SIMON AT60 FULL HYDRAULIC SERVICE MANUAL 89-446107 – PDF

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SIMON AT60 FULL HYDRAULIC SERVICE MANUAL 89-446107 – PDF DOWNLOAD

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SIMON AT60 FULL HYDRAULIC SERVICE MANUAL 89-446107 – PDF DOWNLOAD

Introduction

This manual provides comprehensive guidance on the operation, maintenance, and troubleshooting of the machine models 32/21 and 41/24. It includes detailed descriptions of machine components, lubrication schedules, transportation and emergency procedures, hydraulic systems, drive systems, electrical systems, mechanical components, and maintenance schedules.

Machine Specifications

Machine Component Locator

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

Lubrication Chart

• Detailed lubrication chart specifying lubrication points and recommended lubricants for models 32/21 and 41/24.

Section 1: Transportation and Emergency Procedures

Transporting the Unit

• Instructions for safely transporting the unit.

Lifting the Unit

• Guidelines for lifting the unit using proper lifting equipment and techniques.

Unloading Procedures

• Steps for unloading the unit from a transport vehicle.

Emergency System and Procedures

• Emergency Electrical Pump: Operation and maintenance of the emergency electrical pump.
• Unpowered Emergency Movement: Procedures for moving the unit in case of power failure.
• Emergency Lowering: Steps to safely lower the unit during an emergency.

Section 2: Hydraulic System

Hydraulic Fluid

• Handling Precautions: Safety measures for handling hydraulic fluid.
• Fluid Recommendations: Recommended hydraulic fluids for optimal performance.
• Fluid Contamination Checks: Procedures to check for and address fluid contamination.

System Flushing Procedure

• Detailed instructions for flushing the hydraulic system to ensure cleanliness and performance.

Hydraulic System Components

• Electro-Proportional Circuit
• Hydraulic Pumps
  • Main Hydraulic Pump (Type 1 & Type 2)
    • Adjustment procedures for main hydraulic pumps.
  • Emergency Pump
    • Adjustment procedures for the emergency pump.
• High Pressure Filter
  • Maintenance and replacement of high pressure filters and elements.
• Hydraulic Fluid Reservoir
  • Maintenance procedures for the hydraulic fluid reservoir.

Valve Assemblies and Control

• Drive Brake Valve Assembly
• Motion Control Valve
• Brake Needle Valve
• Brake Shuttle Valve
• Pressure Reducing Valve
• Double Relief Valve
• Drive Cushion Solenoid Valve
• Two Speed Drive Valve

Boom Lift System

• Directional Control Valves and Lift Cylinders
• Boom Telescope System
  • Directional Control Valves
  • Pressure Reducing Valve
  • Telescope Cylinder
• Superstructure Swing System
  • Directional Control Valves
  • Double Counterbalance Valve
  • Swing Drive Motor/Reducer Assembly
• Platform Rotate System
  • Rotate Control Valve
  • Rotary Actuator and Maintenance
  • Platform Rotator Pressure Relief Valve
• Platform Leveling System
  • Level Control Valve
  • Double Pilot Operated Check Valve
  • Master and Slave Level Cylinders

Steer System

• Drive/Steer Manifold Assembly
• Steer Cylinder and Maintenance
• Hydraulic Swivel

Section 3: Drive System

Drive System Components

• Drive Motors (Front Wheel Motor, Hydraulic Drive Motor, Rear Axle Drive Motor)
• Rear Axle Assembly
  • Maintenance, replacement, and adjustment of rear axle components.

Hydraulic Manifold Valve Assembly

• Motion Control Valve
• Flow Control Valve
• Pressure Reducing Valve
• Drive Enable Valve

Section 4: Electrical System

Electrical System Components

• Battery Maintenance (In Use and Storage)
• Battery Troubleshooting and Replacement
• Electrical Theory of Operation
  • Ground Ignition Circuit
  • Platform Ignition Circuit
  • Pump Circuit
  • Drive Control Handle Circuit

Platform Control Box

• Components such as emergency stop button, ignition switch, toggle switch, push button, light emitting diode, foot pedal switch.

Ground Control Box

• Components including circuit breaker, toggle switch, push button, key switch, volt meter, hour meter, engine oil pressure gauge.

Pendant Control

• Toggle Switch
• Movement Alarm
• Tilt Alarm (Test and Sensor Adjustment)
• Warning Horn
• Relays
• Limit Switch
• Electrical and Continuity Checks

Section 5: Mechanical Components

Mechanical Components

• Changing Tires
• Wheels and Lug Nuts
• Wheel Motor Assembly
• Steer Cylinder
  • Replacement of steer cylinder pins and seals.
• Tie Rod Assembly
  • Replacement procedures.
• Superstructure and Platform Maintenance
• Hoses and Cables
• Miscellaneous Equipment

Boom Components

• Lower Boom Lift Cylinder
  • Removal, replacement, and seal replacement procedures.
  • Pivot Pin and Holding Valve Maintenance.
• Middle Boom Lift Cylinder
  • Removal, replacement, and seal replacement procedures.
  • Pivot Pin and Holding Valve Maintenance.
• Upper Boom Lift Cylinder
  • Removal, replacement, and seal replacement procedures.
  • Pivot Pin and Holding Valve Maintenance.

Wear Pads

• Rear and Front Wear Pad Replacement

Boom Telescope Cylinder

• Pin Replacement, Cylinder Removal, Seal Replacement, Installation, and Holding Valve Inspection.

Platform Level Cylinders

• Pin Replacement, Seal Replacement, and Bleeding the Platform Leveling Circuit.

Section 6: Maintenance Schedule

Maintenance Schedule

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

Section 7: Troubleshooting

General Troubleshooting Tips

Troubleshooting Chart

Index

Appendix

S.S 05/24