Simon RP 46 “Reach Plus” Service Manual – PDF DOWNLOAD

Introduction vii
Machine Specifications ix
Machine Component Locator x
Undercarriage Component Locator xi
Superstructure Component Locator xii
Boom Component Locator xiii
Platform Component Locator xv
Lubrication Chart xvi
Lubrication Diagram xvii
Section 1: Transportation and Emergency Procedures
Transporting the Machine 1-3
Towing Procedures 1-3
Truck or Trailer Transport 1-3
Unloading Procedures 1-5
Emergency System and Procedures l -7
Emergency Electrical Pump 1-7
Unpowered Emergency Movement 1-7
Emergency Procedures 1-8
Section 2: Hydraulic System
Hydraulic Fluid 2-4
Handling Precautions 2-4
Fluid Recommendations 2-4
Fluid Contamination Checks 2-4
System Flushing Procedure 2-5
Hydraulic System Components 2-7
Electro-Proportional Circuit 2-7
Hydraulic Pump 2-7
Main Hydraulic Pump (Earlier Models) 2-7
Main Hydraulic Pump Adjustment 2-8
Main Hydraulic Pump (Current Production) 2-9
Pump Adjustment (Current Production) 2-10
Main Pump Replacement (Current Production) 2-1 l
Emergency Pump 2-11
Emergency Pump Adjustment 2-11
Emergency Pump Filter 2-11
Ground Valve Bank Assembly 2-12
Inlet Section 2-12
End Cover (Adapter Manifold) 2-12
Main Valve Segment 2-12
Operation 2-13
Maintenance 2-13
Hydraulic Circuit Line Check 2-13
Main Valve Segment 2-13
Drive/ Brake Control Valve Assembly 2-14
Motion Control Valve 2-14
Brake Needle Valve 2-14
Shuttle Valve 2-15
Pressure Reducing Valve 2-15
Cross Port Relief Manifold 2-15
Stop Cushion Solenoid Valve 2-15
Section 2: Hydraulic System (Continued)
Hydraulic System Components (Continued)
High Pressure Filter (Earlier Models)
High Pressure Filter Element
Hydraulic Filter (Current Production)
Return Filter (Current Production)
High Pressure Filter (Current Production)
Hydraulic Fluid Reservoir
Hydraulic Reservoir Maintenance
Boom Lift System
Boom Lift Valve Segment
Flow Control Valve
Flow Control Valve Adjustment
Lift Cylinder
Boom Telescope (Extend) System
Boom Extend VaIve Segment
Pressure Relief Valve
Telescope (Extend) Cylinder
Superstructure Swing System
Swing Valve Segment
Double Counterbalance Valve (Swing)
Swing Drive Motor/ Reducer Assembly
Platform Rotate System
Rotate Control Valve
Double Relief/ Pilot Operated Check Valve
Rotary Actuator
Rotary Actuator Maintenance
Platform Level System
Level Control Valve
Double Pilot Operated Check Valve
Master Level Cylinder
Slave Level Cylinder
Relief Valves
Steer System
Steer Valve Segment
Hydraulic Swivel
Steer Cylinder
Steer Disconnect Knob (option)
Steer System Maintenance
Jib Boom System
Jib Boom Valve Segment
Jib Articulation Cylinder

Section 3: Drive System
Drive System Components
Drive Control Main Valve Segment
Drive Motors
Front Wheel Motor
Rear Axle Drive Motor
Rear Axle Assembly
Rear Axle Brake Adjustment
Rear Axle Assembly Maintenance
Drive/ Brake Control Valve Assembly
Motion Control Valve
Brake Needle Valve
Shuttle Valve
Pressure Reducing Valve
Cross Port Relief Manifold
Stop Cushion Solenoid Valve

Section 4: Electrical System
Electrical System
Batteries
Battery Maintenance (In Storage)
Battery Maintenance (In Use)
Battery Preventive Maintenance
Battery Replacement
Movement Alarm
Tilt Alarm
Tilt Alarm Test
Tilt Alarm Adjustment
Relays
Circuit Breakers
Limit Switches
Emergency Pump
Emergency Stop Button
Pendant Switch Removal
Ground Control Cabinet Switch Removal
Platform Console Switch Removal
Drive/ Steer Controller
Jib Boom/ Telescope Controller
Boom/ Swing Controller
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
Rear Axle Drive Motor
Rear Axle Drive Motor Replacement
Rear Axle Assembly
Rear Axle Assembly Replacement
Rear Axle Brake Adjustment
Superstructure
Platform
Hoses and Cables
Miscellaneous Equipment
Boom
Boom Pivot Pin and Bushing Replacement
Wear Pads
Base Boom Top Wear Pad Replacement
Tip Boom Top Front Wear Pad Replacement
Moving Anchor Wear Pad Replacement
Boom Lift Cylinder
Lift Cylinder Pivot Pin Replacement
Lift Cylinder Seal Replacement (On Machine)
Bench Replacement Of Lift Cylinder Seals
Counterbalance Valve Inspection
Jib Boom Removal
Jib Boom Installation
Boom Telescope Cylinder
Telescope Boom Cylinder Pin Replacement
Telescope Cylinder Removal
Telescope Cylinder Seal Replacement
Telescope Cylinder Installation
Counterbalance Valve Inspection
Platform Level Cylinders
Platform Level Cylinder Pin Replacement
Level Cylinder Seal Replacement
Platform Leveling Procedure
Section 6: Maintenance
Maintenance
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