close gripper. Step 5: Insert drive chuck (5) into rear rod end. Step 6: Left With minimum thrust and full rotation, begin to Step 7:…
• Page 216
  Release rod gripper: press and hold Rod Gripper Button (2) Step 9: (Step 9) and move rod transfer arm (6) back under rod box. Left With minimum thrust, full rotation, and with front vise Step 10: clamped on downhole rod, thread rear rod into downhole rod and tighten to 3700 psi (255 bar).

• Page 217: Drill Rod Row — Select

  Drill Rod Row — Select Move to next row when row has been completely emptied. Extend rod transfer arm. Step 1: Raise rods with rod lifter. Step 2: Use Rod Row Select Left Key (1) to move rod transfer arms to next row. Step 3: Current row (2) is shown on screen.

• Page 218: Gauges — Monitor

  AUGES ONITOR Monitor gauges to establish a baseline for rotation and thrust/pullback pressures. Try to keep rotation and thrust/pullback pressures as low as possible throughout the bore. Rotation Pressure (1)–Rotation pressure rises as the bore progresses, due to friction on the increasing length of the drill string. But if rotation pressure rises substantially, even when not trying to make forward progress, it could mean that soil is taking on water and swelling around the drill string.

• Page 219: Obstructions — Investigate

  BSTRUCTIONS NVESTIGATE Closely monitor the drilling rate and investigate any obstruction to determine if it might be hazardous. Check to ensure tool is not in contact with a gas line, water line, electrical line, or some other underground obstruction that can be damaged or result in personal injury. LUGGED RILL If a drill rod becomes plugged, use correct lockout procedures:…

• Page 220: Exiting The Bore

  Exiting the Bore It is critical to maintain good communication between the machine operator and locator operator. When the bore reaches the exit point, crew must ensure everyone is clear of the area. The operator should be ready to turn off drilling fluid pump as drill head exits the ground. When the drill head exits the ground, use correct lockout procedures to prevent inadvertent startup and rotation during the tooling change.

• Page 221: Remote Lockout Use

  Remote Lockout Use Always use correct lockout procedures before changing tools. Refer to: • “Lockout Procedure — With Remote Lockout System,” page 30-16 • “Lockout Procedure — Without Remote Lockout System,” page 30-19 Communication Requirements WARNING: Proper communication is essential to prevent unplanned start-up of the drill string and/or tool.

• Page 222: Swivel Use

  Swivel Use The reamer must be equipped with a swivel to prevent trailed rod or product from turning while reaming. If reamer does not have a built-in swivel, install an external swivel. Refer to the Fundamentals of Horizontal “Pullback Tips,” for additional information on reamer selection and swivels. Directional Drilling User’s Guide, DANGER: Entanglement in rotating drill string can result in death or serious injury.

• Page 223: Pullback Tool — Install

  Pullback Tool — Install DANGER: Wrench on rotating drill string can strike you. Death or serious injury will result. Never install tooling that requires the use of pipe wrenches or tongs. Use communication procedures. Refer to “Radio Communication Requirements,” page 40-3. Install backreamer.

• Page 224: Resuming Operation

  Secure with pin (2). Swivel must be aligned with the reamer before rotating the reamer. Vermeer double-eye swivels are designed for use with Vermeer reamers to limit the angle between the reamer and swivel. Vermeer swivels and reamers aligned within this limited angle will reduce the possibility of whipping and rotation of the trailed product.

• Page 225: Pullback — Start

  ULLBACK TART NOTICE: Never rotate drill rod counterclockwise while pulling back or backreaming. Counterclockwise rotation will uncouple the drill string. WARNING: Backreamer may not follow the bore path exactly. Because of increase in bore size and change in bore path, the backreamer may make contact with underground hazards that were missed during drilling.

• Page 226
  Push Front Vise Switch (1) up to clamp onto downhole rod. Step 5: NOTICE: When front vise is clamped, carriage speed changes to HIGH. Push Rear Vise Switch (2) up to clamp onto rod to be removed. Step 6: Right Press Vise Rotation Button (3) to break joint.
• Page 227
  Reverse rotate just enough to break rear joint. Step 14: NOTICE: Do not fully unthread rear joint. Pull back rod far enough so front threads will clear vise Step 15: assembly, to next stop point. Fully unthread rod from drive chuck and move carriage Step 16: toward rear of rack.

• Page 228: Drill Rod Row — Select

  Open rod gripper: press Rod Gripper Release Button (4). Step 19: Press and hold Rod Lift Button (8) to raise rod lifter (9) and lift rod into rod box. Step 20: Left Drill Rod Row — Select Move to next row when row has been completely filled. Extend rod transfer arm.

• Page 229: Breaking Rod Joints — Safety Considerations

  Breaking Rod Joints — Safety Considerations If a drill rod joint cannot be broken at the vise, repair the vise. • Never put a pipe wrench or tong on the drill string and use drilling machine torque to break the joint. •…

• Page 230: Swivel Use

  Swivel Use Refer to “Swivel Use,” page 50-40. NOTICE: Some swivels, such as a double-eye swivel, can be incorrectly aligned with the reamer. If the swivel is not straight in-line with the reamer, it might not swivel as intended. Instead it could turn like a crank, causing the product to turn and whip.

• Page 231: Resuming Operation

  WARNING: Never attach a pipe wrench or tool and apply force from a machine such as a backhoe to tighten or break a connection. If the wrench slips off the bucket, the wrench could rotate or be thrown and strike you. Death or serious injury may result. Attach rod recycler adapter to the first drill rod and tighten snugly.

• Page 232: Pulling Back With Trailing Rod

  Pulling Back with Trailing Rod DANGER: Drill string and tooling can rapidly move sideways along the ground at the exit location if rotation is started when drill rod or tooling is on the ground, away from the exit hole. The larger the diameter of the reamer and the more drill string exposed the faster and farther the reamer and drill string can travel.

• Page 233: Push-Through Method Of Adding Drill Rod For Pre-Reaming

  Push-Through Method of Adding Drill Rod for Pre-Reaming When the drill head exits the pilot bore, rotate drill head to 12:00 position. Step 1: Continue adding more drill rods at the machine and pushing rods through the bore hole. Step 2: DANGER: Entanglement in rotating drill string or cutters can kill.

• Page 234: Resuming Operation

  Resuming Operation Remove breakout device and tools from the drill string. Step 1: Keep everyone away from entire length of the drill string. Step 2: Press Run Button on transmitter and hold for 2 seconds to enable drilling operation. Step 3: DANGER: Wrench on rotating drill string can strike you.

• Page 235: Gauges — Monitor During Pullback

  AUGES ONITOR URING ULLBACK Monitor gauges during drilling. Ideally, the pullback pressure will remain low while the reamer mixes drilling fluid with the soil to form a good slurry flow through the annular space. Rotation Pressure (1)–If rotation pressure is spiking, you may be pulling back too fast for the ground conditions.

• Page 236: After Each Bore

  After Each Bore Power Vises — Clean WARNING: High pressure water can penetrate skin. Serious injury possible. Keep nozzles away from body. Fluid injected under the skin must be removed immediately by a surgeon familiar with this type of injury. Flush power vise assemblies with clean water to remove accumulated polymers or dirt.

• Page 237: Drill Rods — Clean And Store

  Drill Rods — Clean and Store • Clean and lubricate drill rod threads to prevent rusting. Refer to the section, “Lubricants,” in Specifications Maintenance Manual. • Protect drill rod from damage. • Store drill rods in the rod box on drill unit. •…

• Page 238: Machine — Wash

  Connect wash wand to drilling fluid pump quick coupler (1). Step 4: Move Wash Wand/Drill Rod Fluid Selector Switch (2) on operator console Step 5: to wash wand position. Turn on the water system and flush water through wash wand until water Step 6: is clean and clear.

• Page 239
  Before loading onto transport vehicle, wash drill unit with clean water to remove accumulated polymers and dirt. WARNING: High pressure water can penetrate skin. Serious injury possible. Fluid injected under the skin must be removed immediately by a surgeon familiar with this type of injury.
• Page 240
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• Page 241: Supplemental Operations

  Section 55: Supplemental Operations Jump-Starting ATTERY XPLOSION REVENT 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. Do not jump-start or charge a battery that is frozen or low on electrolyte.

• Page 242: Battery Burns — Prevent

  ATTERY URNS REVENT Battery contains sulfuric acid which can cause severe burns. Prevent contact with eyes, skin, and clothing. 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 aid.

• Page 243
  Turn ignition switch OFF. Step 1: Turn Battery Ground Disconnect Switch (A) counterclockwise to Step 2: disconnect battery ground. Connect jumper cables in this order: Step 3: a. Red to discharged battery POSITIVE (+) terminal (1). b. Red to boost battery POSITIVE (+) terminal (2). c.

• Page 244: Pbd7500 Portable Breakout Device

  PBD7500 Portable Breakout Device NTENDED The Vermeer PBD7500 Portable Breakout Device is a compact breakout system, manually activated, which provides a convenient method to loosen or tighten a threaded connection. Its intended use is with drill rod with an outside diameter of 1.88–3.31˝ (4.8–8.4 cm) at 7500 ft-lb (10170 Nm).

• Page 245: Breakout Device Operation

  REAKOUT EVICE PERATION WARNING: Improper use can cause device to fail. Read Operator’s Manual. Use device properly. Position tongs (1) on drill rod, Step 1: one on each side of joint, in makeup or breakout position. Refer to “Configurations,” page 55-8.

• Page 246
  Hand-tighten adjustment Step 2: clamp jaw nuts (4). Use a 1-5/ 16˝ wrench to snug nuts, but do not tighten. Lengths of threaded portion beyond nuts (5) should be approximately equal. Install threaded T-bar (2) and Step 3: pins (3). You may need to adjust tongs.
• Page 247
  NOTICE: Overtorquing will cause shear pins (8) inside tong arms to fail. Replace only with Vermeer pins, P/N 296406760. Thread Makeup Torque Distance Description FST #200 1000 ft-lb/1356 Nm 1/8˝/3.2 mm FST #250 1333 ft-lb/1807 Nm 3/16˝/4.8 mm FST #400 1733 ft-lb/2350 Nm 1/4˝/6.4 mm…

• Page 248: Configurations

  Inspect threaded rod on T-bar for wear or damage to threads. Replace parts immediately if worn or damaged. Contact your Vermeer dealer. Mud Motors Mud motors are long, cylindrical, lobed motors which use fluid pressure to turn the drill bit. Mud motors therefore require high drilling fluid flow rates to operate consistently and without cavitation.

• Page 249: Replacing Broken Drill Rod Underground

  Replacing Broken Drill Rod Underground Retract drill string back to the drill unit until broken rod exits the ground. Keep track of the length of Step 1: drill rod retracted so you can determine the location of the underground break. Use power vises to break the joint and remove broken rod.

• Page 250
  Remove football/balloon. Step 6: DANGER: Wrench on rotating drill string can strike you. Death or serious injury will result. Ensure all tools are removed from the drill string before rotation is started. Tell everyone to move away from the exposed drill string. Use machine to push drill rod forward until Step 7: male threads have engaged the downhole rod.

• Page 251: Drilling With Front Load Wireline Locator System

  Drilling with Front Load Wireline Locator System NITIAL RILL ONNECTION WARNING: Unexpected travel or rotation can crush or entangle. Serious injury or death can result. Disable thrust and rotation before making wireline connections. Test Local Lockout Buttons (1) at front and back of rack before the start of every bore.

• Page 252
  Clamp drill head in front vise. Rotate drive chuck until line compression Step 1: fitting (2) points towards the rear wireline connection station. With carriage fully back, use wireline hook to grab sonde wire from rear of Step 2: drill head. Move first drill rod into position just short of being in-line with the drive Step 3: chuck.

• Page 253: Adding Drill Rod

  Attach alligator clip (4) on wire connected to the bronze collector ring (5) to Step 14: the stripped wire at the compression fitting on the drive chuck. Re-engage thrust and rotation by pulling out Local Lockout Button. Step 15: Drill rod fully into the ground. Step 16: DDING RILL…

• Page 254: Pullback

  Disable thrust and rotation with Local Lockout Button. Step 16: Pull remaining slack out of wireline and tighten the compression fitting. Cut and strip end of wire, and Step 17: attach alligator clip. Re-engage thrust and rotation by pulling out Local Lockout Button. Step 18: Drill rod fully into the ground.

• Page 255: Maintenance

  Shutdown Procedure, 50-4. Visually inspect machine daily before starting the machine. Make no modifications to your equipment unless specifically recommended by Vermeer Corporation. AFETY IGNS AINTENANCE Safety signs located on your machine contain important and useful information that will help you operate your equipment safely.

• Page 256: Maintenance Manual

  AINTENANCE ANUAL Maintenance Intervals are included for reference only. Before performing any maintenance, refer to the for safety guidelines and correct procedures. Maintenance Manual OURMETER HECK FOR AINTENANCE NTERVAL The hourmeter on the machine is used to determine maintenance intervals for the machine. The hourmeter indicates the total number of hours the engine has been in operation.

• Page 257
  NTERVALS = Initial maintenance on new machine. Regular maintenance interval may be different. Initial = Regular maintenance interval. For Vermeer maintenance replacement part numbers, refer to the or call your Vermeer dealer. Parts Manual Maintenance Interval — Service Hours 10 or…
• Page 258
  Maintenance Interval — Service Hours 10 or 50 or Service Daily Weekly 1000 3000 4500 Required Vise Dies — Inspect/Clean Rack Frame Pivot — Grease Rack Frame Pivot Cylinders — Grease Gearbox Slide — Grease Rear stabilizers — Grease Drilling Fluid Pump Crankcase Oil Level — Check Track Planetary Gearbox Oil Level — Check…
• Page 259
  Maintenance Interval — Service Hours 10 or 50 or Service Daily Weekly 1000 3000 4500 Required Automatic Belt Tensioner Spring Tension and Belt Wear — Check Crankcase Vent Tube — Clean Air Intake System — Check Electrical Ground Condition — Check Cooling System — Check/Pressure Test Engine Coolant Concentration — Check Drive Belt Wear and Tension — Check…
• Page 260
  Maintenance Interval — Service Hours 10 or 50 or Service Daily Weekly 1000 3000 4500 Required Thermostats — Test Diesel Particulate Filter (DPF) — Forced Regeneration Alternator Belt — Replace Engine Compartment — Clean Engine Cooling Compartment — Clean Out Battery — Replace Fuses — Replace Air Cleaner Element — Replace…
• Page 261
  Index Battery Burns — Prevent, 55-2 Access, 20-63 Battery Condition, 30-14 Accumulator Gauge, 20-50 Battery Explosion — Prevent, 55-1 Accumulator Pressure — Check, 50-1 Beacon (Option), 20-57 Active Codes Screen, 21-17 Before Starting, 50-1 Adding Drill Rod, 55-13 Before the Bore, 50-24 After Each Bore, 50-54 Begin Drilling, 50-31 After Utility Company Has Shut Off the Power, 50-23…
• Page 262
  Drilling with Front Load Wireline Locator System, 55-11 Dealer Prep, i Driving Machine with Tethered Secondary Remote Control, 50-10 Dealer/Owner Information, iv Driving Machine with Wireless Remote Control, 50-9 Delivery, iii Driving the Machine with Remote Control, 50-6 Diesel Particulate Filter (DPF) Safety, 50-25 Driving the Machine, 50-5 Diesel Particulate Filter (DPF), 21-8 During the Bore, 50-31…
• Page 263
  Forced Regeneration, 21-10 Front Vise Function in Resuming AutoDrill, 30-36 Laws and Regulations — Check, 40-17 Left Joystick, 20-4 Gas, 50-23 Left Panel Controls, 20-2 Gauges — Monitor During Pullback, 50-53 Lifting Machine, 50-13 Gauges — Monitor, 50-36 Loading/Unloading, 50-11 Greaser, 20-50 Local Lockout Buttons, 20-8 Locating Equipment — Prepare, 50-18…
• Page 264
  PVC Pipe Pulling (Option), 30-30 Navigation Screen, 25-2 Non-Cab Machine, 20-19 Rack and Stabilizer Controls — Remote Controls, 20-37 Obstructions — Investigate, 50-37 Radiator Grille Cover, 20-59 Operation, 50-1 Radio Communication Requirements, 40-3 Operator Presence System, 40-14 Radio Communication to Resume Drilling Operation, 40-4 Operator Presence/Seat Controls, 20-56 Radio Communication to Stop Drilling Operation, 40-4 Operator Qualifications, 40-1…
• Page 265
  Remote Lockout System — Shut Down, 30-15 Rotary Tooth Installation/Extraction — Gauntlet Bit, 30-24 Remote Lockout System — Start, 30-15 Run Button, 30-5 Remote Lockout System — Test, 40-15 Remote Lockout System Component Identification, 30-3 Remote Lockout System Intended Use, 30-1 Safe Operating Slope, 50-7 Remote Lockout System Preparation, 40-14 Safety Conscious Operators and Workers, 40-1…
• Page 266
  Tethered Secondary Remote Control (S/N 138 -), 20-6 Top Panel Control, 20-1 Trailering the Machine, 50-11 Zone Steering Setup, 30-39 Trailing Rod While Pre-Reaming, 50-47 Training, 40-2 Transport Controls, 20-26, 20-31 Transport Remote Control, 20-26 Transport with Tethered Remote (S/N 138 -), 20-34 Transporting the Machine, 50-5 Turnbuckle — Adjust, 30-28 Underground Utility Contact, 40-7…
• Page 267
  Revision History Revision Date Page(S) Description to1_00 04/11 Temporary Operator’s Manual released. o1_00 08/11 First Edition Manual released. o1_01 09/11 Sections 20, 21, 50 Rod handling controls, engine hood latches, decals Remote control range, operator station step, o1_02 04/12 Warranty rider, Sections 20, 21, 25, 50, 60 programming, transport safety, engine cooling area cleanout Sections Introduction, R&D, 11, 20, 21, 30, 50,…
• Page 268
  For more information, please visit the California Air Resources Board website at http://www.arb.ca.gov/msprog/ordiesel/ordiesel.htm. Copyright 2011–2012, 2014, 2015. All rights reserved. Vermeer Corporation 1210 Vermeer Road East, P.O. Box 200 Pella, Iowa 50219-020…