SIMON BOXER 170 E HYDRAULIC LIFT PLATFORM TECHNICAL MANUAL 89-413788 – PDF

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SIMON BOXER 170 E HYDRAULIC LIFT PLATFORM TECHNICAL MANUAL 89-413788 – PDF DOWNLOAD 

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SIMON BOXER 170 E HYDRAULIC LIFT PLATFORM TECHNICAL MANUAL 89-413788 – PDF DOWNLOAD 

Subject Page
Amendment Record (i)
Introduction (ii)
SECTION 1 BOXER 170 E SPECIFICATION
Clause Subject Page
1. Closed Dimensions and Weights 1.1
2. Operating Dimensions 1.1
3. Design Specification 1.1
4. Mechanical Components 1.2
5. Hydraulic Components 1.2
6. Oil 1.2
7. Equivalent Oils 1.2
8. Electric Components 1.3
9. Working Envelope 1.3
SECTION 2 SAFE WORKING PRACTICE
Clause Subject Page
1. Use of the Machine 2.1
2. Information Sources 2.1
3. Hazards 2.1
4. Warnings 2.3
SECTION 3 OPERATING PROCEDURES
Clause Subject Page
1. Pre-use Checks 3.1
2. Ground Control Checks 3.1
3. Cage Control Checks 3.2
4. Use on the Highway 3.2
5. Drive Controls 3.3
5.1 Forward and Reverse 3.3
5.2 Drive Speed Control 3.3
5.3 Steering Control 3.3
6. Driving 3.3
7. Differential Lock 3.4
7.1 Engage Differential Lock 3.4
8. Braking System 3.4
8.1 Brakes in Static Mode 3.4
8.2 Brakes in Drive Mode 3.5
SECTION 3
SECTION 4
OPERA TING MANUAL
CONTENTS (continued)
OPERATING PROCEDURES (continued)
Clause Subject
Emergency Braking
Access Operations (Cage Control)
Cage Rotation
Cage Levelling
Access Operations (Ground Control)
Complex Control Operation
After Use
Battery Charging
Battery Indicator
Special Precautions – Cold Weather
Special Precautions – Safe Working Load
Special Precautions – Overhead Electrical Cables
Special Precautions – Towing ·
Special Precautions – Wind Conditions
Special Precautions – Crane Operations
Special Precautions – Driving on Slopes
Special Precautions – Testing the Tilt Alarm Circuit
EMERGENCY PROCEDURES
Clause Subiect
1. Procedure 4.1
2. Cage Operator Incapacity 4.1
3. Cage Control Failure 4.1
4. Immobility due to Loss of Drive 4.1
4.1 Battery Failure 4.1
4.2 Drive Motor/Gearbox Failure 4.1
4.2.1 Towing Operations – Towing Package Fitted 4.2
4.2.2 Towing Operations – Towing Package Not Fitted 4.2
5. Disengage the Brakes 4.3
6. Re-engage the Brakes 4.3
7. Crane Operations 4.3
8. Hydraulic Pump Failure 4.3
8.1 Lowering all Booms 4.4
9. Emergency Rotation 4.4
1 o. Emergency Lowering from Cage (Optional) 4.4
SECTION 5 THE HYDRAULIC CIRCUIT
Clause Subject Page
1. Pump Motor 5.1
2. Lift Function Valve Manifold Block 5.1
3. Hydraulic Steering System 5.1
4. Hydraulic Lift Cylinder 5.1
5. Zoom Cylinder 5.1
6. Cage Levelling Cylinder 5.1
7. Hydraulic Oil Tank 5.3
8. Brakes 5.3
9. Hydraulic Module 5.3
SECTION 6 THE ELECTRICAL CIRCUIT
Clause Subject Page
1. Introduction 6.1
1 .1 Access Circuit 6.1
1.2 Drive Circuit 6.1
2. Batteries 6.1
2.1 Battery Charger 6.1
2.2 Battery Controller 6.1
2.3 Battery Indicator 6.3
3. Pump and Drive Motors 6.3
4. Emergency Stop Pushbuttons 6.3
5. Footswitch Control 6.3
6. Tilt Alarm 6.3
7. Movement Alarm 6.3
8. Relays – Identification and Functions 6.4
9. D.C. Contactors 6.4
10. D.C. Converter (Optional) 6.4
11. Automatic Beacon Warning System (Optional) 6.4
12. Fuses 6.5
13. Drive Motor Controller 6.5
14. Hour Meter 6.5
SECTION 7
OPERATING MANUAL
CONTENTS (continued)
MAINTENANCE INSTRUCTIONS
Clause Subiect
Tyres
Wheel Nuts
Drive Assembly
Back Axle
Gearbox
Drive Motor
Brakes
Steering Assembly
Steering Cylinder
Chassis and Plinth Labels
Chassis Cables
Lift Pump Motor Assembly
Battery and Battery Mountings
Manifold Assembly
D.C. Contactors
Hydraulic Oil Tank
Minor Equipment Mounting
Plinth/superstructure Hoses/cables
Pin Bushes
Pin Replacement
Boom Pin Replacement
Tie-Rail Pin Replacement
Lift Cylinder Pin Replacement
Self Levelling Cylinder Pin Replacement
Zoom Boom Cylinder Pin Replacement
Slew Bearing
Slew Bearing Torque Setting
Slew Ring Lubrication
Su pe rstructu re
Zoom Cylinder
Zoom Cylinder Removal
Zoom Cylinder Seals Replacement
Zoom Pads
Front Zoom Pad Replacement
Rear Zoom Pad Replacement
Lift Cylinders
Lift Cylinder Seal Replacement
Seal Replacement – Cylinder In-place
Seal Replacement – Cylinder Removed
Over-centre Valve Checks
Levelling Cylinders
Levelling Cylinder Seal Replacement
Bleeding the Levelling System and Cage Levelling
SECTION 9
OPERA TING MANUAL
CONTENTS (continued)
FAULT FINDING
Introduction
Fault-finding Procedures
Pump Motor Faults
Pump Motor Will Not Start
Pump Motor Will Not Stop
Pump Motor Operates, But No Hydraulic Power
Pump Motor Operation is Too Slow
Boom Faults
Booms Lowering Fault
Zoom Boom Operation Fault
Rotation Fault
Steering Fault
Drive Faults
Drive Motor Will Not Operate
Fast Drive Fault
Fast Drive Fault – Upper Stage Elevated
Emergency Stop Fault
Drive Motor Controller Fault
MAINTENANCE SCHEDULES
General Information
Hydraulic Oils
Health Warning when Handling Hydraulic Oils
Pivot Pins and Bearings
Servicing Check List (Basic Machine Only)
Daily
Weekly
Monthly
Six Monthly
Yearly
Four Yearly
Daily Routine Servicing
Hydraulic Oil Level
Tyre Condition
Cage Door Lock
Weekly Routine Servicing
Control Valves
Hydraulic System
Steering
Batteries
Pivot Pins
SECTION 9 MAINTENANCE SCHEDULES (continued)
Clause Subject Page
8. Monthly Routine Servicing 9.7
8.1 Hydraulic Oil 9.7
8.2 Chassis Bolts 9.7
8.3 Slewing Ring Gear Teeth 9.7
8.4 Rotation Gearbox Oil Level 9.7
8.5 Lubrication 9.7
8.6 Pivot Pin Security 9.7
8.7 Drive Gearbox Oil Level 9.7
9. Six Monthly Routine Servicing 9.8
9.1 Cage Levelling 9.8
9.2 Cage Pivots 9.8
9.3 Boom Cylinders 9.8
9.4 Axle 9.8
9.5. Pressure Line Filter 9.8
9.6 Machine Systems Tests 9.8
10. Yearly Routine Servicing 9.9
10.1 Rotation Gear Box 9.9
10.2 Slewing Ring Bearings 9.9
10.3 Hydraulic Oil 9.9
10.4 Hydraulic Oil Tank 9.9
10.4.1 Hydraulic Tank Refill Procedure 9.9
10.5 Structural Examination 9.10
10.6 Cage Mounting 9.10
11 . Four Yearly Routine Servicing 9.11
11 .1 Flexible Hoses 9.11
11.2 Pivot Pins And Bearings 9.11
12. Lubrication 9.12
12.1 General Lubrication 9.12
12.2 Slew Bearing/gear Lubricants 9.13
12.2.1 Slew Bearing Lubrication 9.13
12.2.2 Slew Gear Lubrication 9.14
SECTION 10 ILLUSTRATED SPARE PARTS
Subject Page
Ordering Spare Parts 10.1
Upper Chassis Assembly 10.2
Lower Chassis Assembly 10.3
Drive Assembly 10.5
Sige Axle Assembly 10.6
Steering Assembly 10.10
Plinth Assembly 10.11
First Lift Stage 10.13
SECTION 10 ILLUSTRATED SPARE PARTS (continued)
Subiect
Second Lift Stage
Zoom Boom Assembly
Cage Assembly
Electric Module
Hydraulic Module
Ground Controls
Cage Controls
Labels
Towing Arm Assembly.
SECTION 11 APPENDIX

S.S 04/24