Vanguard Equipment, Inc.
VANGUARD EQUIPMENT, INC. 15627 EAST PINE ST TULSA, OKLAHOMA 74116, USA ℡: 918.437.1796 : 918.437.
Table of Contents FOREWORD ........................................................................................................................................................................... 1 LITERATURE INFORMATION .................................................................................................................................................... 1 MACHINE DESCRIPTION .....................................................................................................................
SHIPPING THE MACHINE ....................................................................................................................................................... 23 REMOVAL OF THE BOOM ...................................................................................................................................................... 23 MAINTENANCE AND LUBRICATION SECTION .........................................................................................................
Foreword Literature Information This manual should be stored in the operator's compartment in the literature holder or seat back literature storage area. This manual contains safety information, operation instructions, transportation information, lubrication information and maintenance information. Some photographs or illustrations in this publication show details or attachments that can be different from your machine. Guards and covers might have been removed for illustrative purposes.
Maintenance Intervals Use the service hour meter to determine servicing intervals. Calendar intervals shown (daily, weekly, monthly, etc.) can be used instead of service hour meter intervals if they provide more convenient servicing schedules and approximate the indicated service hour meter reading Recommended service should always be performed at the interval that occurs first.
035-00-05-019A 035-05-05-019A Figure 2: Safety Messages VP 72T Pipelayer There are several specific safety messages on this machine. The exact location of the hazards and the description of the hazards are reviewed in this section. Please become familiarized with all safety messages. Make sure that all of the safety messages are legible. Clean the safety messages or replace the safety messages if you cannot read the words. Replace the illustrations if the illustrations are not visible.
Replace any safety message that is damaged or missing. If a safety message is attached to a part of the machine that is replaced, install a safety message on the replacement part. Do Not Operate (1) Do not operate or work on this machine unless you have read and understand the instructions and warnings in the Operation and Maintenance Manuals. Failure to follow the instructions or heed the warnings could result in injury or death. Contact your dealer for replacement manuals.
Hydraulic Accumulator (3, 4) High Pressure Cylinder: Rapid discharging from disconnecting or disassembly or failure to follow the instructions and warnings could cause an explosion, resulting in possible injury or death. Do not expose to fire. Do not weld. Do not drill. Do not remove any hydraulic system lines, taps or parts until pressure has been relieved. Relieve pressure before discharging. See Operation and Maintenance Manual "Accumulator" for charging and discharging.
Boom Stop Operation and Adjustment (6) The Boom Stop system stops the boom winch from hauling-in when the boom is vertical, preventing overloading of key machine components. Defeating the boom stop valve could result in serious equipment damage, personnel injury, or even death. Its operation must be check and verified daily. Safety message (6) is located on the left side of the crossmember support, at the front, on the boom stop valve access panel.
Counterweight Crushing Hazard (8) Crushing Hazard! When the counterweight is in the fully extended position for servicing the machine, secure the extended counterweight with the counterweight lock lever. Use the counterweight lock lever to avoid possible personnel injury or death from crushing. Use the lock to secure the counterweight when the machine is serviced. Refer to Operation and Maintenance Manual, "Counterweight Lock Lever” for details.
Counterweight Lock Lever Thrown or Flying Objects – Full Body Exposure (10) Thrown or flying objects - full body exposure! Do not operate counterweight while the counterweight lock lever is engaged. Retracting the counterweight while the lock lever is engaged could cause serious equipment damage, personnel injury, or even death. Ensure the counterweight lock lever is fully disengaged before retracting the counterweight. Safety message (10) located on the right side, on the control box.
046-00-05-001 Figure 13: Operator's Field of View as per ISO 5006:2006 The operator is required to survey his/her field of vision when operating the machine. The operator shall take notice of the areas of no visibility located at the front and front left of the machine (see figure) The right-hand overhead mirror shall be adjusted so that a person walking 1m to the right of the machine, for the length L, can be seen in a length of at least 200mm either directly or indirectly at every position (see figure).
Operation Machine Operating Temperature Range The standard pipelayer component configuration is intended for use within an ambient temperature range of -40 °C (-40 °F) to 50 °C (122 °F). Special configurations for different ambient temperatures may be available. Consult your dealer for additional information. Refer to the specific tractor Operation and Maintenance manual for standard tractor capabilities. Machine Operation Only operate the machine while you are in a seat.
Limitations on Lifting Loads That Exceed the Working Range Do not load the boom beyond the maximum load capacity. See Operation and Maintenance Manual, "Lifting Capacities" for the load capacity of the boom. When the load capacity is exceeded, refer to "American National Standards ANSI/ASME B30.14".
Slope Operation Machines that are operating safely in various applications depend on these criteria: the machine model, configuration, machine maintenance, operating speed of the machine, conditions of the terrain, fluid levels. The most important criteria are the skill and judgment of the operator. A well trained operator that follows the instructions in the Operation and Maintenance Manual has the greatest impact on stability.
The operator becomes exposed to a hazardous situation if the machine is used improperly or if poor operating techniques are used. This situation can occur even though a machine is equipped with an appropriate protective guard. Follow the established operating procedures that are recommended for your machine.
Specifications A B C 035-05-05-002A 035-05-05-021A Figure 15: Standard shipping specifications, height and width VP 72T Pipelayer Approximate operating weight of the standard machine1 Approximate shipping weight of the standard machine2 Weight of the 20 ft boom, the boom sheave blocks, and the load blocks Height of the machine without the boom (A) 28894 kg (63700 lb) 28009 kg (61750 lb) 936 kg (2064 lb) [24 ft boom add 286 kg (630 lb)] 3214 mm (10-feet 6-5/8-inch) 4498 mm (14-feet 9-inch) Length of t
Lifting Capacities The machine may tip and personal injury may occur if the maximum load capacities are exceeded. Load capacities assume that the machine is stationary on a level concrete surface with the counterweight extended. Lift capacities will decrease on slopes or soft ground. Figure 16: Lifting Capacities A D C The following are as per ANSI/ASME B30.
VP 72T Pipelayer Wire rope diameter 19.05 mm ( 0.75 inch) Minimum breaking strength of the wire rope 261.56 kN (58,800 lb) 4 part load line 4 part boom line Mass of the extended counterweight 5822 kg ( 12,835 lb) Standard boom length 6.
Daily Inspection 035-05-05-019B Figure 19: Daily inspection walk around For maximum service life of the machine, perform a daily walk-around inspection. Note: Watch closely for leaks. If leaking is observed, find the source of the leak and correct the leak. If leaking is suspected or leaking is observed, check the fluid levels more frequently. Inspect the machine for the following items: • • • • Inspect the hydraulic system for leaks. Repair any hydraulic system leaks.
• • • • • • "Counterweight Hinge Pins - Lubricate" "Fairlead Sheave - Lubricate" "Hook and Wire Cable Inspect" "Hydraulic System Oil Level - Check" "Sheave Block Bearings - Lubricate" "Boom Stop Valve - Check operation" Note: Refer to the tractor operation manual for detailed information on the specific daily checks of the tractor unit. Tractor Operation Refer to the tractor’s operation and maintenance manual for the specific procedures regarding complete Tractor Operation.
LOCKED MODE—WINCH AND CONTROLS LOCKED: To prevent accidental actuation of the hook and boom winch controls while not in use, move the speed/lockout control lever to the centre position and flip the speed/lockout control lock to engage the lever (2) and lock it in position. In this mode, the hook and boom winch controls do not function.
Accumulator - Relieving Charge To relieve the accumulator charge, with no load on the hook and the engine stopped, move the hook control lever from "HOLD" to "RAISE" 10 times. Boom Control (4) A) HOLD: The lever self centres to this position whenever it is released. In this position, the boom winch brake will set, and the boom will stop and remain at the position it is in. B) LOWER: Move the lever to this position to lower the boom.
Throttle control switch & MVP switch (7) NOTE: New location of this tractor's control, refer to the tractors operation and maintenance manual for correct operation. A B C TRACTOR'S HYDRAULIC LOCKOUT DISABLED ON VP 72T; USE THE PIPELAYER SPEED/LOCKOUT CONTROL LOCK LEVER AND THE PIPELAYER COUNTERWEIGHT CONTROL-LOCKOUT Figure 21: Control Switches A. Throttle Control Switch B. MVP Switch C.
1 035-05-68-031 Figure 23: Counterweight Lock Lever (1), locked in the extended position, side view (1) 2 035-09-63-059A Figure 24: Counterweight control-lockout (2), open position NOTICE When you engage the locking device for the counterweight or when you disengage the locking device for the counterweight use the Counterweight Control-Lockout lever for the counterweight controls. Lock the counterweight controls in HOLD in order to avoid the inadvertent movement of the counterweight.
Transportation Information Shipping the Machine Investigate the travel route for overpass clearances. Make sure that there is adequate clearance for the machine that is being transported. Remove ice, snow, or other slippery material from the loading dock and from the truck bed before loading. Removing ice, snow, or other slippery material will prevent slippage while you load the machine. Removing ice, snow, or other slippery material will prevent the machine form slipping in transit.
1. Lower the boom enough to remove the load blocks and the sheave block. 2 LUFF BLOCK 1 LOAD BLOCK HOOK BLOCK 035-20-30-007A Figure 26: Removal of boom, steps 1, 2 2. Remove cotter pin, the retainer, and pin (1). Lower the load block and the hook block to the ground. The approximate weight of the load block is 88 kg (194 lb). The approximate weight of the hook block is 100 kg (220 lb). The combined weight of the load block and the hook block is approximately 188 kg (414 lb). 3.
7. To remove load block and hook block from stowing-link, reverse the above steps, and ensure the stowing-link is placed firmly back into the slot in bumper. 8. Lower the boom to the horizontal position onto wood blocks that are sufficient to support the boom. 9. Remove the cotter pin, the retainer, and pin (2). The approximate weight of the luff block is 76 kg (168 lb). 10. Replace the pin and the retainer (2) in the boom. 11.
Maintenance and Lubrication Section Lubricant Viscosities General • • • Follow tractor manufacture's maintenance and lubrication instructions for tractor service as required. Follow tractor and/or winch manufacture’s lubrication instructions for the pipelayer hydraulic system. To prevent corrosion damage to the winch interiors, if not used regularly, cycle the winches up and down several times at least once every two weeks.
S-O-S Information S O S Services is a highly recommended process for Caterpillar customers to use in order to minimize owning and operating cost. Customers provide oil samples, coolant samples, and other machine information. The dealer uses the data in order to provide the customer with recommendations for management of the equipment. In addition, S O S Services can help determine the cause of an existing product problem.
• Hydraulic System Oil - Change Every 2000 Service Hours or 1 Year Accumulator This system contains high pressure gas. Failure to follow the instructions and warnings could cause an explosion, resulting in possible injury or death. Do not expose to fire. Do not weld. Do not drill. Do not remove any hydraulic system lines, taps or parts until pressure has been relieved. Relieve pressure before discharging. See Operation and Maintenance Manual "Accumulator - Relieving Charge".
Boom Stop Valve Operation and Adjustment The Boom Stop system stops the boom winch from hauling-in when the boom is vertical, preventing overloading of key machine components. Incorrectly adjusting, or defeating the boom stop valve could result in serious equipment damage, personal injury, or even death. Its operation must be check and verified daily. Boom Stop Valve 035-09-12-001 Figure 31: Boom stop valve located behind access cover in Left Hand tower.
Boom Line – Install Do not operate or work on this equipment unless you have read and understand the instructions and warnings in the Operation and Maintenance Manual. Failure to follow the instructions or heed the warnings could result in injury or death. Contact your dealer or Vanguard Equipment or visit our website at vanguardequip.com for replacement manuals. Proper care is your responsibility. Personal injury or death can result from worn wire rope cable.
Figure 32: Installing boom line, cable anchor assembly 4. Install the cable (1) into the small slot and through the larger slot in the drum for the boom. a. Make sure that 2 to 4 threads of capscrew (2) are engaged into the cable anchor assembly (4). Start with the capscrew and insert the cable anchor assembly into the longer slot as far as allowed. b. Make sure that the lip of retainer (3) faces the top edge (5) of the small slot in order to hold the retainer in place.
6. Install the wire rope from the winch to sheave (8) in the upper sheave block. Install the wire rope over sheave (8) from the front of the machine toward the rear of the machine. 7. Install the wire rope under sheave (9) in the lower sheave block. 8. Install the wire rope over sheave (10) in the upper sheave block. 9 12 035-05-05-027A 035-05-30-015 11 Figure 34: Inserting wire rope into cable anchor 9. Insert the wire rope into the pocket and around the wedge (11).
Counterweight Cylinder Bearings – Lubricate 035-05-05-019B Figure 36: Counterweight cylinder bearings fittings location 035-60-68-002 035-60-68-001 Figure 37: Counterweight cylinder bearings location There are two grease fittings for the counterweight cylinder. 1. Extend the counterweight and lock the counterweight into position. Refer to the Operation and Maintenance Manual, “Counterweight Lock Lever” for the proper procedure to lock the counterweight into position. 2.
Counterweight Hinge Pins - Lubricate Use a stable work platform placed in a secure location when lubricating the counterweight hinge pins. If a secure location is not available, use the appropriate safety equipment to prevent falling off of the machine. Failure to work from a secure location may result in injury or death from a slip or a fall. Lubricate the six pins through the grease fittings.
Fairlead Sheave – Lubricate 035-05-05-004 Figure 40: Fairlead sheave lubrication points Lubricate one fitting in the lower sheave and lubricate one fitting in the upper pin. Hook and Wire Cable – Inspect Inspect the Hook Inspect the hook frequently. The inspections should include observation of the hook during operation of the hook. A designated person determines if the conditions that are found during the inspections constitute a hazard.
• Inspect the cable end for connections that are corroded, cracked, bent, worn, or improperly installed. • Inspect the cable for sections that are crushed or kinked and for any loose wire strands. Excessive wear or broken wires may occur in sections of the cable that are in contact with saddles, equalizer sheaves, or other sheaves. Excessive wear or broken wires can also occur when cable travel is limited. Take care to inspect the ropes at these locations.
Hook Load Line – Install Do not operate or work on this equipment unless you have read and understand the instructions and warnings in the Operation and maintenance Manual. Failure to follow the instructions or heed the warnings could result in injury or death. Proper care is your responsibility. Personal injury or death can result from worn wire rope cable. Worn or frayed cable could break causing injury. Check the wire rope cable. If cable is worn or is frayed install new cable.
1. Install the cable (1) into the small slot and through the larger slot in the drum for the hook load line. a. Make sure that 2 to 4 threads of capscrew (2) are engaged into the cable anchor assembly (4). Start with the capscrew and insert the cable anchor assembly into the longer slot as far as allowed. b. Make sure that the lip of retainer (3) faces the top edge (5) of the small slot in order to hold the retainer in place.
h. Pull the cable until the line is tight in order to seat wedge (13). Lift the lower block above the ground. i. Raise the boom. Hydraulic System Oil - Change Refer to the specific tractor Operation and Maintenance Manual "Hydraulic System Oil - Change" for complete requirements and procedures. At operating temperature, the hydraulic tank is hot and under pressure. Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin.
6. Remove the pipe nipple. The valve for the hydraulic tank will close. 7. Clean drain plug (2) and install drain plug (2). Tighten drain plug (2) to a torque of 68 ± 7 Nm (50 ± 5 lb ft). 8. See the Operation and Maintenance Manual, Maintenance and Lubrication section, “Hydraulic System Oil Filter – Replace”. Change the hydraulic system filter (4). 9. See the Operation and Maintenance Manual, Maintenance and Lubrication section, “Hydraulic System Case Drain Filter – Replace”.
3 2 1 046-11-60-002A Figure 45: Filter locations 4 035-60-64-001 Figure 46: Filter location (1) (2) (3) (4) Transmission oil filter Hydraulic system filter Hydraulic Tank filler cap Case drain filter pipelayer 3. Remove filter (1, 2, and 4). Note: Remove case drain hydraulic filter (1). Discard the used filter. Filter (1) must be removed for access to hydraulic system filter (2). Replace both of the filters at the same time. 4. Inspect the seal on the filter housings for filter (1, 2, and 4).
Hydraulic System Oil Level – Check At operating temperature, the hydraulic tank is hot and under pressure. Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin. Remove the filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand. Remove the filler cap slowly in order to relieve pressure. The hydraulic tank is on the right rear corner of the machine. 2 1 046-11-60-001A Figure 47: Hydraulic Tank 1.
If metals are found in the filter element, a magnet can be used to differentiate between ferrous metals and nonferrous metals. Ferrous metals would indicate wear on steel parts and on cast iron parts. Non ferrous metals would indicate wear of the brass or aluminum part of the hydraulics such as main bearings, pump sleeves, etc. Small amounts of debris may be found in the filter element. This could be caused by friction and normal wear.
Tractor Maintenance Refer to the tractor’s operation and maintenance manual for the specific procedures regarding complete Tractor Maintenance.
