SIMON RP 120 REACH PLUS SERVICE MANUAL 89-126307 – PDF DOWNLOAD

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SIMON RP 120 REACH PLUS SERVICE MANUAL 89-126307 – PDF DOWNLOAD 

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TABLE OF CONTENTS:

SIMON RP 120 REACH PLUS SERVICE MANUAL 89-126307 – PDF DOWNLOAD 

Introduction vii
Machine Specifications ix
Machine Component Locator xi
Undercarriage Component Locator xii
Superstructure Component Locator xiii
Boom Component Locator xiv
Platform Component Locator xvii
Lubrication Chart xviii
Lubrication Diagram xix
Section l: Transportation and Emergency Procedures
Transporting the Unit 1-3
Towing procedures 1-3
Truck or Trailer Transport, Boom in STOW-N-GO™ Mode 1-4
Truck or Trailer Transport, Boom in Conventional Mode 1-9
Unloading Procedure 1-11
Emergency System and Procedures 1-15
Emergency Pumps 1-15
Emergency Drive Function 1-16
Emergency Lowering 1-17
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 2-7
Electro-Proportional Circuit 2-7
Hydraulic Pump 2-7
Hydraulic pump adjustment 2-7
Emergency Pumps 2-7
Emergency Pump Adjustment 2-7
Ground Valve Bank Assembly 2-8
Inlet Section 2-8
End Cover (Adapter Manifold) 2-8
Main Valve Segment 2-8
Operation 2-9
Maintenance 2-9
Hydraulic Circuit Line Check 2-9
Main Valve Segment 2-9
Valves 2-1 O
Drive Relief Valve 2-10
Drive Valve Assembly 2-10
Hi/ Low Speed Drive Valve 2-10
Selector Valve 2-1 O
Flow Divider Valve Assembly 2-11
Motion Control Valve Assembly 2-11
Selector Valve Assembly 2-11
Selector Valve 2-11
Check Valve 2-11
Hydraulic Fluid Reservoir 2-12
Hydraulic reservoir maintenance 2-12
High Pressure Filter 2-12
Boom Lift System 2-12
Boom Lift Valve Segment 2-12
Flow Control Valve 2-13
Flow Control Valve Adjustment 2-13
Lift Cylinder 2-13
Boom Telescope (Extend) System 2-13
Boom Extend valve segment 2-13
Pressure Relief Valve 2-14
Telescope (Extend) Cylinder 2-14
Superstructure Swing System 2-14
Swing Valve Segment 2-15
Swing Drive/ Reducer Assembly 2-15
Swing Drive/ Reducer Assembly Adjustment 2-15
Integral Brake Assembly 2-15
Swing System Maintenance 2-16
Jib Boom System 2-16
Jib Boom Valve Segment 2-16
Jib Cylinder 2-16
Platform Rotate System 2-17
Rotate Control Valve 2-17
Double Pilot Operated Check Valve 2-17
Rotary Actuator 2-17
Rotary Actuator Maintenance 2-18
Platform Rotator Manifold 2-18
Platform Level System 2-18
Level Control Valve 2-19
Double Pilot Operated Check Valve 2-19
Master Level Cylinder 2-19
Slave Level Cylinder 2-19
Relief Valves 2-20
Steer System 2-20
Selector Valve Assembly 2-20
Selector Valve 2-20
Check Valve 2-21
Steer Valve Segment 2-21
Hydraulic Swivel 2-21
Steer Cylinder 2-21
Steer Disconnect Knob 2-21
Steer System Maintenance 2-22
Axle Extend System 2-22
Axle Extend Cylinders 2-23
Selector Valve Assembly 2-23
Selector Valve 2-23
Check Valve 2-23
Steer Valve Segment 2-23
Hydraulic Swivel 2-23
Section 3: Drive System
Drive System Components 3-3
Drive Motor and Brake Assembly 3-3
Drive Valve Segment 3-4
Drive Valve Assembly 3-4
Selector Valve 3-4
Motion Control Valve Assembly 3-4
Motion Control Valve 3-4
Flow Control Valve 3-4
Flow Divider Valve Assembly 3-5
Flow Divider/ Combiner Valve 3-5
Gate (Globe) Valve : 3-5
Drive Relief Valve 3-5
Brake Metering Valve 3-5
Brake Metering Valve Adjustment 3-5
Toggle Switch on the Pendant Control 3-5
Platform Control Handle (Joystick) 3-5
Section 4: Electrical System
Electrical System 4-3
Battery 4-3
Battery Maintenance (In Storage) 4-3
Battery Maintenance (In Use) 4-3
Battery Preventive Maintenance 4-4
Battery Replacement 4-4
Movement Alarm 4-4
Tilt Alarm 4-4
Tilt Alarm Test 4-4
Tilt Alarm Adjustment 4-5
Relays 4-5
Circuit Breakers 4-5
Limit Switches 4-5
Emergency Pumps 4-5
Platform Envelope Control System 4-6
Emergency Stop Buttons 4-6
Emergency Stop Cable Adjustment 4-6
Pendant Switch Removal 4-6
Ground Control Cabinet Switch Removal 4-6
Platform Console Switch Removal 4-6
Drive Controller 4-6
Creep Speed Adjustments 4-8
Boom Telescope Adjustment 4-8
Superstructure Swing Adjustment 4-8
Section 5: Mechanical Components
Mechanical Components 5-3
Tires 5-3
Changing Tires 5-3
Wheels and Lug Nuts 5-3
Drive Hub Assembly 5-4
Steer Cylinder Pins 5-5
Steer Cylinder 5-5
Steer Arm Pin 5-6
Tie Rod Assembly 5-6
Superstructure 5-7
Hoses and Cables 5-8
Miscellaneous Equipment 5-8
Boom 5-8
Boom Pivot Pin and Bushing Replacement 5-8
Boom Lift Cylinder 5-9
Lift Cylinder Pivot Pin Replacement 5-9
Lift Cylinder Seal Replacement (On Machine) 5-9
Check Holding Valves 5-9
Boom Disassembly 5-1 O
Boom Assembly 5-14
Boom Telescope (Extend) Cylinder 5-17
Telescope (Extend) Boom Cylinder Pin Replacement 5-18
Telescope (Extend) Cylinder Removal 5-18
Telescope Cylinder Seal Replacement 5-18
Telescope Cylinder Installation 5-18
Checking Holding Valves 5-18
Boom Wire Rope Adjustment 5-18
Boom Wire Rope Replacement 5-21
Wear Pads 5-21
Platform Level Cylinders 5-21
Platform Level Cylinder Pin Replacement 5-22
Level Cylinder Seal Replacement 5-22
Platform Leveling Procedure 5-22
Axle Extend Assembly 5-24
Axle Extend Cylinder 5-24
Axle Extend Cylinder Replacement 5-24
Axle Extend Cylinder Seal Repacement 5-26
Mechnical Axle Stop 5-26
Axle Tube Assembly Replacement 5-26
Section 6: Maintenance Schedule
Maintenance Schedule 6-3
General Maintenance Tips 6-3
Routine Servicing 6-3
Shift Service 6-3
Monthly Service 6-4
Semi-Annual 6-4
Annual Service 6-5
Four Year Interval Service 6-5
Shift Operational Checklist 6-6
Weekly Operational Checklist 6-9
Monthly Operational Checklist 6-11
Semi-Annual Operational Checklist 6-13
Section 7: Troubleshooting
General Troubleshooting Tips 7-3
Troubleshooting Chart 7-4
Index
Appendix

S.S 05/24