SIMON AT45 CONSTRUCTOR SERVICE MANUAL 89-445007 – PDF

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SIMON AT45 CONSTRUCTOR SERVICE MANUAL 89-445007 – PDF DOWNLOAD

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TABLE OF CONTENTS:

SIMON AT45 CONSTRUCTOR SERVICE MANUAL 89-445007 – PDF DOWNLOAD

Introduction

Machine Specifications

• Model 32/21
• Model 41/24

Primary Machine Component Locators

• Undercarriage Component Locator
• Superstructure Component Locator
• Lower Boom Component Locator
• Middle Boom Component Locator
• Upper Boom Component Locator
• Platform Component Locator

Lubrication Information

• Lubrication Chart
• Lubrication Diagram

Section 1: Transportation and Emergency Procedures

Transporting the Unit

• Transporting the Unit
• Unloading Procedures

Emergency System and Procedures

• Emergency Pump
• Unpowered Emergency Movement
• Emergency Lowering

Section 2: Hydraulic System

Hydraulic Fluid

• Handling Precautions
• Fluid Recommendations
• Hydraulic Fluid Analysis
• System Flushing Procedure

Hydraulic System Components

• Hydraulic Pump
  • Main Hydraulic Pump
  • Main Hydraulic Pump Adjustment
  • Main Hydraulic Pump De-stroke Valve
• Emergency Pump
  • Emergency Pump Relief Valve Adjustment
• Drive/Steer Manifold Assembly
• Control Valve Manifold
• Directional Control Valves
  • Motion Control Valve Assembly
  • Motion Control Valve
  • Brake Needle Valve
  • Shuttle Valve
  • Pressure Reducing Valve
  • Cross Port Relief Manifold
  • Stop Cushion Solenoid Valve
• High Pressure Filter
  • High Pressure Filter Element
• Hydraulic Fluid Reservoir
  • Hydraulic Reservoir Maintenance
• Boom Lift System
  • Directional Control Valves (Platform/Ground)
  • Boom Telescope System
    • Directional Control Valves (Platform/Ground)
    • Pressure Reducing Valve
    • Telescope Cylinder
• Superstructure Swing System
  • Directional Control Valves (Platform/Ground)
  • Double Counterbalance Valve (Swing)
  • Swing Drive Motor/Reducer Assembly
• Platform Rotate System
  • Rotate Control Valve
  • Rotary Actuator
  • Rotary Actuator Maintenance
  • Platform Rotator Pressure Relief Valve
• Platform Leveling System
  • Level Control Valve
  • Double Pilot Operated Check Valve
  • Master Level Cylinder
  • Relief Valves
  • Slave Level Cylinder
• Steer System
  • Drive/Steer Manifold Assembly
  • Steer Cylinder
  • Steer System Maintenance
• Hydraulic Swivel (Optional)
• Solenoid Valve Checks

Section 3: Drive System

Drive System Components

• Drive Motors
  • Front Wheel Motor
  • Hydraulic Drive Motor
• Rear Axle Assembly
  • Rear Axle Drive Motor
  • Rear Axle Drive Motor Replacement
  • Rear Axle Assembly Replacement
  • Rear Axle Brake Adjustment
• Hydraulic Manifold Valve Assembly
  • Motion Control Valve Assembly
  • Motion Control Valve
  • Flow Control Valve
  • Shuttle Valve
  • Pressure Reducing Valve
  • Cross Port Relief Manifold
  • Solenoid Valve
  • Drive Enable Valve
  • Platform Drive Control Handle

Section 4: Electrical System

Electrical System

• Battery Maintenance (In Storage)
• Battery Maintenance (In Use)
• Battery Troubleshooting
• Battery Replacement
• Battery Charger
• Battery Charger Troubleshooting
• Movement Alarm
• Tilt Alarm
  • Tilt Alarm Test
  • Tilt Alarm Adjustment
• Descent Alarm (Optional)
• Automatic Warning Beacon (Optional)
• Electric Motors
• Emergency Stop Buttons

Electrical Theory of Operation

• Ground Ignition Circuit
• Platform Ignition Circuit
• Pump Circuit
• Drive Control Handle Circuit

Platform Control Box

• Emergency Stop Button
• Ignition Switch
• Push Button
• Light Emitting Diode
• Foot Pedal Switch

Ground Control Box

• Circuit Breaker
• Toggle Switch
• Push Button
• Key Switch
• Volt Meter
• Hour Meter
• Engine Oil Pressure Gauge

Pendant Control

• Toggle Switch
• Movement Alarm
• Tilt Alarm
  • Tilt Alarm Test
  • Tilt Alarm Sensor Adjustment
• Warning Horn
• Relays
• Limit Switch

Electrical and Continuity Checks

Section 5: Mechanical Components

Mechanical Components

• Tires
  • Changing Tires
• Wheels and Lug Nuts
• Wheel Motor Assembly
• Steer Cylinder
  • Steer Cylinder Pins
  • Base End Cylinder Pin Replacement
  • Steer Cylinder Seal Replacement
• Tie Rod Assembly
  • Tie Rod Assembly Replacement
• Superstructure
• Platform
• Hoses and Cables
• Miscellaneous Equipment

Boom Components

• Lower Boom
  • Lower Boom Lift Cylinder
    • Removal
    • Replacement
    • Seal Replacement
    • Lower Boom Lift Cylinder Holding Valve Replacement
    • Lower Boom and Lift Cylinder Pivot Pin Replacement
• Middle Boom
  • Middle Boom Lift Cylinder
    • Removal
    • Replacement
    • Seal Replacement
    • Middle Boom Lift Cylinder Holding Valve Replacement
    • Middle Boom and Lift Cylinder Pivot Pin Replacement
• Upper Boom
  • Upper Boom Lift Cylinder
    • Removal
    • Replacement
    • Seal Replacement
    • Upper Boom Lift Cylinder Holding Valve Replacement
    • Upper Boom and Lift Cylinder Pivot Pin Replacement

Wear Pads

• Rear (Upper End) Wear Pad Replacement
• Front (Lower End) Wear Pad Replacement

Boom Telescope Cylinder

• Telescope Boom Cylinder Pin Replacement
• Telescope Cylinder Removal
• Telescope Cylinder Seal Replacement
• Telescope Cylinder Installation
• Holding Valve Inspection

Platform Level Cylinders

• Platform Level Cylinder Pin Replacement
• Level Cylinder Seal Replacement
• Bleeding the Platform Leveling Circuit

Section 6: Maintenance Schedule

Maintenance Schedule

• General Maintenance Tips
• First Three Months of Operation
• Routine Servicing
• Shift Operational Checklist
• Monthly Operational Checklist
• Semi-Annual Operational Checklist

Section 7: Troubleshooting

General Troubleshooting Tips

Troubleshooting Chart

Index

Appendix

S.S 05/24