Superior spx 960 Technical Document

Cod. 5.201.0464-EN - 03-2011 REV. 00
Instruction Manual
for Operating
and Maintenance
WARNING
Incorrect and unsafe equipment operation may cause serious
damage and eventually lead to fatal injuries. Equipment and
maintenance operators must carefully read and get familiar with
the instructions provided in this manual.
The manual must be stored near the operator’s seat, and the
operator is expected to read it at regular intervals.
THE MANUAL MUST ALWAYS FOLLOW THE EQUIPMENT
ESPECIALLY WHEN THE EQUIPMENT IS SOLD.
spx 960

Istruction Manual for Operation and Maintenance SPX-960:
DO NOT OPERATE THIS MACHINE AND ITS EQUIPMENT BEFORE READING AND
FULLY UNDERSTANDING THIS MANUAL.
SCAIP DECLINESANYANDALL RESPONSIBILITY FOR DAMAGE DUE TO CARELESS
USE OF THE MACHINE LACK COMPLIANCE WITH INSTRUCTIONS GIVEN
IN THIS MANUAL.
SCAIP SHALLNOT BE HELD LIABLE FOR DAMAGE CAUSED BY INCORRECT INTER-
PRETATIONS OF THE INSTRUCTIONS PROVVIDED IN BOTH THE MANUAL AND ITS
ANNEXES.
WARNING
• PIPELINER - SPX-960:
S/N
• DIESEL ENGINE CATERPILLAR C13-ACERT:
S/N
ARRANGEMENT N.
• YEAR OF CONSTRUCTION:
• INTERNAL COMPANY CODE:
• REMARKS:
WRITE THE ID INFORMATION OF YOUR MACHINE BELOW:
THANK YOU FOR CHOOSING SUPERIOR!
SERVING THE PIPELINE INDUSTRY FOR OVER 50 YEARS
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Istruction Manual for Operation and Maintenance SPX-960:
CONTENTS Pagina
CHAPTER 1 - PRELIMINARY REMARKS ...................................................................................... 1-1
1.1 Presentation .................................................................................................................................. 1-3
1.1.1 Instruction manual for operation and maintenance......................................................... 1-3
1.1.2 Manual users................................................................................................................... 1-3
1.2 Safety information ...................................................................................................................... 1-4
1.2.1 Terminology used in this manual..................................................................................... 1-4
1.2.2 Safety signs .................................................................................................................... 1-5
1.2.3 Noise levels..................................................................................................................... 1-6
1.2.4 Vibration levels................................................................................................................ 1-6
1.3 Machine identification................................................................................................................. 1-7
1.4 Technical specifications.............................................................................................................. 1-8
1.4.1 Standard machine........................................................................................................... 1-8
1.4.2 Pipe layer conversion equipment.................................................................................... 1-10
1.4.3 Loading curve.................................................................................................................. 1-11
1.5 «CE» Declaration of Conformity................................................................................................. 1-13
CHAPTER 2 - SAFETY RULES ........................................................................................................ 2-1
2.1 General safety rules ................................................................................................................... 2-3
2.2 Adhesive safety and warning signs............................................................................................ 2-4
2.3 Non-authorized modifications..................................................................................................... 2-11
2.4 Safety at work ............................................................................................................................ 2-11
2.4.1 Operation on rough terrain.............................................................................................. 2-11
2.4.2 Safety devices................................................................................................................. 2-12
2.4.3 Personal protection equipment (PPE)............................................................................. 2-12
2.4.4 Prevention of fire and explosions.................................................................................... 2-13
2.4.5 In the event of fire ........................................................................................................... 2-14
2.4.6 Operator control station................................................................................................... 2-14
2.4.7 Climbing on and off the machine..................................................................................... 2-14
2.4.8 Fire extinguisher and first aid kit ..................................................................................... 2-15
2.4.9 Rops-Fops structure........................................................................................................ 2-15
2.4.10 Precautions prior to operation ......................................................................................... 2-16
2.4.11 Hazards at work .............................................................................................................. 2-16
2.5 Ecology and pollution ................................................................................................................. 2-16
2.6 Machine maintenance ................................................................................................................ 2-17
2.7 Parking the machine .................................................................................................................. 2-18
SEZIONE 3: MACHINE TRANSPORTATION ................................................................................... 3-1
3.1 Machine handling and transportation ......................................................................................... 3-3
3.1.1 Machine loading and transportation on trailer................................................................. 3-3
3.1.2 Unloading the machine from the trailer ........................................................................... 3-5
3.1.3 Towed machine ............................................................................................................... 3-6
CHAPTER 4 - MACHINE OPERATION ............................................................................................ 4-1
4.1 Machine scope ........................................................................................................................... 4-3
4.2 Machine description ................................................................................................................... 4-3
4.2.1 Hydraulic system............................................................................................................. 4-4
4.3 Operator control station.............................................................................................................. 4-6
4.3.1 Controls and control devices........................................................................................... 4-6
4.3.2 Controls and control devices........................................................................................... 4-8
4.3.3 Control instruments featured in Optional Visio terminal.................................................. 4-14
4.3.4 Optional Visio terminal features ...................................................................................... 4-16
4.4 Pipe layer operation ................................................................................................................... 4-20
4.4.1 Pipe layer start-up ...................................................................................................................... 4-21
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Istruction Manual for Operation and Maintenance SPX-960:
4.4.2 Pipe layer movement. ..................................................................................................... 4-23
4.4.3 Pipe layer shutdown........................................................................................................ 4-24
4.4.4 Emergency stop .............................................................................................................. 4-25
4.5 Machine operation...................................................................................................................... 4-25
4.5.1 Boom and hook movements ........................................................................................... 4-26
4.6 End of operating cycle................................................................................................................ 4-28
4.7 Installation of boom and blocks.................................................................................................. 4-28
4.7.1 Boom kickout................................................................................................................... 4-30
4.8 Anti-tipping and boom kickout control unit ................................................................................. 4-30
4.8.1 Anti-two block.................................................................................................................. 4-31
4.8.2 Lifting hook...................................................................................................................... 4-31
4.8.3 Precautions required to prevent load release from hook ................................................ 4-32
4.9 Wire ropes.................................................................................................................................. 4-33
4.9.1 Wire rope specifications.................................................................................................. 4-33
4.9.2 Montaggio della fune Wire rope installation .................................................................... 4-33
4.9.3 Wire rope installation....................................................................................................... 4-34
CHAPTER 5 - MAINTENANCE ........................................................................................................ 5-1
5.1 General ...................................................................................................................................... 5-3
5.1.1 Preliminary remarks on lubricants and coolants ............................................................. 5-3
5.1.2 Machine cleaning ............................................................................................................ 5-5
5.2 Wire ropes.................................................................................................................................. 5-6
5.2.1 Wire rope wear. ............................................................................................................... 5-6
5.2.2 Wire rope corrosion......................................................................................................... 5-7
5.2.3 Other possible causes of wire rope damage................................................................... 5-7
5.2.4 Wire rope replacement.................................................................................................... 5-7
5.2.5 Wire rope inspection ....................................................................................................... 5-7
5.2.6 Wire rope maintenance................................................................................................... 5-8
5.3 Lifting hook................................................................................................................................. 5-9
5.4 Diesel engine ............................................................................................................................. 5-9
5.4.1 Air filter............................................................................................................................ 5-9
5.4.2 Cooling radiators............................................................................................................. 5-10
5.5 Hydraulic system (lifting/drive purposes) ................................................................................... 5-11
5.5.1 Hydraulic oil reservoir...................................................................................................... 5-11
5.5.2 Diesel fuel tank................................................................................................................ 5-13
5.6 Tracks ........................................................................................................................................ 5-13
5.6.1 Pads................................................................................................................................ 5-13
5.6.2 Track tensioning.............................................................................................................. 5-14
5.7 Electric system ........................................................................................................................... 5-15
5.7.1 Batteries.......................................................................................................................... 5-15
5.7.2 Fuses .............................................................................................................................. 5-16
5.7.3 Lights............................................................................................................................... 5-16
5.8 Scheduled maintenance............................................................................................................. 5-16
5.9 Lubrication points ....................................................................................................................... 5-18
5.10 Machine shutdown ..................................................................................................................... 5-19
5.11 Oil and lubricant table ................................................................................................................ 5-20
5.12 Recommended lubricants .......................................................................................................... 5-21
5.13 Lubricant viscosity chart............................................................................................................ 5-21
5.14 Problem, causes and possible solutions .................................................................................... 5-22
CHAPTER 6 - SPARE PARTS ........................................................................................................... 6-1
6.1 Instructions for ordering parts........................................................................................................ 6-3
CHAPTER 7: ANNEXS....................................................................................................................... 7-1
1) CHECK LIST FOR PERIODIC WIRE ROPE TESTING .................................................................. 7-3
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Istruction Manual for Operation and Maintenance SPX-960: PRELIMINARY REMARKS
CHAPTER 1
Preliminary remarks
1.1 Presentation ............................................................................. 1-3
1.1.1 Instruction manual for operation and maintenance.... 1-3
1.1.2 Manual users.............................................................. 1-3
1.2 Safety information ................................................................. 1-4
1.2.1 Terminology used in this manual................................ 1-4
1.2.2 Safety signs................................................................ 1-5
1.2.3 Noise levels................................................................ 1-6
1.2.4 Vibration levels........................................................... 1-6
1.3 Machine identification............................................................ 1-7
1.4 Technical specifications......................................................... 1-8
1.4.1 Standard machine...................................................... 1-8
1.4.2 Pipe layer conversion equipment1-10
1.4.3 Loading curve............................................................1-11
1.5 «CE» Declaration of Conformity.......................................... 1-13
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Istruction Manual for Operation and Maintenance SPX-960: PRELIMINARY REMARKS 1
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Istruction Manual for Operation and Maintenance SPX-960:
1.1 PRESENTATION
This instruction manual provides all the necessary information to know how to properly operate and
maintain
the «PIPE LAYER SPX 960», hereafter simply referred to as the “machine”, which is manufactured by the
company SCAIP, San Pancrazio (Parma, Italy), hereafter referred to as the “Manufacturer”.
The following sections are not meant to provide a comprehensive description of all the machine parts or a
detailed exposition of their operation. It is, instead, meant to give the operator what is normally necessary
to know about the machine to operate it safely and keep it in good condition.
Compliance and implementation of the instructions provided in the manual as well as correct maintenance
guarantee proper operation, long life and reduced consumption of the machine.
WARNING
Non-compliance with what is hereafter described, operator carelessness, improper use of the machine
and unauthorized changes can lead the Manufacturer to void the warranty they provide.
For very complex repairs or upgrading of the machine the owner must address the Manufacturer directly,
who are at the client’s disposal to provide prompt and careful technical service and whatever can be done
to improve the machine operating levels in order to get the best performance possible from it.
1.1.1 INSTRUCTION MANUAL FOR OPERATION AND MAINTENANCE
This manual is an integral part of the machine and must go with it whenever it is moved or sold. The
manual must be kept in a sheltered and safe place to facilitate consultation and preservation throughout
the life of the machine.
Any operator involved with the different functions of the machine (see 1.1.2 “Manual users”) must read
this manual, and the other manuals supplied with the machine, and must memorize their contents prior
to performing any operation.
If the manual is damaged or gets lost, immediately ask the Manufacturer for a copy.
1.1.2 MANUAL USERS
This manual is the main reference for personnel in charge of carrying out the different operations rela-
ted to the machine. Personnel include:
- operators in charge of machine handling and transportation;
- operators in charge of the different work processes;
- maintenance operators;
- demolition operators.
These operators must read and memorize the contents of this manual before carrying out the opera-
tions for which they are competent.
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PRELIMINARY REMARKS

Istruction Manual for Operation and Maintenance SPX-960:
1.2 SAFETY-SPECIFIC INFORMATION
The user will inform the machine operators about the risks of injury, the safety devices installed on the
machine for the operator’s safety and the accident-prevention rules complying with existing directives and
regulations.
Operators’ safety is one of the main concerns to OEMs. When a new machine is built, the manufacturer tries
to foresee all the possible danger conditions and consequently implement the required safety devices.
Despite this, the rate of accidents due to careless and improper machine operation is still high. Distrac-
tion, lack of carefulness and over confidence are still the most frequent causes of accidents along with
tiredness and sleepiness.
The user must comply with general safety and accident-prevention rules.
Pay attention to the risk symbols whenever you see them in this manual. They indicate possible
danger situations.
Three different symbols of risk are used in this manual:
DANGER
The DANGER symbol warns about maximum danger: the operations described can cause serious injuries,
death or long term risks to the operator’s health if they are not carried out correctly.
WARNING
The WARNING symbol warns that the operations described can cause serious injuries, death or long term
risks if they are not carried out correctly..
CAUTION
The CAUTION symbol warns that the operations described can cause damage to the machine and/or
persons if they are not carried out correctly.
1.2.1 TERMINOLOGY USED IN THIS MANUAL
To complete the description of risk levels, below is a list of words describing risky situations, directly in-
volving the machine and/or the machine operators.
• USER: the person, company or contractor that either buys or hires this machine to operate it according
to its scope
• WORK AREA: any area within which the machine operator and the other operators perform actions
intended to operate the machine.
• DANGER ZONE: any area inside and/or close to the machine where a person is exposed to a danger
for his safety and health.
• RESIDUAL RISK: any risk remaining, especially during maintenance, installation and cleaning, even
after safety measures have been taken, in terms of design and construction, and safety devices and
deterrents have been installed.
• EXPOSED PERSON: anyone completely or partially finding himself in a danger area.
• OPERATOR: the person and/or persons who are assigned the task of installing, operating, adjusting,
maintaining, cleaning, repairing and transporting the machine.
• SKILLED OPERATORS: this definition includes persons who are trained and entitled to carry out mainte-
nance or repair works, requiring a deep knowledge of the machine, its operating principle, safety devices,
maintenance procedures, as well as the persons who are also able to recognize and consequently avoid
the hazards arising during machine operation.
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PRELIMINARY REMARKS

Istruction Manual for Operation and Maintenance SPX-960:
1.2.2 SAFETY SIGNS
The machine has been equipped with all the necessary sa-
fety devices required to safeguard the operators.
However, residual risks still exist and are signaled on the
machine with safety signs (decals).
These signs (decals) have been attached to the machine and
briefly warn about any unsafe and danger situation.
Keep these signs clean and replace them immediately when
they come off or get damaged.
The pictures alongside show some examples of decals (Fig. 1).
Section 2.2 illustrates all the decals affixed on the machine and
their location.
• SERIOUS DANGER sign. When you see this sign: pay
attention to overhead electrical cables. There is a risk of
electrocution which may have a lethal effect if cables are
contacted.
• CAUTION AND WARNING sign. When you see this sign:
do not remove the guards protecting moving parts.
• DANGER sign. In this safety sign the two symbols respec-
tively indicate the risk (top symbol) and the solution (bottom
symbol). When you see this sign: the top symbol warns that
upper limbs may get injured if the operator puts his hands
close to moving parts; the bottom symbol shows the operator
that he has to move away from rotating parts.
Pict. 1
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PRELIMINARY REMARKS

Istruction Manual for Operation and Maintenance SPX-960:
1.2.3 NOISE EMISSION LEVELS
Two decals have been affixed on the machine (Fig. 2) to show
the noise level during machine operation.
The noise level was measured according to standard ISO 3746
with the following results:
• Noise pressure, operator sitting in his seat during machine
operation: LpA dB (A)............................................ 93
• Noise pressure, operator sitting in his seat during machine
operation: LwA dB (A)........................................... 115
Pict. 2
According to these results the operator must wear ear defenders such as ear muffs or plugs to
protect his hearing.
1.2.4 VIBRATION LEVELS
The weighted root mean acceleration value was measured according to standard ISO 5349 with the fol-
lowing results
• Whole body vibration (seat): m/sq. sec .......................................................................................... 0,31
• Hand-arm vibration at operator’s seat (control lever): m/sq. sec.................................................... 1,46
WARNING
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PRELIMINARY REMARKS

Istruction Manual for Operation and Maintenance SPX-960:
1.3 MACHINE IDENTIFICATION
The machine is supplied with an identification plate (Fig. 3) located in the operator’s cabin which shows
the following information:
- CE marking;
- Manufacturer’s or Dealer’s name and address;
A) Machine model*;
B) Machine chassis number*;
C) Machine serial number*:
D) Engine power;
E) Machine weight;
F) Year of construction;
G) Arrangement number.
*The information on the identification plate must always be referred to whenever an order is placed for
spare parts and/or service.
For the engine identification refer to the relevant CATERPILLAR engine manual.
The machine is supplied complete with the following:
- CE Declaration of Conformity;
- Instruction Manual for Operation and Maintenance;
- Instruction Manual for Operation and Maintenance of the CATERPILLAR Engine;
- Hydraulic system diagram;
- Electric system diagram
A
Fig. 3
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B
C
D
E
F
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PRELIMINARY REMARKS

Istruction Manual for Operation and Maintenance SPX-960:
1.4 TECHNICAL SPECIFICATIONS
1.4.1 STANDARD MACHINE
DIMENSIONS (see next page)
Length (with rear tow point and bumpers) 6200 mm - 244 in
Shipping width (36” shoes) 3790 mm - 149.2 in
Operating width 4150 mm - 163.4 in
Operating height 3500 mm - 137.8 in
Total working weight 62000 Kg - 136684 Lb
DIESEL ENGINE
Brand CATERPILLAR
Model C13 ACERT
Emissions (ref. stds “Tier 3” according to American standards, “Stage IIIA” according to European stds)
Net flywheel power (DIN 6270 - SAEJ 1349) 440 HP - 324 kW
Rev. per minute 2,200 rpm
Displacement 12.5 lt - 763 cu in
Consumption (tentative) 42 l/h - 11 U.S.Gal/h
HYDRAULIC SYSTEM
Main pumps (BOSCH-REXROTH) 2 independent, variable pumps
Max. flow rate 2x450 lt/min - 2x119 U.S. gal/min
Max. operating pressure 400 bar - 5,800 p.s.i.
Service pumps 1 tandem gear pump
Max. flow rate 50 lt/min - 13 U.S. gal/min
DRIVE
Type hydrostatic, closed circuit, including one pump and two motors per track
Brakes (4) integrated, negative control
Final drives (2) planetary , in oil bath
Speed:
1st speed 1.7 Km/h - 1 miles/hr
2nd speed 2.6 Km/h - 1.6 miles/hr
3rd speed 5.3 Km/h - 3.3 miles/hr
CONTROLS
Type Two-side operation
Safety devices Emergency shut-off
TSSystem: steering wheel complete with 2 additional levers for safer and more precise steering.
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PRELIMINARY REMARKS

Istruction Manual for Operation and Maintenance SPX-960:
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• Lifting boom 28’ = 2450 Kg • N. 2 counterweight leave packs = 4655 Kg + 6650 Kg • A-frame = 550 Kg • Removable steps = 32 Kg
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PRELIMINARY REMARKS

Istruction Manual for Operation and Maintenance SPX-960:
TRACKED CARRIAGE
Tracks with sealed and lubricated chain
Track support rollers 9+9
Track support rollers 2+2
Length of track on ground 2.6 m - 8.5 ft
Track gauge 4.08 m - 13.4 ft
STD shoe width 914 mm - 36 in
Shoe area 73440 cm2- 11382 sq in
Optional shoe width 1015 mm - 40 in
Shoe area 82824 cm2- 12837 sq in
Chain spacing 260.35 mm - 10.25 in
CAPACITIES
Diesel fuel tank 720 liters - 190 U.S. gal
Hydraulic tank 345 liters - 91 U.S. gal
Engine cooling system 65 liters - 17.2 U.S. gal
Diesel engine oil 34 liters - 9 U.S. gal
Drive circuit 12 liters - 3.4 U.S. gal
ELETTRIC SYSTEM
Operating voltage 24 V
Serial maintenance-free batteries 2
Total capacity 220 Ah
Starter 7.5 Kw
Alternator 55 A
ROPS-FOPS PROTECTION
Rops (ref. standards) EN 13510 - ISO 3471:1994 (1:1997 modified) - SAE J1040
Fops (ref. standards) EN ISO 3449 - SAE J231
Weight 400 Kg -882 Lb
The test is to be considered successful even if the required power values have not been reached. In the
event that the pipe layer tips to one side, it will never touch the ground with the Rops-Fops protection, but
rather with the counterweight rack on one side and the boom on the other
1.4.2 PIPELAYING EQUIPMENT
BOOM
STD boom length 7.31 m - 24 ft
Optional boom length 8.53 m - 28 ft
Wire rope diameter 19 mm - 3/4 in
Min. breaking strength 323 KN - 72,530 lb
Part load line 8
Part boom line 5
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PRELIMINARY REMARKS

Istruction Manual for Operation and Maintenance SPX-960:
ADJUSTABLE COUNTERWEIGHT
QD-CS: this system for quick counterweight disconnection allows for removal of the entire counterweight
rack in a short time.
Removable counterweight leaves 17 leaves 660 Kg - 1,452 lb each
Total weight extendible 11,300 Kg - 24,900 lb
HYDRAULIC WINCH
Type. Hydraulic drum (reversible). The winch is controlled by a variable pump and an open circuit shut-off
valve.
Final drive compact, three-stage planetary gear
Brakes integrated multiple disk brake, negative control
Hook Arm
Drum diameter 390 mm - 15.3 in 390 mm - 15.3 in
Flange diameter 590 mm - 23.2 in 530 mm - 20.8 in
Drum length 360 mm - 14.1 in 360 mm - 14.1 in
Capacity (19 mm - 3/4 in) 136 m - 446 ft 76 m - 249 ft
Wire rope installed 120 m - 394 ft 70 m - 230 ft
Hook speed 0-16 m/min - 0-52 ft/min
1.4.3 LOAD CURVE (see next page)
LIFTING APPLIANCES
Reference standards ISO 4301/1
Grade T4
Loading condition L2
Loading condition M4
Total working weight 62000 Kg - 136684 Lb
LIFTING PERFORMANCE WITH 28’ BOOM (8.53 m)
Max. capacity with 1.22 m overhang (“tipping limit” according to SAE J743B) 97000 Kg - 231400 Lb
Max. lifting capacity with 1.22 m overhang (“work cond.” according to ISO 8813) 48000 Kg - 105600 Lb
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PRELIMINARY REMARKS

Istruction Manual for Operation and Maintenance SPX-960:
Exceeding working capacities (ref. to diagram below) means putting the machine stability and the
operator’s safety at risk.
WARNING
DIAGRAM SPECIFICATIONS
1) BLACK CURVE - This curve describes the max. capacity before the machine tips over according to
the boom overhang in compliance with SAEJ743B. The anti-tipping system prevents reaching the
situation described by this curve, because it is dangerous and must not be considered for normal and
safe operating conditions.
2) RED CURVE -This curve describes the max. lifting capacity during machine operation according to the
boom overhang in compliance with ISO 8813. The anti-tipping system takes this curve as the max.
threshold above which a danger condition arises: a buzzer and warning lights warn the operator, and
the system stops all the controls which may be engaged to exceed this critical curve. At the same
time, all the controls for boom lifting and hook fall are free, because they may be engaged in critical
situations.
3) YELLOW CURVE - This curve describes an alert condition, i.e. the system is 15% before the red
curve. The anti-tipping system detects this condition and causes a warning light to go on to warn the
operator.
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2
3
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Istruction Manual for Operation and Maintenance SPX-960:
1.5 «CE» DECLARATION OF CONFORMITY
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PRELIMINARY REMARKS

Istruction Manual for Operation and Maintenance SPX-960:
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Istruction Manual for Operation and Maintenance SPX-960: SAFETY RULES 2
CHAPTER 2
Safety rules
2.1 General safety rules ...............................................................2-3
2.2 Adhesive safety and warning signs........................................2-4
2.3 Non-authorized modifications...............................................2-11
2.4 Safety at work ......................................................................2-11
2.4.1 Operation on rough terrain........................................2-11
2.4.2 Safety devices...........................................................2-12
2.4.3 Personal protection equipment (PPE).......................2-12
2.4.4 Prevention of fire and explosions..............................2-13
2.4.5 In the event of fire .....................................................2-14
2.4.6 Operator control station.............................................2-14
2.4.7 Climbing on and off the machine...............................2-14
2.4.8 Fire extinguisher and first aid kit ...............................2-15
2.4.9 Rops-Fops structure..................................................2-15
2.4.10 Precautions prior to operation ...................................2-16
2.4.11 Hazards at work ........................................................2-16
2.5 Ecology and pollution ...........................................................2-16
2.6 Machine maintenance ..........................................................2-17
2.7 Parking the machine ............................................................2-18
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Istruction Manual for Operation and Maintenance SPX-960:
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SAFETY RULES