Simon AT60 ‘Full Hydraulic’ Service Manual – PDF DOWNLOAD

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Simon AT60 ‘Full Hydraulic’ Service Manual – PDF DOWNLOAD

FILE DETAILS:

Simon AT60 ‘Full Hydraulic’ Service Manual – PDF DOWNLOAD

Language : English
Pages :144
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Simon AT60 ‘Full Hydraulic’ Service Manual – PDF DOWNLOAD

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Introduction vi
Machine Specifications viii
Machine Component Locator ix
Undercarriage Component Locator x
Superstructure Component Locator xi
Lower Boom Component Locator xii
Mid Boom Component Locator xiii
Upper Boom Component Locator xiv
Platform Component Locator xv
Lubrication Chart xvi
Section 1: Transportation and Emergency Procedures
Transporting the Unit – 1-4
Lifting the Unit 1-6
Unloading Procedures 1-8
Emergency System and Procedures 1-10
Emergency Electrical Pump 1-10
Unpowered Emergency Movement l -10
Emergency lowering 1-11
Section 2: Hydraulic System
Hydraulic Fluid 2-5
Handling Precautions 2-5
Fluid Recommendations 2-5
Fluid Contamination Checks 2-5
System Flushing Procedure 2-6
Hydraulic System Components 2-9
Electro-Proportional Circuit 2-9
Hydraulic Pumps 2-9
Main Hydraulic Pump (Type l) 2-9
Main Hydraulic Pump Adjustment 2-10
Main Hydraulic Pump (Type 2) 2-11
Main Hydraulic Pump Adjustment 2-13
Emergency Pump 2-13
Emergency Pump Adjustment 2-13
High Pressure Filter 2-14
High Pressure Filter Element 2-14
Hydraulic Fluid Reservoir 2-14
Hydraulic Reservoir Maintenance 2-14
Drive/ Brake Valve Assembly 2-15
Motion Control Valve 2-15
Brake Needle Valve 2-15
Brake Shuttle Valve 2-15
Pressure Reducing Valve 2-16
Double Relief Valve 2-16
Drive Cushion Solenoid Valve 2-16
Two Speed Drive Valve 2-16
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Section 2: Hydraulic System (Continued)
Boom Lift System 2- l 6
Directional Control Valves 2-16
Lift Cylinders 2-17
Boom Telescope System 2-18
Directional Control Valves 2-18
Pressure Reducing Valve 2-18
Telescope Cylinder 2-19
Superstructure Swing System 2-20
Directional Control Valves 2-20
Double Counterbalance Valve 2-20
Swing Drive Motor/ Reducer Assembly 2-20
Platform Rotate System 2-21
Rotate Control Valve 2-21
Rotary Actuator 2-21
Rotary Actuator Maintenance 2-21
Platform Rotator Pressure Relief Valve 2-21
Platform Level System 2-22
Level Control Valve 2-22
Double Pilot Operated Check Valve 2-22
Master Level Cylinder 2-22
Relief Valves 2-22
Slave Level Cylinder 2-22
Steer System 2-24
Drive/ Steer Manifold Assembly 2-24
Steer Cylinder 2-24
Steer System Maintenance 2-24
Hydraulic Swivel 2-24
Section 3: Drive System
Drive System Components 3-3
Drive Motors 3-3
Front Wheel Motor 3-3
Hydraulic Drive Motor 3-3
Rear Axle Drive Motor 3-4
Rear Axle Drive Motor Replacement 3-4
Rear Axle Assembly Replacement 3-4
Rear Axle Brake Adjustment 3-6
Rear Axle Assembly 3-6
Drive/ Brake Valve Assembly 3-7
Motion Control Valve 3-7
Brake Needle Valve 3-7
Brake Shuttle Valve 3-7
Pressure Reducing Valve 3-8
Double Relief Valve 3-8
Drive Cushion Solenoid Valve 3-8
Two Speed Drive Valve 3-8
Drive Enable Valve 3-8
Hydraulic Manifold Valve Assembly 3-8
Table of Contents (Continued)
Section 4: Electrical System
Electrical System 4-3
Battery 4-3
Battery Maintenance (In Use) 4-3
Battery Troubleshooting 4-4
Battery Replacement 4-4
Electrical Theory of Operation 4-5
Ground Ignition Circuit 4-5
Platform Ignition Circuit 4-5
Pump Circuit 4-5
Drive Control Handle Circuit 4-5
Platform Control Box 4-6
Emergency Stop Button 4-6
Ignition Switch 4-6
Toggle Switch 4-6
Push Button 4-6
Light Emitting Diode 4-7
Foot Pedal Switch 4-7
Ground Control Box 4-8
Circuit Breaker 4-8
Toggle Switch 4-8
Push Button 4-8
Key Switch 4-8
Volt Meter 4-8
Hour Meter 4-8
Engine Oil Pressure Gauge 4-9
Pendant Control 4-9
Toggle Switch 4-9
Movement Alarm 4-9
Tilt Alarm 4-9
Tilt Alarm Test 4-10
Tilt Alarm Sensor Adjustment 4-10
Warning Horn 4-10
Relays 4- l 0
Limit Switch 4-10
Electrical and Continuity Checks 4-11

Table of Contents (Continued)
Section 5: Mechanical Components
Mechanical Components 5-3
Tires 5-3
Changing Tires 5-3
Wheels and Lug Nuts 5-3
Wheel Motor Assembly 5-4
Steer Cylinder 5-5
Steer Cylinder Pins 5-5
Base End Cylinder Pin Replacement 5-5
Steer Cylinder Seal Replacement 5-5
Tie Rod Assembly 5-6
Tie Rod Assembly Replacement 5-6
Superstructure 5-6
Platform 5-9
Hoses and Cables 5-9
Miscellaneous Equipment 5-9
Boom 5-10
Lower Boom 5- l 0 Lower Boom Lift
Cylinder 5-10
Lower Boom Lift Cylinder Removal 5-10
Lower Boom Lift Cylinder Replacement 5-11
Lower Boom Lift Cylinder Seal Replacement 5-11
Lower Boom Lift Cylinder Holding Valve 5-11
Lower Boom and Lift Cylinder Pivot Pin 5-12
Middle Boom 5-13
Middle Boom Lift Cylinder 5-13
Middle Boom Lift Cylinder Removal 5-13
Middle Boom Lift Cylinder Replacement 5-13
Middle Boom Lift Cylinder Seal Replacement 5-14
Middle Boom Lift Cylinder Holding Valve 5-14
Middle Boom and Lift Cylinder Pivot Pin 5-14
Upper Boom 5- l 5 Upper Boom Lift
Cylinder 5-15
Upper Boom Lift Cylinder Removal 5-15
Upper Boom Lift Cylinder Replacement 5-15
Upper Boom Lift Cylinder Seal Replacement 5-16
Upper Boom Lift Cylinder Holding Valve 5-16
Upper Boom and Lift Cylinder Pivot Pin 5-16
Wear Pads 5-17
Rear (Upper End) Wear Pad Replacement 5-17
Front (Lower End) Wear Pad Replacement 5-17
Boom Telescope Cylinder 5-18
Telescope Boom Cylinder Pin Replacement 5-18
Telescope Cylinder Removal 5-19
Telescope Cylinder Seal Replacement 5-19
Telescope Cylinder Installation 5-19
Holding Valve Inspection 5-20
Platform Level Cylinders 5-21
Platform Level Cylinder Pin Replacement 5-21
Level Cylinder Seal Replacement 5-22
Bleeding the Platform Leveling Circuit 5-22
Section 6: Maintenance Schedule
Maintenance Schedule 6-3
General Maintenance Tips 6-3
First Three Months of Operation 6-3
Routine Servicing 6-3
Shift Operational Checklist 6-6
Weekly Operational Checklist for Severe Usage 6-9
Monthly Operational Checklist 6- l 0
Semi-Annual Operational Checklist 6-12
Section 7: Troubleshooting
General Troubleshooting Tips 7-3
Troubleshooting Chart 7-4
Index Appendix

S.M 04/12/24