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Istruction Manual for Operation and Maintenance

SPX-960

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Keep the lifting ropes constantly under control for wear, deteriorations and breakage. Refer to section
«5.2.5 Wire rope inspection».

Figure 45 shows some examples of wire rope deterioration which require replacement.

A) Slackened strands.
B) Tightened strands.
1) Looped strand.
2) Strand relaxation due to small diameter sheave.
3) Damage caused by cable derailment.
4) Damage caused by incorrect cable winding on winch.
5) Problem due to small diameter pulleys.
6) Problem due to worn groove pulleys.
7) Strand relaxation due to small diameter pulleys.

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4-27

Fig. 45

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3

6

1

4

5

7

A

B

MACHINE OPERATION

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Summary of Contents for spx 960

Page 1: ...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 ...

Page 2: ...IANCE WITH INSTRUCTIONS GIVEN IN THIS MANUAL SCAIP SHALL NOT 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 SUPERI...

Page 3: ...t 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 ...

Page 4: ...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 ...

Page 5: ...enance 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 1 1 1 ...

Page 6: ...Istruction Manual for Operation and Maintenance SPX 960 PRELIMINARY REMARKS 1 1 2 ...

Page 7: ...ess 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 ...

Page 8: ...y 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 ...

Page 9: ... 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 symb...

Page 10: ...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 se...

Page 11: ...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...

Page 12: ...0 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...

Page 13: ...Istruction Manual for Operation and Maintenance SPX 960 1 Lifting boom 28 2450 Kg N 2 counterweight leave packs 4655 Kg 6650 Kg A frame 550 Kg Removable steps 32 Kg 1 9 PRELIMINARY REMARKS ...

Page 14: ... 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...

Page 15: ...sk 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...

Page 16: ...URVE 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 contr...

Page 17: ...Istruction Manual for Operation and Maintenance SPX 960 1 5 CE DECLARATION OF CONFORMITY 1 1 13 PRELIMINARY REMARKS ...

Page 18: ...Istruction Manual for Operation and Maintenance SPX 960 1 1 14 PRELIMINARY REMARKS ...

Page 19: ... 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...

Page 20: ...Istruction Manual for Operation and Maintenance SPX 960 2 2 2 SAFETY RULES ...

Page 21: ...nattended with the engine running Park the machine in a leveled area engage the parking brake lock the controls and switch the engine off before leaving the operator cabin Eventually take out the ignition key Before operating the machine check that no person is standing within the machine outreach Do not authorize any operator to stand near the machine while it is working Consider that the wider t...

Page 22: ...the instructions and warning remarks provided in the manual The manual must be stored in the cabin near the operator s seat If the manual gets lost contact SCAIP for a replacement copy Decal 2 yellow background Warning sign remarks for machine operation During machine operation or when the machine is traveling pay great attention that there is no one near the work area and especially at the back o...

Page 23: ...Istruction Manual for Operation and Maintenance SPX 960 Fig 4 A Location of safety and warning decals on the machine 2 1 18 4 3 STOP 12 7 5 11 1 15 16 17 2 14 13 9 2 10 7 3 4 14 14 2 5 SAFETY RULES ...

Page 24: ...Istruction Manual for Operation and Maintenance SPX 960 Fig 4 B Location of safety and warning decals on the machine 8 14 2 21 10 7 3 4 4 3 14 14 2 6 SAFETY RULES ...

Page 25: ...tention when removing the safety bolt during counterweight disassembly from the frame Decal 9 yellow background Pay attention when moving the lifting boom and standing close to the counterweight Keep away from moving parts There is a risk of cutting the arms and legs Decal 10 yellow background Pay attention when moving the lifting boom and blocks Keep away from the machine when it is operating Con...

Page 26: ...omplied with during machine handling Deal 16 yellow background Danger high voltage equipment Corrosion hazard due to battery acid lubricant oils and fuel Be cautious while using these substances Deal 17 yellow background Risk of explosion or fire Do not smoke or light free flames Deal 18 yellow background Risk of explosive gas Do not operate the machine in loca tions where an explosive atmosphere ...

Page 27: ... before ope ning the cap to prevent hot water from spraying out on persons Wear protective gloves Do not drill the piping in the hydraulic system The oil is at high pressure and may burst out Read the relevant sections of the instruction manual before carrying out work maintenance replacement operations or other activities on the hydraulic system pipes Wear protective gloves Under no circumstances...

Page 28: ...hese precautions may cause serious or even fatal injuries Under no circumstances should unauthorized persons be allowed or transported on the machine and its equipment Risk of falling The machine was designed for one operator only Keep unauthorized persons away from the machine Risk of crushing cutting hands Do not open the engine hood when the engine is running If the operation above is necessary...

Page 29: ...ep the machine clean and clear from flammable material such as waste grease oil or fuel Make sure that all safety devices are in good operating condition Check the soil and ground conditions in the work area Work out the safest way to start operations Do not work in areas presenting a risk of landslides or rock fall Make sure that no water and or gas pipe run underneath the work area Check for hig...

Page 30: ... in the controls or moving parts leading to serious injury During machine operation or maintenance wear approved safety garments Fig 7 such as hard hat tight overalls and reflective jackets ear muffs protective gloves goggles safety shoes respirators especially when working in areas with plenty of dust or polluting gases Ask your employer about the existing safety rules and accident prevention equ...

Page 31: ...s on the frame move flammable material to a safe place Use an inflammable lubricant to wash parts requiring it Diesel fuel and gasoline may ignite do not use these fluids For greater safety at work move cloths soaked with grease and other flammable material into a safe container Do not weld or oxy fuel cut pipelines or piping which contain flammable fluids Do not leave lighters or gas cylinders ar...

Page 32: ...abin Do not use mobile phones in the cabin while driving or operating the machine Do not take hazardous objects such as flammable or explosive material to the operator cabin Before starting the machine fasten your seat belt carefully 2 4 7 GETTING ON AND OFF THE MACHINE Before getting on the machine make sure that there is no oil grease or mud on the pads rails steps or platforms 1 in Fig 10 If th...

Page 33: ...ial Prepare a list of useful emergency telephone numbers to be dialed in the event of an accident 2 4 9 ROPS E FOPS PROTECTION Fig 12 Do not remove the Roll Over Protective Structure ROPS from the machine The ROPS structure has been installed to protect the operator if the machine tips over It has been designed to support the load if the machine tips over and to absorb the energy impact Replace th...

Page 34: ...ss the control station or climb on the machine during operation Before starting any operation check that personnel walk away from the work area 2 4 11 HAZARDS AT WORK Before carrying out any operation it is important to be aware of existing hazards Before starting operation contact the local utility company ies in order to identify and locate any underground piping such as gas and water pipes or e...

Page 35: ...ea and wear goggles and rubber gloves Do not charge a frozen battery it may burst During recharge operations lead batteries generate hydrogen and oxygen which is an explosive mi xture Keep away from free flames DO NOT DUMP FLUIDS TO THE GROUND SEWAGE OR RIVERS COMPLY WITH THE ENVI RONMENTAL RULES AND THE REGULATIONS FOR DISPOSING OF OIL FUEL BATTERY AND OTHER POLLUTING SUBSTANCES To check the elec...

Page 36: ...s 2 7 PARKING THE MACHINE WARNING The machine must be parked following some baseline safety rules Consider that the operator is responsible for safe machine parking Below is a short list of baseline safety rules for parking Park the machine on a flat ground away from moving equipment pedestrians or traffic areas Lock the side boom in vertical position after having removed the load Lock all the con...

Page 37: ...nce SPX 960 3 CHAPTER 3 Machine transportation 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 3 1 MACHINE TRANSPORTATION ...

Page 38: ...Istruction Manual for Operation and Maintenance SPX 960 3 3 2 MACHINE TRANSPORTATION ...

Page 39: ...un away space namely a free and safe area to move to should the machine roll over 3 1 1 MACHINE LOADING AND TRANSPORTATION ON TRAILER The Pipe layer SPX 960 can be hauled on long distances on trailers authorized to transport job site equipment keeping the platforms low Fig 17 WARNING The machine must be prepared for transportation by disassembling the components described below according to the co...

Page 40: ...sported in narrow or low places The machine has a permanent integral hydrostatic drive and cannot be towed with the engine off To move the machine drive it from the control station The platform the machine is meant to be loaded onto must be perfectly flat This will prevent the load from moving Loading unloading ramps must not exceed a max tilt of 15 Check that the ground in the loading area is com...

Page 41: ...t the machine is in good condition and in a position preventing it from being a danger Unload the machine on a stable ground using suitably sized ramps after locking the trailer wheels Keep at a safety distance from the edge of the road Load and unload the machine exclusively on flat stable ground Engage the trailer brakes and place blocks under the tires to prevent trailer movements Place the ram...

Page 42: ...ine or errors when selecting or inspecting the tow cable may lead to serious accidents or even death Always wear safety gloves to handle tow cables Connect a metal cable to the part 1 or 2 shown in Fig 20 During machine towing operations do not stand between the towing vehicle and the towed machine Do not tow the machine along gradients Do not use tow cables presenting cut terminations having a do...

Page 43: ...0 4 4 1 Pipe layer start up 4 21 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 ...

Page 44: ...Istruction Manual for Operation and Maintenance SPX 960 4 4 2 MACHINE OPERATION ...

Page 45: ...ontrol cabin 9 in Fig 20 the counterweight rack 26 in Fig 20 and the side boom Two winches control lifting and lowering of the boom 5 in Fig 20 and lifting and lowering of the blocks 14 in Fig 20 A hydraulic system which is fully operated from the operator control cabin through the diesel engine controls all machine movements as well as lifting and lowering of the different parts The tracked carri...

Page 46: ... controls both the free fall and low pressure in the main hose This valve must be enabled to allow for system operation the second solenoid controls the boom down end of stroke whenever the machine is in tip over condi tions ATP version the third solenoid opens closes the piping that controls boom up movements as the end of stroke point during boom kick out the fourth solenoid opens closes the pip...

Page 47: ...rotection grid with inspection hole to monitor boom tip 11 Boom up down control cable 12 Boom support block 13 Articulated sheave block 14 Hook block 15 Hook block up down control cable 16 Boom frame 17 Side lights 18 Hydraulic oil diesel fuel tank 19 Steps for climbing up down cabin removable 20 Pulleys 21 Left hand track 22 Open steel flooring for block storage during transportation 23 Bumpers 2...

Page 48: ...tional 1 Left hand drive control lever 2 Right hand drive control lever 3 Multiple function joystick for combined left and right hand drive control 4 Multiple function joystick for hook and boom control 5 Counterweight control lever 6 Diesel engine ignition key 7 Emergency stop engine 8 Orange light diesel engine diagnostic 9 Horn button 10 Step button preset at 900 rpm 11 Step button preset at 13...

Page 49: ... and Maintenance SPX 960 Fig 21 Control panel for version ATP plus STANDARD 40 45 44 38 39 A B 4 41 4 7 24 3 4 5 10 13 33 42 1 2 11 12 7 6 14 17 16 8 25 22 19 20 21 9 18 46 23 26 27 29 30 28 32 43 34 35 36 37 31 15 MACHINE OPERATION ...

Page 50: ...forward and causes the machine to turn right When the lever is released it automatically goes back to neutral position pull lever 1 to B the left hand track moves backward and causes the machine to turn left When the lever is released it automatically goes back to neutral position LEVER 2 Fig 22 push lever 2 to A the right hand track moves forward and causes the machine to turn left When the lever...

Page 51: ...ush the joystick to B to lift the hook push the joystick to C to lower the boom push the joystick to E to lift the boom 5 Counterweight control lever Fig 25 Press button 1 and push the lever to A to let the counterweight out C in Fig 26 pull the lever to B to let the counterweight in D in Fig 26 6 Diesel engine ignition key 6 Fig 27 Turn the ignition key clockwise the first turn switches the dashb...

Page 52: ... rpm 12 Diesel engine rpm presetting button 12 Fig 28 Press this button to set the diesel engine rpm at medium high speed 1800 rpm 13 Diesel engine rpm presetting button 13 Fig 28 Press this button to set the diesel engine rpm at high speed 2100 rpm 14 Diesel engine rpm progressive accelerator decelerator button 14 in Fig 29 15 Two speed selector 15 Fig 29 first and second gear turning right 16 Wi...

Page 53: ...e Customer Service dept 28 Temperature fuse 15A 28 Fig 30 protecting the dashboard indicators 29 Temperature fuse 10A 29 Fig 30 protecting the anti tipping system 30 Temperature fuse 15A 30 Fig 30 protecting the diesel en gine control unit 31 Temperature fuse 60A 31 Fig 30 protecting the ignition key and right hand dashboard instruments 32 Fuse holder blocks 32 Fig 30 33 Anti tipping control panel...

Page 54: ...ing system 38 White light electric system error 37 Fig 31 This light indicates that an electric error has occurred 39 Yellow light anti tipping alert 38 Fig 31 This light goes on during lifting operations 15 before the max lifting capacity is reached see yellow curve in the lifting capacity diagram on page 15 Red light anti tipping alarm 38 Fig 31 This light goes on during lifting operations 15 be...

Page 55: ...batteries are off when the key is turned by 45 to the right pos B the batteries are on 42 Drive stop lever 42 Fig 34 When the lever is all the way up in position A the drive does not work and the diesel engine can be started When the lever is all the way down in position B the drive works but the diesel engine cannot be started if the machine is off WARNING Always bring the lever to position A bef...

Page 56: ...ght diesel engine diagnostic 9 Horn button 10 Step button preset at 900 rpm 11 Step button preset at 1300 rpm 12 Step button preset at 1800 rpm 13 Step button preset at 2100 rpm 14 Progressive throttle button 15 Two speed selector 16 Windscreen wiper switch 17 Light switch unit 18 Rpm programming button located under the plate to be used by service technicians only 19 Parking and brake button for ...

Page 57: ...eration and Maintenance SPX 960 A B 4 41 4 15 Fig 36 Control panel featuring optional Visio terminal 41 3 4 5 10 13 42 1 2 11 12 18 46 26 27 29 30 28 32 43 34 35 36 37 6 7 20 23 22 21 17 8 16 14 9 19 15 31 33 MACHINE OPERATION ...

Page 58: ...tored in the engine ECU Button 7 Video shows the image captured by the camera installed at the back optional Button 8 Menù Button 9 Exit Screen shot 1 Starting engine Screen shot 2 Display Screen shot 3 Language choice only for first start Screen shot 4 ATP Display 1 The color of the arrow has the fol lowing meaning GREEN enabled movement RED blocked movement 2 The color of the bars has the fol lo...

Page 59: ...red by the camera installed at the back optional Screen shot 6 Night display Screen shot 7 Error fault messages specific to lifting system A popup window with a message appears on screen whenever a setup fault malfun ction or error occurs The message disap pears spontaneously after a few seconds and on screen a yellow round icon remains to indicate that alarms are active Error fault messages speci...

Page 60: ...r when the system is initialized for the first time after language selection It is used to set the boom kick out and the anti two block parameters Detailed in structions assist the operator during setup The example below shows the necessary steps to set up the position of the anti two block Screen 8 ATB setup 4 4 18 MACHINE OPERATION ...

Page 61: ... enable set the direction of the boom encoder to enable the solenoid valve controlling the lower hook limit to enable the trigger of the electric limit switch controlling the boom upper limit As for ATB setup parameters detailed instructions are provided to assist the operator step by step Screen shot 10 LAS setup menu This page is accessed from Screen shot 9 Advanced ATP setup menu It is used for...

Page 62: ...ERATION CHECK THAT THE AREA IS CLEAR FROM ELECTRICAL AND TELE PHONE LINES OR ANY OTHER POTENTIAL DANGER OR OBSTACLE Fig 37 ALWAYS KEEP AT A SAFE DISTANCE FROM OVERHEAD ELECTRICAL CABLES For greater safety the operator must be familiar with the work area and the operations that he is going to start examine the entire work area before starting lifting the boom always keep in mind that electrical cab...

Page 63: ...been installed correctly Check for any oil spills on the ground if this is the case there may be leaks from the hydraulic oil system Make sure that the battery is in efficient conditions Charge the battery if necessary Ensure that nobody is working on or around the engine or other parts connected to the engine before reaching the control position Before any operation for putting the machine in pos...

Page 64: ...from a door on the left hand side near the hydraulic oil radiator Turn the key to the right to position B Fig 40 4 If the machine was blocked the light in the red parking brake button 19 in Fig 41 A B must be off Before starting the machine up press this button to release all the machine functions The light in the button goes on 5 Put the ignition key in 6 in Fig 41 A B rotate it clockwise by one ...

Page 65: ...g 42 located on the left hand side of the operator seat Set the operating speed by pressing one of the 4 buttons on the joystick button 5 Fig 44 sets 900 rpm button 6 Fig 44 sets 1300 rpm button 7 Fig 44 sets 1800 rpm button 4 Fig 44 sets 2100 rpm The joystick features other two buttons which are used for fine tuning the number of rpms press the button 14 in Fig 40 A B to progressively incre ase r...

Page 66: ...ig 30 and let it run at min speed 3 Turn the ignition key 6 in Fig 28 anticlockwise and remove it from its lock 4 Press the parking brake button 20 in Fig 31 the light built in the button turns red 5 Turn the key Fig 42 to position A to disable the battery and remove it from its lock 6 Put the safety lever Fig 38 in position A Before leaving the machine if the machine is left unattended collect th...

Page 67: ...H RUN SPACE NAMELY FREE SAFE MOVE TO SHOULD HANDLED LOAD FALL DOWN DUE BRISK MOVEMENT OR ANY OTHER RE ASON WHATSOEVER CORRECT SELECTION HARNESSES PLAYS FUNDAMENTAL ROLE DO SELECT RIGID MATERIAL SUCH AS TIE RODS MADE ROUND BARS STEEL SECTIONS BECAUSE THESE MAY COME OUT HOOK AN OBSTACLE HIT In any case 1 avoid brisk jerking and braking when lifting loads 2 prevent harnesses from slackening in the ho...

Page 68: ...angerous if great care is not taken in carrying them out Ask unauthorized persons to move away from the area Clear and fence the lifting han dling area Ensure that the work area is clear and that there is enough run away space namely a free and safe area to quickly move to should the load fall down During operation the hook is subjected to mechanical and thermal stress which over time inevitably l...

Page 69: ...wire rope deterioration which require replacement A Slackened strands B Tightened strands 1 Looped strand 2 Strand relaxation due to small diameter sheave 3 Damage caused by cable derailment 4 Damage caused by incorrect cable winding on winch 5 Problem due to small diameter pulleys 6 Problem due to worn groove pulleys 7 Strand relaxation due to small diameter pulleys 4 4 27 Fig 45 2 3 6 1 4 5 7 A ...

Page 70: ...FETY DEVICE BYPASS KEY 35 IN FIG 41 A AND 41 B KEEP MIND THAT WHEN THIS OPERA TION IS PERFORMED ANTI TIPPING SYSTEM NO LONGER CONTROLS MACHINE STABILITY 1 Position the pipe layer on a flat and compact ground 2 Support the boom clear it from any obstacles and harness it to a suitable hoist 1 in Fig 46 3 Position the ends of the boom in the hinging points and fit the two pins 2 in Fig 46 After this ...

Page 71: ... SPX 960 2 6 3 4 Fig 47 1 Boom hinging pins 2 Boom support block 3 Boom block pin 4 Hook block support pin 5 Articulated attachment 6 Hook blocks 7 Block support pin housing 8 Lifting hook 1 2 7 5 6 8 10 cm min 8 10 cm circa 4 4 29 MACHINE OPERATION ...

Page 72: ...boom reaches the almost vertical position it engages a mechanical kickout device consisting in a strut bar 1 in Fig 48 The strut bar on its turn engages a micro switch 2 in Fig 48 which starts a solenoid valve that stops the boom from lifting The boom kickout is already set when the machine is released from the factory If it needs calibration because it goes out of sync or for other reasons set it...

Page 73: ... Press the programming button 2 in Fig 49 and hold it pres sed until the display flashes 3 in Fig 49 Hold the programming button 2 in Fig 49 pressed and press the enable programming button simultaneously 1 in Fig 49 Now the display stops flashing and stores the anti two block position NOTE if the machine is supplied with an optional Visio terminal refer to section 4 3 4 for the setup parameters of...

Page 74: ...teel sections because these may come out of the hook if an obstacle is hit In any case 1 avoid brisk jerking and braking when lifting loads 2 do not overload the hook throat cables or chains near the hook tip are likely to be released 3 prevent harnesses from slackening in the hook should the load be temporarily deposited or positioned on a support 4 prevent the harnesses from getting entangled in...

Page 75: ...trength per sq mm 220 kg mmq Winding crociata destra Composition N 6 strands 36 wires each Core type 49 wire metal core Nominal mass per linear meter 1 52 kg Length upper winch boom 70 m Length lower winch hook 120 m 4 9 2 WIRE ROPE INSTALLATION The wire rope must be installed with the boom at approx one meter from ground level Fig 47 Unwind the rope as illustrated in Fig 50 Put one end of the wir...

Page 76: ...ations and excessive contact between the rope elements strands and core this may jeopardize wire rope performance and duration The wire rope duration is also affected by groove wear For instance if the groove is excessively sco red or deformed the wire rope is more likely to get worn DANGER The wire rope is wound on parts which are specifically sized according to the rope diameter For this reason ...

Page 77: ...intenance 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 Lubri...

Page 78: ...Istruction Manual for Operation and Maintenance SPX 960 5 5 2 MAINTENANCE ...

Page 79: ...ne is like blood to the human body for this reason do not let it get fouled with impu rities water metal particles dirt etc Most of the operating problems with machinery are caused by impurities in the oil Take all the measures required to prevent impurities from fouling the oil during storage or top up opera tions Do not mix oils of different types and brands Fill the required amount of oil Exces...

Page 80: ...ms will arise due to the presence of air in the agent GREASE Grease is used to prevent the joints from bending and being noisy There are greasing nipples which are not included in the MAINTENANCE chapter that do not need periodic greasing because they are only used for overhauling purposes Grease any element that gets stiff or noisy after long hours of operation Remove any used grease that may lea...

Page 81: ...ation which has an impact on the life of the machine and its operating cycle So lubricate parts at regular inter vals and following the instructions provided The lubrication intervals recommended here depend on machine operation in normal working condi tions If the machine is used in tough conditions these intervals must be shorter 5 1 2 CLEANING THE MACHINE WARNING Do not use gasoline solvents or...

Page 82: ...sonnel Refer to section 4 9 Wire ropes for rope specifications and installation 5 2 1 WIRE ROPE WEAR Great wire wear is the first step to wire breakage Worn wires beyond an acceptable limit must be consi dered as broken wires The limit is reached when the wire diameter has visibly halved compared to the original diameter When the wires start being worn we recommend repeating the periodic inspectio...

Page 83: ...owing factors number of broken wires and their position lever of wire rope wear lever of wire rope corrosion other damage or alterations generated by wire rope condition The wire rope must be replaced in the following cases the reduction in total wire rope diameter is equal to 10 of the original diameter regardless whether it is in one point only a strand is completely broken and is damaged to suc...

Page 84: ... he services any equipment malfunctioning such as no engagement of the anti two block switches wire rope release from the drums or pulleys WARNING The wire ropes must be replaced every 1500 hours funi Small grooves cause wire rope deformations and excessive contact between the rope elements strands and core Fig 54 this may jeopardize wire rope performance and duration The wire rope duration is als...

Page 85: ...e of the CATERPILLAR engine For engine inspection open the side doors of the engine compartment 5 4 1 AIR FILTER WARNING Switch off the engine before starting air filter inspection cleaning and maintenance Whenever compressed air is used be careful with flying polluting particles which may cause personal injury In these cases wear goggles a mask and other personal protection equipment The air filt...

Page 86: ...t install the cartridge if the folds seal or seal ring are damaged Replace the outer element after six cleaning cycles or at least once a year Replace the internal car tridge as well Fit the cover back in place 1 in Fig 57 after installing the filtering cartridges in their housing 5 4 2 COOLING RADIATORS The oil in the hydraulic system is cooled by a radiator that is fitted inside the engine hood ...

Page 87: ... oil level on a daily basis If the level is below the min value required open the door to access the hydraulic oil fill plug 3 in Fig 59 and fill with oil until the level between the min and max marks 1 2 in Fig 59 is reached Change the oil after the first 1000 hours of operation Then change the oil every 2000 hours or once a year at least Always change the oil and the oil filter at the same time ...

Page 88: ...ed the first time after 50 hours of operation then every 1000 hours and whenever the oil is changed This is done as follows considering that the filter cover has been removed already take out the filter and the corresponding cartridge remove any residual dirt put the cartridge and filter cover back in place fit a genuine cartridge when the existing one needs replacement When the oil filter has bee...

Page 89: ... drum cover and do not take condensed water from the drum bottom Check that the 10 micron vent filter is in efficient condition 2 in Fig 60 5 6 TRACKS The tracks play an important role for vehicle stability and easy driving This is why the shoes must be monitored constantly as well as the track tensioning which must always be at the correct value The pins and bushings in the undercarriage wear acc...

Page 90: ...s between the upper roller and the idle wheel as illustrated in Fig 63 Then measure the distance between the bar and the shoe top The track is tensioned correctly when on its top the section of the chain having no support has a flexure of approx 30 50 mm Fig 62 Check and adjust in the same operating conditions as ex plained above Tension the track as instructed below Take out the cover of the insp...

Page 91: ...elease is located alongside of the operator seat Fig 65 Check the battery condition every 100 hours Top up the bat tery fluid with distilled water if necessary recharge the battery whenever it is needed Clean the clamps every 400 hours and protect them with Vaseline The fluid in the battery must cover the internal elements Check the battery fluid level before recharging the battery Before checking...

Page 92: ...r lighting these lights must always be in good operating condition Replace blown bulbs with new ones of the same type 5 8 SCHEDULED MAINTENANCE AFTER THE FIRST 8 HOURS OF OPERATION Check the machine and its units equipment Make sure that all the bolts are tightened properly none of the parts in the hydraulic system presents oil lea ks moving or rotating parts are lubricated properly only the lubri...

Page 93: ...evel in the batteries Check the level in the hydraulic system Check and if necessary tighten all the bolts and screws Check for any worn parts and replace them Paint dented or damaged areas with rust preventing chemicals Grease each point requiring it Clean the engine air filter Clean the radiator fins OGNI 250 ORE DI SERVIZIO O 6 MESI sostituzione olio motore e filtro EVERY 300 HOURS OF OPERATION...

Page 94: ...culated pins grease 2 Hydraulic system for lifting drive oil 3 Engine see CATERPILLAR manual 4 Cooling system radiator water 5 Block pins grease 6 Air filter clean 7 Fuel tank diesel fuel 8 Wire rope joint grease 9 Planetary gearbox oil 10 Boom joints grease 11 Chain carriage grease 5 1 2 3 4 11 10 10 7 8 9 5 5 5 6 5 1 1 1 1 5 18 MAINTENANCE ...

Page 95: ...ill benefit great advantages from performing the operations described above with due care In fact the machine will be in very good condition when work is resumed Comply with laws existing in the country where the machine is operated regarding the use and dumping of products to clean and maintain the machine Also follow instructions given by the producer of these substances WARNING If the machine n...

Page 96: ...ection 5 12 HYDRAULIC SYSTEM 132 SAE10W 20 TRACK END GEARS 50 50 Rotra MP see section 5 12 1 3 4 1 3 4 SAE 80W 90 Rotra JD F SAE 80W ENGINE 40 Antifreeze extra Water and anti freeze agent COOLLING 10 1 2 mix to be blended with water SYSTEM at 50 This blend has anti oxidant anti corrosive anti incrusting and anti foam properties and does not freeze until 35 C MISC GREASING NIPPLES Grease GR MU 2 Gr...

Page 97: ...MENDED LUBRICANT VISCOSITY FOR START UP TEMPERATURES BETWEEN 23 C AND 48 C 5 SAE 10W 20 SAE 15W 40 30 40 SAE 80W 90 SAE 80W GREASE AGIP SIGMA S SIGMA TRUCK ROTRA HP ROTRA JD F GR MU 2 SIGMA TURBO ESSO ESSOLUBE GEAR GX D3 HEAVY TRUCK MOBIL DELVAC 1330 MOBILUBE HD DELVAC 1330 SUPER BP VENELLUS C3 HYPOGEAR EP VENELLUS C3 EXTRA TAMOIL HP 300 MOTOROIL TAMGEAR MP SHELL RIMULA CT SPIRAX HD US DEPARTMENT ...

Page 98: ...y impurity from the in the diesel fuel system and or diesel fuel system Replace the die diesel filter clogged diesel filter No ventilation in Replace the plug with a fuel tank plug ventilated plug Dirty or malfunctioning injectors Contact an authorized dealer for injector replacement No fuel in tank Fill the fuel tank The engine has irregular revolutions Low engine oil level Top up the oil until t...

Page 99: ... filter Oil leaks Locate the leak and fix it Excessively high engine temperature Check the cooling system Exhaust gases are either black Incorrect fuel Fill with the correct fuel or grey Incorrect synchronization of Contact an authorized dealer pump injectors Dirty or malfunctioning injectors Contact an authorized dealer The exhaust gas is white Incorrect fuel Fill with the correct fuel Engine coo...

Page 100: ... Let the temperature in the hydraulic are too slow Incorrect oil Fill with the correct oil Excessively slow engine speed Contact an authorized dealer Hydraulic pump broken Contact an authorized dealer Excessively high oil temperature Incorrect oil Fill with the correct oil Filter clogged Replace the filter Hydraulic pump broken Contact an authorized dealer Radiator or exchanger clogged Clean the f...

Page 101: ... Contact an authorized dealer All the movements do not work Hydraulic pump broken Contact an authorized dealer there is noise coming from the pump Drain pressure setpoint Contact an authorized dealer low Hydraulic oil level low Add some more oil One of the cylinder does not work Oil seals damaged Fix or replace them or is weak Oil leaks caused by a Fix or replace them damaged cylinder stem Hydraul...

Page 102: ...Istruction Manual for Operation and Maintenance SPX 960 ...

Page 103: ...Istruction Manual for Operation and Maintenance SPX 960 6 CHAPTER 6 Spare Parts 6 1 Instructions for ordering parts 6 3 6 1 SPARE PARTS ...

Page 104: ...Istruction Manual for Operation and Maintenance SPX 960 6 6 2 SPARE PARTS ...

Page 105: ...achine identification Code of the part requested The code is indicated in the relevant page s of the Parts Book Part description and quantity requested Shipping terms If the applicant does not provide this detail despite SCAIP s commitment in the pro vision of this service SCAIP srl will not be held responsible for possible shipping delays due to force majeure Shipping costs are intended at the Pu...

Page 106: ...Istruction Manual for Operation and Maintenance SPX 960 6 6 4 SPARE PARTS ...

Page 107: ...Istruction Manual for Operation and Maintenance SPX 960 7 CHAPTER 7 Annexes 1 CHECK LIST FOR PERIODIC WIRE ROPE TESTING 7 3 7 1 ANNEXES ...

Page 108: ...Istruction Manual for Operation and Maintenance SPX 960 7 7 2 ANNEXES ...

Page 109: ...Istruction Manual for Operation and Maintenance SPX 960 DATE WIRE ROPE CONDITIONS REMARKS AND SIGNATURE ANNEX 1 CHECK LIST FOR PERIODIC WIRE ROPE TESTING 7 7 3 ANNEXES ...

Page 110: ...Istruction Manual for Operation and Maintenance SPX 960 ALLEGATI DATE WIRE ROPE CONDITIONS REMARKS AND SIGNATURE 7 7 4 ...

Page 111: ...Istruction Manual for Operation and Maintenance SPX 960 NOTES ...

Page 112: ...128 44379 Dortmund Phone 0049 0231 9633073 Fax 0049 0231 9633076 e mail jhafemann wwmach com AUSTRALIA Worldwide Paciﬁc Ent Ltd 60 Castlereagh Street Sydney NSW 2000 Aus Cell 0061 0 400 144 432 e mail jhafemann wwmach com ITALY Via Roma 18 43016 San Pancrazio Parma Italy Phone 0039 0521 671288 Fax 0039 0521 673295 e mail info scaip srl it ...

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