Simon RP 66 “Reach Plus” Service Manual – PDF DOWNLOAD

Introduction vi
Machine Specifications viii
Machine Component Locator ix
Undercarriage Component Locator x
Superstructure Component Locator xi
Boom Component Locator xii
Platform Component Locator xiv
Lubrication Chart xvi
Lubrication Diagram xvii
Section 1: 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 1-6
Unloading Procedures 1-8
Emergency System and Procedures 1-11
Emergency Electrical Pump 1-11
Unpowered Emergency Movement 1-11
Emergency Lowering 1-12
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 (Type l) Adjustment 2-1O Main Hydraulic Pump (Type 2)
Main Hydraulic Pump (Type 2) Adjustment 2-13
Emergency Pump 2-13
Emergency Pump Adjustment 2-13
Ground Valve Bank Assembly 2-14
Inlet Section 2-14
End Cover (Adapter Manifold) 2-14
Main Valve Segment 2-14
Operation 2-15
Maintenance 2-15
Hydraulic Circuit Line Check 2-15
Main Valve Segment 2-15
Valves 2-16
Drive Relief Valve 2-16
Drive Valve Assembly 2-16
Hi/ Low Speed Drive Valve 2-16
Flow Divider Valve Assembly 2-16
Motion Control Valve Assembly 2-16

Table of Contents (Continued)
Section 2: Hydraulic System (Continued)
Hydraulic Fluid Reservoir 2-17
Hydraulic Reservoir Maintenance 2-17
High Pressure Filter 2-17
Boom Lift System 2-17
Boom Lift Valve Segment 2-17
Flow Control Valve 2-18
Flow Control Valve Adjustment 2-18
Lift Cylinder 2-18
Boom Telescope (Extend) System 2-18
Boom Extend Valve Segment 2-19
Pressure Relief Valve 2-19
Telescope (Extend) Cylinder 2-19
Superstructure Swing System 2-20
Swing Valve Segment 2-20
Swing Drive Motor/ Reducer Assembly 2-20
Swing Drive/ Reducer Assembly Adjustment 2-21
Swing System Maintenance 2-21
Steer System 2-22
Steer Valve Segment 2-22
Hydraulic Swivel 2-22
Steer Cylinder 2-22
Steer Disconnect Knob 2-22
Steer System Maintenance 2-23
Jib Boom System 2-23
Jib Boom Valve Segment 2-23
Jib Cylinder 2-23
Platform Rotate System 2-24
Rotate Control Valve 2-24
Rotator Manifold Check/ Relief Valve 2-24
Rotary Actuator 2-24
Rotary Actuator Maintenance 2-24
Platform Rotator Manifold 2-24
Platform Level System 2-25
Level Control Valve 2-25
Double Pilot Operated Check Valve 2-25
Master Level Cylinder 2-26
Slave Level Cylinder 2-26
Relief Valves 2-26
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
Batteries 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 Pump 4-5
Emergency Stop Button 4-5
Pendant Switch Removal 4-5
Ground Control Cabinet Switch Removal 4-6
Platform Console Switch Removal 4-6
Drive/ Steer Controller 4-6
Jib Boom/ Telescope Controller 4-7
Boom/ Swing Controller 4-8
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 Cylinder Seal Replacement 5-5
Tie Rod Assembly 5-6
Tie Rod Assembly Replacement 5-6
Superstructure 5-7
Platform 5-9
Hoses and Cables 5-9
Miscellaneous Equipment 5-9
Boom 5-10
Boom Pivot Pin and Bushing Replacement 5-10
Wear Pads 5-l 0
Base Boom Top Wear Pad Replacement 5-11
Moving Anchor Wear Pad Replacement 5-11
Mid Boom Top Front Wear Pad Replacement 5-12
Mid Boom Rear Wear Pad Replacement 5-12
Tip Boom Top Front Wear Pad Replacement 5-13
Boom Lift Cylinder 5-14
Lift Cylinder Pivot Pin Replacement 5-14
Lift Cylinder Seal Replacement (On Machine) 5-15
Bench Replacement Of Lift Cylinder Seals 5-15
Counterbalance Valve Inspection 5-16
Jib Boom Removal 5-17
Jib Boom Installation 5-17
Boom Telescope Cylinder 5-18
Telescope Cylinder Removal · 5-18
Telescope Cylinder Seal Replacement 5-19
Telescope Cylinder Installation 5-19
Counterbalance Valve Inspection 5-19
Platform Level Cylinders 5-20
Platform Level Cylinder Pin Replacement 5-20
Level Cylinder Seal Replacement ,5-20
Platform Leveling Procedure 5-21
Bleeding the Platform Leveling Circuit 5-22

Section 6: Maintenance
Maintenance 6-3
General Maintenance Tips 6-3
First Three Months of Operation 6-3
Routine Servicing 6-3
Shift Operational Checklist 6-6
Monthly Operational Checklist 6-9
Semi-Annual Operational Checklist 611
Section 7: Troubleshooting
General Troubleshooting Tips 7-3
Troubleshooting Chart 7-4
Index Appendix