Vanguard

Equipment,
Inc.

032-08OP-007C
Oct-09

Operation and
Maintenance Manual
Pipelayer attachment for D4H LGP, D5M LGP, and D5N LGP
S/N D4H0038 – UP (Sideboom)
S/N D5M0021 –UP (Sideboom)
S/N D5N0021 –UP (Sideboom)

TO BE USED WITH CATERPILLAR
D4H, D5M, AND D5N TRACTOR OPERATION AND MAINTENANCE MANUALS

VANGUARD EQUIPMENT, INC.
15627 EAST PINE ST
TULSA, OKLAHOMA
74116, USA
℡: 918.437.1796
: 918.437.1794

Table of Contents
FOREWORD ........................................................................................................................................................................... 1 
MACHINE DESCRIPTION ......................................................................................................................................................... 1 
SAFETY ................................................................................................................................................................................... 1 
WARNING SIGNS AND LABELS................................................................................................................................................ 1 
GENERAL HAZARD INFORMATION .......................................................................................................................................... 1 
MOUNTING AND DISMOUNTING.............................................................................................................................................. 1 
Alternate Exit (Cab models only)....................................................................................................................................... 2 
Operating with Cab Doors Open ....................................................................................................................................... 3 
SWITCH TO DOZER MODE WHEN DOZING .............................................................................................................................. 3 
LIFTING CAPACITY ................................................................................................................................................................. 4 
D4H LIFT CHART............................................................................................................................................................. 5 
D5M LIFT CHART ............................................................................................................................................................ 5 
D5N LIFT CHART ............................................................................................................................................................. 6 
ELECTRIC POWER LINES ......................................................................................................................................................... 6 
Minimum Distances ........................................................................................................................................................... 6 
WIRE ROPE ............................................................................................................................................................................. 7 
COLLISION AVOIDANCE ......................................................................................................................................................... 7 
PINCH POINTS ......................................................................................................................................................................... 7 
FOLDING BOOM LOCK-PINS ................................................................................................................................................... 7 
HAND SIGNALS....................................................................................................................................................................... 7 
MACHINE PARKING ................................................................................................................................................................ 8 
HIGH HYDRAULIC SYSTEM PRESSURE .................................................................................................................................... 8 
ELECTRICAL STORM INJURY PREVENTION ............................................................................................................................. 9 
COMPONENTS AND SPECIFICATIONS .......................................................................................................................... 9 
LOCKOUT CYLINDERS .......................................................................................................................................................... 10 
DRAW WORKS CONTROLS ............................................................................................................................................. 11 
MODE CONTROL LEVER ........................................................................................................................................................ 11 
Limited Dozer Functions ................................................................................................................................................. 11 
HOOK CONTROL LEVER ....................................................................................................................................................... 12 
BOOM CONTROL LEVER ....................................................................................................................................................... 13 
BOOM STOP VALVE .............................................................................................................................................................. 14 
FOLDING BOOM ................................................................................................................................................................. 15 
EXTENDING .......................................................................................................................................................................... 15 
STOWING .............................................................................................................................................................................. 16 
BOOM REMOVAL AND INSTALLATION (FOLDING AND RIGID BOOMS) ......................................................... 19 
MAINTENANCE AND LUBRICATION............................................................................................................................ 19 
GENERAL.............................................................................................................................................................................. 19 
LUBRICANT VISCOSITIES ...................................................................................................................................................... 19 
REFILL CAPACITIES .............................................................................................................................................................. 19 
PIPELAYER SERVICE INTERVALS .......................................................................................................................................... 19 
Wire rope cable ............................................................................................................................................................... 19 
Service Intervals .............................................................................................................................................................. 20 
10 Hours Service Interval or Daily.................................................................................................................................. 20 
50 Hours Service Interval or Weekly ............................................................................................................................... 22 
200 Hours Service Interval or Monthly ........................................................................................................................... 22 
500 Hours Service Interval or 3 Months.......................................................................................................................... 23 
2000 Hours Service Interval or 1 Year ............................................................................................................................ 23 
WIRE ROPE ........................................................................................................................................................................... 23 
ACCUMULATOR .................................................................................................................................................................... 23 
BOOM STOP VALVE ADJUSTMENT ........................................................................................................................................ 23 
AIR CONDITIONER FILTER ACCESS (CAB MODELS ONLY)..................................................................................................... 23 
WINCH TRAIN OIL CHANGE ................................................................................................................................................. 24 
RIGGING ............................................................................................................................................................................... 24 
WIRE ROPE SPECIFICATIONS ................................................................................................................................................ 24 
18 ft Folding Boom .......................................................................................................................................................... 24 
20 ft Rigid Boom .............................................................................................................................................................. 24 
032-08OP-007C

S/N D4H0038 – UP
S/N D5M0021 – UP
S/N D5N0021 – UP

i

................................................................................................................................................... 24  BOOM WINCH LINE INSTALLATION ..........................................................................LOAD WINCH LINE INSTALLATION .................................. 26  032-08OP-007C S/N D4H0038 – UP S/N D5M0021 – UP S/N D5N0021 – UP ii . 25  APPENDIX:  RIGGING ANCHOR PROCEDURES .................................................................................................................

until familiar with machine operation. Mounting and Dismounting Do not attempt to mount or dismount the machine between the machine and any object that may move. or missing. The following represents the minimum considerations for safe operations. or D5N LGP tractor. Do not use solvent. and medium duty bulldozing. Note: Refer to the Caterpillar operation manual for detailed information on the specific operation of the tractor unit. Replace any warning sign that is damaged. a minimum of five full-wraps of cable must remain on the winch drum at maximum working extension of the hook or boom. Do not use pressure washers to clean the warning signs. Replace the illustrations if the illustrations are not visible. Use a cloth. Safety Certain conditions and precautions are peculiar to pipelaying operations. regulations.Foreword Machine Description The side boom equipment is attached to a Caterpillar D4H LGP. or other harsh chemicals to clean the warning signs. The operator must comply with all pipelayer procedures. D5M LGP. 032-08OP-007C S/N D4H0038 – UP S/N D5M0021 – UP S/N D5N0021 – UP 1 . General Hazard Information To prevent cable from slipping off the drum. Figure 1: Canopy access. and follow both the tractor and pipelayer operating and maintenance instructions. gasoline. water and mild soap to clean the warning signs. urban and residential water and gas line installation. The daily service/inspection procedure should be performed before start-up. Operate all pipelayer controls with no load. Warning Signs and Labels Make sure that all of the warning signs are legible. understand. Clean or replace the warning signs if you cannot read the words. The primary use of this machine is for petroleum-product pipeline-construction. The operator should read. and safety precautions. install a warning sign on the replacement part. If a warning sign is attached to a part that is replaced.

Maintain three-point contact with the steps and with the handholds. Ground personnel must be kept clear at all times and only approach the machine when signaled to do so by the operator. clean the steps and handholds. Inspect the steps and handholds. Pull ring and push out glass Figure 3: Alternate exit. Note: Three-point contact can be two feet and one hand. Do not use any controls as handholds when entering or exiting the operator compartment. To remove the rear window. Three-point contact can also be one foot and two hands. This will provide enough clearance so that the seal can hinge.Figure 2: Cab access. Alternate Exit (Cab models only) In machines that are equipped with cabs. the rear window serves as an alternate exit. Do not get onto or off a moving machine. Make all necessary repairs. 032-08OP-007C S/N D4H0038 – UP S/N D5M0021 – UP S/N D5N0021 – UP 2 . Before getting on the machine. Do not try to get onto or off the machine while carrying tools or supplies. Never jump off the machine. Remove the O-ring seal from the glass support seal. Get on the machine only at locations that have steps and/or handholds. pull the ring and push out the glass. Face the machine whenever getting on or off the machine. Use a hand line to pull equipment onto the platform. Get off the machine only at locations that have steps and/or handholds. Now the glass can pass outward.

to allow it to be moved to clear obstacles or to improve vision. Dozing in pipelayer mode–with the lockout cylinders extended–will damage the cylinders to the point where they will no longer provide adequate support for the sideboom during lifting. Figure 5: Mode Control Position Warning. the entire sideboom may unexpectedly tip. Figure 4: Cab door open operation Warning: Located on inside cab door. Switch to Dozer Mode When Dozing This machine is equipped with hydraulic cylinder-rams that automatically extend to lockout the tractor’s equalizer bar in pipelayer mode. lower any suspended load to the ground. Refer to the sections on Lockout Cylinders and on Draw Works Controls in this manual for operating procedures. NO DOZING SHOULD BE DONE IN PIPELAYER MODE.Operating with Cab Doors Open When the pipelayer winches are in operation. Failure to do so could cause damage to the right cab access door and possibly result in personal injury. SWITCH TO DOZER MODE WHEN DOZING. Located on winch control box. NO LOAD IS TO BE SUPPORTED OR CARRIED BY THE SIDE BOOM IN DOZER MODE. Before switching to dozer mode. Figure 6: Lower Loads Before Switching to Dozer Mode Warning. The suspended load may shift unexpectedly causing injury or death to personnel working around it. The blade remains active while in pipelayer mode. Located by dozer-blade control. resulting in personal injury or death. 032-08OP-007C S/N D4H0038 – UP S/N D5M0021 – UP S/N D5N0021 – UP 3 . the right side cab door must be kept closed. with its operational speed reduced. and automatically retract in dozing mode.

Capacities assume stationary machine on level concrete surface with fixed counterweights (if required) in place. An inspection before and following the lift reveals no defects in the wire rope cable. See the warning decal and lifting capacity chart located on the machine for maximum load capacity ratings. Lift capacities will decrease on slopes or soft ground. no side boom shall be loaded beyond the maximum load capacity. if maximum load capacities are exceeded. All lifts must be made with the load line vertical. and the boom centerline directed toward the load. and ANSI/ASME B30.2. Except for test purposes. located on left side of machine. were developed by VEI for standard equipment— unless specified otherwise—tractor models: D4H LGP with an LGP 4VPAT blade. D5M LGP with an LGP 5VPAT blade. shown below. Wire rope limitations. the following requirements must be met: 1. Installation of additional equipment or other options may reduce the tipping characteristics of the machine below those given in the VEI chart.14-1979 Section 14.Lifting Capacity Figure 7: Tip warning decal. The units are rated for lifting capacities in accordance with SAE recommended practice SAE J743. When exceeding the ratings. additional counterweight is available to operate the unit with the blades removed. soil conditions. the load hanging vertically from the hook and balanced by the weight of the pipelayer components. No additional counterweight is required with the specified blades installed. and slope of terrain reduce actual capacity. follow American National Standards ANSI B30. The lift and inspections are made under controlled conditions under the direction of a competent person. In addition. 2. 3. The maximum load capacity of the side boom is not exceeded. The load must be handled in a manner and at speeds minimizing tipping effects.14. Capacity ratings are established on a level concrete surface with fixed counterweights (if required) in place. Optional. 4. Machine may tip and personal injury may occur. near operator seat. The VEI pipelayer attachment lift capacity charts. 032-08OP-007C S/N D4H0038 – UP S/N D5M0021 – UP S/N D5N0021 – UP 4 . and D5N LGP with an LGP 5VPAT blade with no additional attachments installed.

D5M LIFT CHART Figure 9: D5M LGP Lift capacity chart. near operator seat. near operator seat.D4H LIFT CHART Figure 8: D4H LGP Lift capacity chart. located on left side of machine. located on left side of machine. 032-08OP-007C S/N D4H0038 – UP S/N D5M0021 – UP S/N D5N0021 – UP 5 .

22 m (4 ft) Over 0. near operator seat.75 kV 1. located on left side access door of machine.D5N LIFT CHART (MODIFIED – 24-IN Tack Shoe) Figure 10: D5N LGP Lift capacity chart. located on left side of machine.75 to 50 kV 1. and energized power lines.83 m (6 ft) Over 50 to 345 kV 3.05 m (10 ft) Over 50 to 200 kV 4.10 m (20 ft) Over 750 to 1000 kV 7.05 m (10 ft) Over 345 to 750 kV 6. Electrocution or serious bodily injury may occur unless a minimum clearance is maintained between the machine or the load being handled.62 m (25 ft) 6 .67 m (35 ft) Over 750 to 1000 kV 13.10 m (20 ft) Over 350 to 500 kV 7.06 m (15 ft) Over 200 to 350 kV 6.72 m (45 ft) 032-08OP-007C S/N D4H0038 – UP S/N D5M0021 – UP S/N D5N0021 – UP WHILE IN TRANSIT WITH NO LOAD Normal Voltage Minimum Required Phase to Phase) Clearance Up to 0. Electric Power Lines Figure 11: Electrocution Warning. See the following chart: Minimum Distances WHEN OPERATING NEAR LINES Normal Voltage Minimum Required (Phase to Phase) Clearance Up to 50 kV 3.62 m (25 ft) Over 500 to 750 kV 10.

Located at both elbow joints on folding boom. Figure 12: Pinch points. the boom. Figure 13: Folding boom lock-pin warning. or serious damage with resulting loss of strength may result.14 for further details. Install one lock pin at each of the two elbow joints. sheaves. Wear protective gloves when handling wire rope. Continued use is a matter of good judgment on the part of an authorized person. and blocks. winch drums.Wire Rope The wire rope must be evenly spooled onto the drum. Ground personnel must be kept clear at all times and only approach the machine when signaled to do so by the operator. Hand Signals Standard hand signals. 032-08OP-007C S/N D4H0038 – UP S/N D5M0021 – UP S/N D5N0021 – UP 7 . or has broken strands. and latch the retainer rings. worn. Personnel must keep clear of the pinch points these elements create to avoid serious injury or death. Collision Avoidance The pipelayer attachment structures and the boom may extend considerable distance from the tractor. The operator must be aware of boom position and attachment structure clearance at all times. Keep hands. should be followed. away from moving wire rope.14. blocks. similar to those outlined in ANSI B30. Precise rules for replacement cannot be given since many variable factors are involved. Consult ANSI B30. kinked.. Folding Boom Lock-Pins Two lock-pins are required to fix the folding boom in the extended position. etc. and suspended loads all move during operation. Replace wire rope that is corroded. sheaves. Pinch Points Wire ropes.

Always move the mode control lever to the "LOCKED" position before shutting off the engine or immediately after the engine quits running to prevent unintentional load release or. with no load on the hook and the engine stopped. If necessary to park on a grade. after the engine is restarted. NOTE: The hydraulic implement system and some machine controls are "LIVE" for as long as the accumulator holds a charge. draw works operation. move the hook control lever from "HOLD" to "RAISE" 10 times. outside edge of winch base. Move the transmission control lever to "NEUTRAL" and the speed control to "LOW IDLE". High Hydraulic System Pressure Figure 15: High pressure warning decal. 032-08OP-007C S/N D4H0038 – UP S/N D5M0021 – UP S/N D5N0021 – UP 8 . located on front. • • • • • • Park on level surface. Apply the service brake to stop the machine. even if the engine is not running. Refer to the tractor’s operation manual for the specific procedures regarding engine shut down and/or other implement attachments. Lower any load to the ground. block the machine.Machine Parking 032-05-05-003 Figure 14: Parking machine. This pressure charge will take approximately four hours or more to bleed off. To relieve the accumulator charge. Engage the parking/secondary brake.

VEI D4H LGP.5 m (18 ft ) 6. Components and Specifications Boom Winch Load Block Luff Block Cross Member Hook Block Load Winch Tower Assembly Boom (Folding shown) 032-05-05-005A Figure 16: Pipelayer main components.NOTE: Refer to the SAFETY SECTION of the Operation and Maintenance Manual of the specific tractor for additional information.2m (4ft) Folding boom length (extended) Rigid boom length Operating Weight (approximate) Length (with blade straight) Width (boom removed) – calculated Width (folding boom folded) Height (less boom) Height (folding boom folded) Height (rigid boom vertical) Height (folding boom vertical) D4H LGP D5M LGP D5N LGP 11 192 kg (24 675 lb.) 5105 mm (201 in) 3188 mm (125. the operator should never attempt the following procedures: • Mount the machine.6 in) 3429 mm (135 in) 6746 mm (265. If you are in the operator’s station during an electrical storm.) 5064 mm (199 in) 3143 mm (123.5 m (18 ft ) 6. stay in the operator’s station.5 in) 3353 mm (132 in) 2986 mm (118 in) 3429 mm (135 in) 6756 mm (266 in) 6215 mm (244. If you are on the ground during an electrical storm.5 in) 3353 mm (132 in) 3124 mm (123 in) 3429 mm (135 in) 6756 mm (266 in) 6215 mm (244.1 m (20 ft) 16 330 kg (36 000 lb.7 in) 11 790 kg (26 000 lb.) 5.75 in) 3327 mm (131 in) 3038 mm (119. D5M LGP. stay away from the vicinity of the machine. Electrical Storm Injury Prevention When lightning is striking or threatening to strike near the vicinity of the machine.6 in) 6205 mm (244.) 4939 mm (194 in) 3188 mm (125.) 5.3 in) NOTE: Refer to the GENERAL SECTION of the Operation And Maintenance Manual of the specific tractor for additional information.5 m (18 ft ) 6.) 5.7 in) 12 428 kg (27 400 lb.1 m (20 ft) 15 160 kg (33 420 lb.1 m (20 ft) 16 565 kg (36 520 lb. D5N LGP PIPELAYER Maximum tip load at 1. 032-08OP-007C S/N D4H0038 – UP S/N D5M0021 – UP S/N D5N0021 – UP 9 . • Dismount the machine.

to allow the lockout cylinders to hydraulically release and retract. While the tractor may initially feel unbalanced until it has been maneuvered about enough so that the equalizer bar levels out. Pipelaying operations can occur as soon as the pipelaying mode is selected. NO LOAD IS TO BE SUPPORTED OR CARRIED BY THE SIDE BOOM IN DOZER MODE. Dozer-blade function speeds are significantly reduced in pipelayer mode. lower any suspended load to the ground. preventing any upward movement. Figure 18: Lockout cylinder operational concept. before commencing dozing. By only allowing the equalizer bar to move down toward the level position.Lockout Cylinders Figure 17: Equalizer bar lockout cylinder (one per side). Before switching to dozer mode. The VEI pipelayer locks out the tractor’s equalizer bar with hydraulically actuated cylinders. 032-08OP-007C S/N D4H0038 – UP 10 S/N D5M0021 – UP S/N D5N0021 – UP . shown deployed. The lockout cylinders will not automatically level the tractor when initially deployed. These cylinders automatically deploy in pipelaying mode. they extend to contact the equalizer bar. It is strongly recommended that the tractor be maneuvered about a short distance after the mode control lever is switched back to the dozing mode. resulting in personal injury or death. Dozing in pipelayer mode–with the lockout cylinders extended–will damage the cylinders to the point where they will no longer provide adequate support for the sideboom during lifting. NOTE: NO DOZING SHOULD BE DONE IN PIPELAYER MODE. the unit is stable as soon as the cylinders are deployed. and automatically retract in dozing mode as controlled through the mode control lever. SWITCH TO DOZER MODE WHEN DOZING. the tractor levels out through normal maneuvering. When deployed. The suspended load may shift unexpectedly causing injury or death to personnel working around it. and providing a stable-lifting platform. the entire sideboom may unexpectedly tip. The extended cylinders will retract when the maximum rated tip load is exceeded.

The blade controls still function. Limited Dozer Functions In order to remind the operator not to carry out any bulldozing in Pipelayer Mode. While the winch controls do not function. It must be physically moved to the desired function. Mode control lever The position of the lever selects the function (Pipelayer or Dozer) of the machine. ensure that no load is supported from the sideboom and switch the Pipelayer Mode control to Dozer Mode. B) PIPELAYER MODE—WINCH CONTROLS LOCKED: To prevent accidental actuation of the winch controls while in pipelayer mode. Figure 20: Mode control positions. the equalizer lockout cylinders are deployed. however. and the lever will remain in position once released. the equalizer lockout cylinders are deployed so that a load can be supported or carried by the side boom. DO NOT CARRY OUT ANY BULLDOZING IN THIS MODE. The winch controls function. The mode control is detented. move the lever to this position and flip the mode lock to engage the lever and lock it in position. The blade controls still function. the dozer-blade function speeds are significantly reduced in the two pipelayer modes. To regain full blade-function speeds for dozing. A) PIPELAYER MODE—WINCH CONTROLS UNLOCKED: Move the lever to this position to operate the unit in the pipelayer mode. however.Draw Works Controls HOOK CONTROL MODE CONTROL MODE CONTROL LOCK BOOM CONTROL Figure 19: Draw works control box. DO NOT CARRY OUT ANY BULLDOZING IN THIS MODE. 032-08OP-007C S/N D4H0038 – UP S/N D5M0021 – UP S/N D5N0021 – UP 11 .

located on winch control box. The blade controls function. In this position. the equalizer lockout cylinders are retracted. The winch controls do not function. located by dozer-blade control. C) DOZER MODE—WINCH CONTROLS LOCKED: Before switching to dozer mode. 032-08OP-007C S/N D4H0038 – UP 12 S/N D5M0021 – UP S/N D5N0021 – UP . lower any suspended load to the ground. NO LOAD IS TO BE SUPPORTED OR CARRIED BY THE SIDE BOOM IN DOZER MODE. and the hook will stop and remain at the position it is in. A) HOLD: The lever self centres to this position whenever it is released. Hook Control Lever Figure 23: Hook control positions. Figure 22: Lower loads before switching to dozer mode warning.Figure 21: Mode control position warning. the load winch brake will set. Move the lever to this position to operate the unit as a bulldozer.

and the hook will move down under the weight of the load. The load winch's quick drop brake will release. the slower the hook will raise. The further the lever is pulled away from "HOLD". Hook winch line speed varies with engine throttle setting. located on winch control box. the faster the hook will raise. and the hook will stop and remain at the position it is in. In this position. C) LOWER: Move the lever to this position to lower the hook with controlled winch power. NOTE: Quick drop is only available in pipelayer mode⎯winches unlocked. Hook winch line speed varies with engine throttle setting. The lever will return to the "HOLD" position when released.Figure 24: Quick drop still live warning. D) RAISE: Move the lever to this position to raise the hook. The closer the lever is toward "HOLD". When the lever is released. The further the lever is pushed away from "HOLD". Boom Control Lever Figure 25: Boom control positions. A) HOLD: The lever self centres to this position whenever it is released. it will return to the "HOLD" position. the faster the hook will lower. the slower the hook will lower. and the hook will stop and remain at the position it is in. the boom winch brake will set. Hook control is smoothest at engine speeds faster than idle. it will return to the "HOLD” position. 032-08OP-007C S/N D4H0038 – UP S/N D5M0021 – UP S/N D5N0021 – UP 13 . When the lever is released. B) EMERGENCY LOWER (Quick Drop): Move the hook control lever to this position to lower the load fast in an emergency. and the boom will stop and remain at the position it is in. the load winch brake will set and the hook will stop and remain at the position it is in. the winch brake will set. Hook control is smoothest at engine speeds faster than idle. The closer the lever is toward "HOLD".

Boom control is smoothest at engine speeds faster than idle. Boom control is smoothest at engine speeds faster than idle. 032-08OP-007C S/N D4H0038 – UP S/N D5M0021 – UP S/N D5N0021 – UP 14 . C) RAISE: Move the lever to this position to raise the boom. Refer to the Operation and Maintenance manual. The closer the lever is toward "HOLD". Boom winch line speed varies with engine throttle setting. When the lever is released. Defeating the boom stop valve could result in serious equipment damage. personnel injury. When the lever is released. it will return to the "HOLD" position. preventing overloading of key machine components. Boom Stop Valve Adjustment. for correct operation and adjustment. or even death. Boom winch line speed varies with engine throttle setting. and the boom will stop and remain at the position it is in. and the boom will stop and remain at the position it is in. the slower the boom will raise.B) LOWER: Move the lever to this position to lower the boom. Check its function daily. the faster the boom will raise. The further the lever is pushed away from "HOLD". the slower the boom will lower. it will return to the "HOLD" position. Its operation must be check and verified daily. Boom Stop Valve The Boom Stop system stops the boom winch from hauling-in when the boom is vertical. The closer the lever is toward "HOLD". The further the lever is pulled away from "HOLD". preventing overloading of key machine components. The Boom Stop valve is a safety device that is intended to automatically stop the boom winch from hauling-in when the boom is vertical. the faster the boom will lower.

Type II sidebooms are not fitted with cablestowing brackets.S/N0042 and D4H0038 – D4H0042. Unhook stowing chain from top of folded boom and stow in the clip on the winch frame. Extending 1. To unfold the boom further. Haul in (raise) on the hook winch and pay out (lower) on the boom winch. Keep only enough slack in the boom line so that it closely follows the unfolding boom. 032-08OP-007C S/N D4H0038 – UP S/N D5M0021 – UP S/N D5N0021 – UP 15 . Provide support for the lower boom section so that it will be slightly below horizontal when unfolded. 5. the boom line will support the folded boom. 3. 2. b) Chain to left-hand frame.Folding Boom Extending or stowing the folding boom must be done with the machine on level ground. 4. by either of the following means: a) Block to ground. Figure 26: Stowing chain unclipped from boom. For Type I sidebooms (S/N D5M0021 . pay out (lower) on the boom winch and pay out (lower) on the hook winch. Type I booms. remove the hook and boom lines from the cable-stowing bracket on the upper section of the folded boom. Figure 27: lower folding boom section chained for support. Keep only enough slack in the hook line so that it closely follows the unfolding boom. After the upper folded section goes over centre (hook line vertical). Type I S/N D4H0038-D4H0042 S/N D5M0021-D5M0042 Figure 28: Lines removed from cable-stowing bracket. Begin to unfold the boom using the hook and boom winches together.

7. 032-25-09-001 Figure 30: Boom-elbow lock pin installed at elbow joint. 032-08OP-007C S/N D4H0038 – UP S/N D5M0021 – UP S/N D5N0021 – UP 16 . 8. located at both elbow joints on folding boom. S/N D5N0021-UP 6.Type I S/N D4H0038-D4H0042 S/N D5M0021-D5M0042 Figure 29: Extending folding boom over centre. Lower the boom to approximately the horizontal position. Remove the boom-elbow lock-pins from their stowing holes in the lower boom section at the uppermost cross-member. Continue to unfold until the top section is straight with the lower section. Stowing 1. Install one lock-pin at each of the two elbow joints. Unfold the boom until the lower section rests on the support that was set-up in step 1. Figure 31: Folding boom lock-pin warning. Raise the boom and remove the support. and latch the retainer rings. Two lock-pins are required to fix the folding boom in the extended position. 032-05-25-002 Type II S/N D4H0043-UP S/N D5M0043-UP. The boom is now ready for use.

7. Continue to haul in (raise) on the boom winch and pay out (lower) on the hook winch.2. hauling in (raising) on the hook line will tighten it. 8. 032-05-25-004 Type I S/N D4H0038-D4H0042 S/N D5M0021-D5M0042 Figure 33: Stowing folding boom over centre. Keep a watchful eye on the hook line tension. 032-08OP-007C S/N D4H0038 – UP S/N D5M0021 – UP S/N D5N0021 – UP 17 . As the boom continues to fold and goes over centre. Keep only enough slack in the hook line so that it closely follows the unfolding boom. 6. Once the upper boom section is perpendicular (at a 90° angle) to the lower section. Figure 32: Hook block in folding boom stowing bracket. As soon as this point is reached. S/N D5N0021-UP Failure to pay out (lower) the hook line after the boom goes over centre could result in serious damage and possible injury or death. Haul in (raise) on the boom winch and follow with the hook winch. 5. hook the hook block into the stowing bracket at the bottom of the upper boom section. 4. Keep only enough slack in the hook line so that it closely follows the folding boom. 3. the entire boom rotates about the boom pivot pin on the track-roller frame bracket. b) Chain to winch frame. increasing the stress on the boom. the hook line must be played out (lowered) to continue to closely follow the boom. Remove the boom-elbow lock pins and store them in their stowing holes in the lower boom section at the uppermost cross-member. Provide support for the lower boom section by either of the following means: a) Block to ground. Type II S/N D4H0043-UP S/N D5M0043-UP. Slacken off the boom and hook lines. When the upper section is close to 90° with the lower section. Begin to fold the boom using the boom and hook winches together.

Keep only enough slack in the hook line so that it closely follows the unfolding boom. Leave enough slack in the chain so that the boom will be able to move as the track roller frames oscillate. but keep the length short enough so that the top section of the boom cannot bounce excessively. 10. Secure the top of the folded boom with the stowing chain attached to the winch frame. do not pinch the cables. Ensure that blocks. With the boom completely folded. 032-08OP-007C S/N D4H0038 – UP S/N D5M0021 – UP S/N D5N0021 – UP 18 . Figure 34: Slacken lines on stowed folding boom.9. Slowly pay out (lower) the hook winch and haul in (raise) on the boom winch to continue to fully fold the boom. 11. Figure 35: Folding boom secured to stowing chain. etc. pay out (lower) both the boom and hook lines to leave enough slack– approximately two to three feet–so that the boom is not over stressed during dozing or transport.. Located on winch guard to right of operator.

4 3. To prevent corrosion damage to the winch interiors. Block up the boom. Keep a dated report of the condition of the rope on file in a location that is available to designated personnel. Maintenance and Lubrication • • • General Follow tractor manufacture's maintenance and lubrication instructions for tractor service as required. The weight of the luff-block is approximately 27 kg (60 lb. Raise the boom to the horizontal position.). Perform a close inspection of sections of the rope that are normally hidden during the visual inspection and maintenance inspection.).). Note any deterioration that results in a notable loss of the original strength. 7. Remove the cotter pin and the pin from the luff-block. The weight of the hook-block is approximately 38 kg (85 lb.). Remove the boom-pin pivot shafts and shims from the track roller frame and lift the boom from the machine. Reinstalling boom pivot shims in such away as to centre the boom on the track roller frame. Installation is the reverse order. this includes parts of the rope that pass over the sheaves. run winches up and down at least once every two weeks. 32 8.8 1. as outlined below. if not used regularly. Lift the sheave blocks and fasten them to the machine for shipping.0 Imperial Gal. Replace the pins in the boom.0 0. Draw in the cable for the boom in order to pull the luff-block to the machine. and to allow the track roller frames to oscillate for dozing operations. Lower the boom onto blocks.12. The weight of the load-block is approximately 27 kg (60 lb. Lower the luff-block to the ground. Replace the boom-pin pivot shafts and shims in the track roller frame. The weight of the folding boom is approximately 680 kg (1500 lb.7 1. Replace the pins in the boom. Draw in the load cable in order to pull the sheave blocks to the machine.5 78. Lift the luff-block and fasten it to the machine for shipping. Hook winch gear train Hydraulic system Oil Viscosity SAE 80W90 SAE 80W90 See tractor operation and maintenance manual Ambient (outside) Temperatures ºC ºF Min Max Min -30 +50 -22 -30 +50 -22 Max +122 +122 Refill Capacities System Hydraulic tank Hydraulic system (includes tank) Boom winch gear trains Hook winch gear trains Refill Capacities (approximate) Liters US Gal. Move the mode control lever to dozer mode to lockout the winches to prevent accidental operation of the draw works while the boom is folded. Remove the cotter pin and block pin from the load-block.3 0.5 0.8 Pipelayer Service Intervals Wire rope cable Visually inspect all running ropes that are in continuous service at least once per working day. Lubricant Viscosities System Boom winch gear train. Lower the load-block to the ground. Inspect the cable on a daily basis for the following conditions: 032-08OP-007C S/N D4H0038 – UP S/N D5M0021 – UP S/N D5N0021 – UP 19 . as these points are the sections of rope that are most likely to fail.).4 20. The weight of the rigid boom is approximately 544 kg (1200 lb. Connect a lifting cable to the boom.0 17. A designated person shall perform all inspections. Inspect all ropes at least once a month. Follow tractor and/or winch manufacture’s lubrication instructions for the pipelayer hydraulic system. Boom Removal and Installation (Folding and Rigid booms) • • • • • • • • • Folding boom should be locked in the extended position.

internal corrosion. Perform the following servicing at EVERY interval they occur. etc. twists. Any new poured socket or swaged socket assembly that is used as a standing rope or guy. for worn end connections. Inspect the cable for kinks. and yokes for wear or damage. for sections of cable that are crushed. • • • • • • • • • • • • • • 10 Hours Service Interval or Daily Check hydraulic oil level as per tractor’s operation/maintenance manual. ice. or gouges. Inspect the cable for corroded end connections. and damage at end connections. Inspect the hook for any wear. all maintenance from the previous interval must be performed. Inspect the hook for any distortion. luff-lock. Inspect the cable for worn outside wires. and hook block bearings. for cuts in the cable. authorized person should perform the inspection. Check for correct function of boom stop valve. snow.1 Inspect blocks. broken or damaged wires. load block. Take care in the inspection of rope that is resistant to rotation. or for improperly applied end connections. Inspect folding boom-elbow lock pins for wear or damage. loose fittings. Inspect the cable for broken outside wires. Grease fairlead sheave. Check to ensure that area between tractor tracks and pipelayer-tractor attachment structures are free from dirt. Note: For additional information on the proper maintenance and on inspection of the cable. Refer to American National Standard Institute ANSI/ASME B30. or for any strands that have come loose. Check for the degree of distribution of the broken outside wires. Check controls for proper operation of boom and hook.14” Service Intervals Note: Before each consecutive interval is performed. the 10 hour and 50 hour service are also performed at the 200 hour interval. Check pipelayer structures and components for loose bolts. The authorized person’s approval is required for further use of the rope. replace as required. nicks. A designated. etc. Inspect wire rope for proper spooling. A dated report on the condition of the rope should be kept on file. shall be proof tested to the lift capacity of the sideboom machine or to the manufacturer’s recommendation. Grease boom-pin pivot shafts. etc. When a sideboom machine has been in storage for a month or more. Never give the cable a rating that is greater than 50 percent of the component wire rope’s nominal strength or of the structural strand’s nominal strength. 032-08OP-007C S/N D4H0038 – UP S/N D5M0021 – UP S/N D5N0021 – UP 20 . repair as required. and where rope travel is limited. Ensure that the guards and cylinders are securely in place. equalizer sheaves. Ensure that the cylinders extend in pipelayer mode and retract in dozer mode (it may be necessary to move the dozer to allow the cylinders to unlock and retract). wear. bends. Excessive wear or broken wires may occur in sections that are in contact with saddles. and loose or damaged bolts. Check hoses and fittings for leaks. A reduction in the diameter of the cable can occur because of: the loss of core support. etc. Inspect the folding boom-elbow lock pin bores at the lower and upper boom sections’ elbow-joints for excessive elongation. inspect all ropes thoroughly. cracks. refer to “American National Standards Institute ANSI/ASME B30. wear of the outside wires. or with other sheaves. replace as required per specifications in rigging section. inspect all rope thoroughly. When a machine is shutdown for a month or more. tail block. Check lockout cylinders for leaks.• • • • • Inspect the cable for a reduction in the diameter of the cable below the nominal diameter. for cracked end connections. corrosion. Check for the concentration of outside broken wires. Take care to inspect the ropes at these locations. external corrosion. for example. debris.

Figure 38: Hook block grease nipple. 032-08OP-007C S/N D4H0038 – UP S/N D5M0021 – UP S/N D5N0021 – UP 21 .Figure 36: Fairlead sheave grease nipple. Figure 37: Load and luff block grease nipples. Figure 39: Boom-pin pivot shaft grease nipples (one on forward and rear).

200 Hours Service Interval or Monthly Inspect the wear of the inner boom stop bushing on the kick-out rod. Check track tension to ensure that the tracks are not too loose. 038-07-66-001A Figure 41: Check inner and outer boom stop bushings.Figure 40: Attachment structures free from debris. Loose tracks can damage the pipelayer attachment structures. Move the boom in to verify the alignment of the kick-out rod with the boom stop valve through the complete contact-travel range of the two. If the centre of the kick-out rod is misaligned with the centre of the boom stop valve plunger by more than 4. • • • • 50 Hours Service Interval or Weekly Lightly lubricate wire rope with recommended engine or hydraulic oil. 032-08OP-007C S/N D4H0038 – UP S/N D5M0021 – UP S/N D5N0021 – UP 22 . If boom kick-out plate on boom will soon wear through the bushing to make direct contact with the tower when the boom is vertical. Inspect the wear of the nylon bushing at the outer end of the boom kick-out rod. then the bushing should be replaced immediately. throughout the entire 10 mm (3/8”) contact travel range of the rod with the valve. replace BOTH the inner boom stop bushing AND the outer kick-our rod nylon. inside the boom stop valve compartment in the tower.8 mm (3/16-in).

with the kick-out disc bushing against the tower. S/N D4H0038 – UP S/N D5M0021 – UP S/N D5N0021 – UP 23 . • Change hydraulic system oil. boom kick-out rod is fully retracted into the tower. Ensure that the extra hose length is neatly stowed in the tower. Change winches' gear train oil (SAE 80W90). and the mounting bolts tightened. prior to operating the draw works. Air Conditioner Filter Access (Cab models only) Lower the boom all the way to the ground. NOTE: 032-08OP-007C The cross member must be completely reinstalled. refer to High Hydraulic System Pressure safety section for charge pressure. by qualified personnel. The cross member unbolts from the tower and swings up to allow access to the air conditioner filter access panel. The tower houses extra length for the hydraulic control hoses that run through the cross member. 2000 Hours Service Interval or 1 Year Wire Rope • Lightly lubricate wire rope with engine oil. Move the valve an additional 10 mm (3/8”) towards the boom.500 Hours Service Interval or 3 Months • • Change hydraulic system filter element. Replace the cutout valve access panel from the tower. Remove the boom stop valve access panel from the tower. • Accumulator to be charged with dry nitrogen (N2) gas. out of the way of the load line when the cross member is reinstalled. Accumulator Boom Stop Valve Adjustment KICK-OUT ROD BOOM STOP VALVE Figure 42: Boom stop valve located in tower. • • • • • • • Raise the boom vertical so that it is JUST in contact with the tower. Loosen the boom stop valve nuts. Do not over tighten the lines to the point that the boom or left structures are overly stressed. Tighten the valve in position with the valve nuts. Move the valve so that it just contacts the boom kick-out rod.

3 m (80 ft) Boom line 20.4 m (63.7 ft) Specification 637IWRC USA made [41 200 lb. or seize ends of wire rope before installing to prevent fraying. (18 700 kg) minimum breaking strength] 637IWRC USA made [26 600 lb. Unwind the load line from the winch drum. • Spool half of the wire rope evenly across the load winch drum. never lift it off in loops. After all of the oil has drained from the winch drive train. 5/8-in (16 mm) 1/2-in (13 mm Load Winch Line Installation Lower the boom to the ground and support the boom. Weld the wire rope ends to prevent fraying. 18 ft Folding Boom Line Load line Length 22. Install the fill plug (1). Unroll the new load line wire rope from the spool. Note: Weld. install the drain plug (2). Install the wire rope ferrule to the load winch drum. (12 070 kg) minimum breaking strength] Size dia.Winch Train Oil Change 1 2 Figure 43: Winch train oil ports. take to a recycling centre). Disconnect the wire rope anchor from the load drum. (12 070 kg) minimum breaking strength] Size dia. never lift it off in loops.6 m (67. frayed. Dispose of used oil in an environmentally sound manner (e. Check winch train oil level after 24 hours. Wire Rope Specifications Unroll the wire rope from the spool. follow the PULLMASTER winch rigging procedures outlined in appendix.6 m (74 ft) Boom line 19. Add oil to top off level if necessary. Wear gloves when handling wire rope. braze. Rigging Do not use wire rope that is kinked. 032-08OP-007C S/N D4H0038 – UP 24 S/N D5M0021 – UP S/N D5N0021 – UP .6 ft) Line Load line Length 24. Fill the winch with new oil until level with the bottom of the fill plug port. 5/8-in (16 mm) 1/2-in (13 mm 20 ft Rigid Boom • • • • • • Specification 637IWRC USA made [41 200 lb. or has worn spots. • • • • • • • Place a suitably large container (at least 4 liters or 1 US gallon) under the drain plug (2) to collect drained oil. (18 700 kg) minimum breaking strength] 637IWRC USA made [26 600 lb. Remove fill plug (1) and drain plug (2) and allow oil to drain into the container.g.

Anchor the wire rope with the wedge. Note: • • • • • • • • Weld. or seize end of cable before inserting cable into socket. Reeve the wire rope from the boom winch drum over the upper boom block sheave on the boom. Figure 44: Line terminators. Unroll the new load line wire rope from the spool. and into the cable socket on the upper load-block. on Type II it is located above the hook winch on the winch frame. Spool half of the wire rope evenly across the boom winch drum. follow the PULLMASTER winch rigging procedures outlined in the appendix. and secure it to the line terminator. braze. Type I S/N D4H0038-D4H0042 S/N D5M0021-D5M0042 032-05-30-002 Type II S/N D4H0043-UP S/N D5M0043-UP. the terminator is located on the top-front lug on the tower. 032-08OP-007C S/N D4H0038 – UP S/N D5M0021 – UP S/N D5N0021 – UP 25 . Install cable clamp on end of wire rope as per Crosby instructions outlined in the appendix. Unwind the boom line from the winch drum. Weld the wire rope ends to prevent fraying. Install the wire rope ferrule to the boom winch drum. never lift it off in loops. Disconnect the wire rope anchor from the boom drum. over the upper load-block on the boom. Boom Winch Line Installation Lower the boom to the ground and support the boom. On Type I machines. under the hook-block sheave. S/N D5N0021-UP Figure 45: Boom line terminator. as per Crosby instructions outlined in the appendix.• Reeve the wire rope cable from the load winch drum under the tower fairlead sheave on the left structure.

Appendix: 032-08OP-007C Rigging Anchor procedures S/N D4H0038 – UP S/N D5M0021 – UP S/N D5N0021 – UP 26 .

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DIN Forselection of ropes. 4) Alwayswarm up equipmentpriorto operatingwinch.971001 .a reverseanda neutral position. thewinchdoesnotfunctionproperly.chains. 5) Preventcorrosion damageto winchinterior. 6) To ensureproperwinchinstallation andfunction. inthecorrectdirection of rotation. to avoid recommendations and maintenance Refer to manufaclure/s handling.oneforclockwise molor whenlookingat thehydraulic for counterclockwise hoisting. prEN1452-112.To primethe winchwithwarmoil. Eachwinchis shippedfromthefactorywilha labelon thedrum indicatingthecorrectcableanchorslot. runwinchupanddownat leastonceevery two weeks.operatethe winchat slowspeed. . 3) Thewinchoperation iscontrolled bya singleconlrolvalveleverwhichhasa forward.SEVEREINJURYORDEATH.Loopropebackintoslot as shown.Speedcontrolin eitherdirectionis obtainedby modulation of thecontrolvalve lever.severaltimes. WIREROPEINSTALLATION Clockwisehoistingwinchshown. IMPORTANT: The ropes. hydraulicoilthroughthewinchcontrolvalve for severalminulesto warmthehydraulicsystem.lfthewireropeiswoundonthecabledruminthewrongdirection the winchwillhaveno brakingcapacity. andone planetary 1) Thecabledrumof thePULLMASTER winchhastwocableanchorslots. thewireropecanbe fastened to thecabledrum.lt is criticalto selectthecableanchorslotwhichwillpermitwindingof the wireropeon the drum of rotation.referto theTROUBLESHOOTING of this manual.raiseandlowera fulltestloadto a safeheightbeforeusing winchfor regularoperationat the startof eachshift.forwardand reverse.M12 st1013 2) Onwireropeinstallation.Maximumline speedin eitherdirectionis obtainedwhenthecontrolvalveleveris movedas far as it cango. section lf.etc.Insertcableanchorinto slot. Standardrotationfor hoistingisclockwise of the unit.Thecabledrumrequires3-4wrapsof wire ropefor safety.Thediscbrake of the winchwillcomeon automatically whenthe winchconlrolleveris returnedto neutral. completelyaroundthecableanchor caremustbetakenthatthewire ropeiswrapped and properlypulledintothe cableanchorslotin thecabledrum. aftera newinstallation.are notpartof the winchandare notcoveredby thismanual.AooNGER WILL INSTRUCTIONS FAILURETO FOLLOWOPERATING RESULTIN PROPERTY DAMAGE.lf notusedregularly. prEN1677-1/3 andolherrelevant 15020. (Usecableanchorsloton oppositesideof drumfor counterclockwise hoistingwinch.particularly Circulate in low ambienttemperature.slings.) Feedthe wireropethroughthe cable anchorslot.etc.pleasecheckfollowing productstandards. P A G E1 0 245REV.prENBlB-1/9.Pullrope tightto wedgeropein slot. planetarywinch has been installedin accordancewith the INSTALLATION After the PULLMASTER INSTRUCTIONS.smallendfirstand longside nearestthe drumflange.inspection productstandards: potentialaccidents.

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