SIMON TRAILBLAZER 40 SERVICE MANUAL 89-240107 – PDF DOWNLOAD

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SIMON TRAILBLAZER 40 SERVICE MANUAL 89-240107 – PDF DOWNLOAD

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TABLE OF CONTENTS:

SIMON TRAILBLAZER 40 SERVICE MANUAL 89-240107 – 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 xiii
Lubrication Chart xiv
Lubrication Diagram xv
Section 1: Transportation and Emergency Procedures
Transporting the Unit 1-3
Unloading Procedures 1-4
Emergency System and Procedures 1-5
Emergency Pump 1-5
Un powered Emergency Movement 1-5
Emergency Lowering 1-6
Section 2: Hydraulic System
Hydraulic Fluid 2-5
Handling Precautions 2-5
Fluid Recommendations 2-5
Hydraulic Fluid Analysis 2-5
System Flushing Procedure 2-6
Hydraulic System Components 2-9
Hydraulic Pump 2-9
Main Hydraulic Pump 2-9
Main Hydraulic Pump Adjustment 2-1 O
Emergency Pump 2-11
Emergency Pump Adjustment 2-11
Drive/ Steer Manifold Assembly 2-11
Control Valve Manifold 2-11
Directional Control Valves 2-11
Motion Control Valve Assembly 2-12
Motion Control Valve 2-12
Flow Control Valve 2-12
Shuttle Valve 2-12
Pressure Reducing Valve 2-12
Cross Port Relief Manifold 2-13
Stop Cushion Solenoid Valve 2-13
High Pressure Filter 2-13
High Pressure Filter Element 2-13
Hydraulic Fluid Reservoir 2-13
Hydraulic Reservoir Maintenance 2-13
Boom Lift System 2-14
Directional Control Valves 2-14
Platform 2-14
Ground 2-14
Shuttle Valve Assembly 2-15
Flow Control Valve 2-15
Lift Cylinder 2-1 5
Boom Telescope System 2-1 5
Directional Control Valves 2-16
Platform 2-16
Ground 2-16
Shuttle Valve Assembly 2-16
Flow Control Valve 2-16
Telescope Cylinder 2-16
Superstructure Swing System 2-17
Directional Control Valve 2-17
Platform 2-17
Ground 2-17
Shuttle Valve Assembly 2-18
Flow Control Valve 2-18
Double Counterbalance Valve (Swing) 2-18
Swing Drive Motor/ Reducer Assembly 2-18
Platform Rotate System 2-19
Rotate Control Valve 2-19
Rotary Actuator 2-19
Rotary Actuator Maintenance : 2-19
Platform Rotator Manifold 2-20
Platform Leveling System 2-21
Level Control Valve 2-21
Double Pilot Operated Check Valve 2-21
Master Level Cylinder 2-22
Relief Valves 2-22
Slave Level Cylinder 2-22
Steer System 2-23
Drive/ Steer Manifold Assembly 2-23
Steer Cylinder 2-23
Steer System Maintenance 2-23
Hydraulic Swivel (Optional) 2-23
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 Assembly 3-4
Hydraulic Manifold Valve Assembly 3-4
Motion Control Valve Assembly 3-4
Motion Control Valve 3-4
Flow Control Valve 3-4
Shuttle Valve 3-4
Pressure Reducing Valve 3-5
Cross Port Relief Manifold 3-5
Solenoid Valve 3-5
Drive Enable Valve 3-5
Platform Drive Control Handle 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 Troubleshooting 4-4
Battery Replacement 4-4
Platform Control Box 4-5
Emergency Stop Button 4-5
Ignition Switch 4-5
Toggle Switch 4-5
Push Button 4-5
Light Emitting Diode 4-5
Ground Control Box 4-6
Circuit Breaker 4-6
Toggle Switch 4-6
Push Button 4-6
Key Switch · 4-6
Volt Meter 4-6
Hour Meter 4-6
Engine Oil Pressure Gauge 4-7
Pendant Control 4-7
Toggle Switch 4-7
Foot Pedal Switch 4-7
Movement Alarm 4-7
Tilt Alarm 4-8
Tilt Alarm Test 4-8
Tilt Alarm Sensor Adjustment 4-8
Tilt Alarm Horn 4-9
Horn 4-9
Relays 4-9
Limit Switches 4-9
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
Rear Axle Drive Motor 5-7
Rear Axle Drive Motor Replacement 5-7
Rear Axle Assembly 5-8
Rear Axle Assembly Replacement 5-8
Rear Axle Brake Adjustment 5-9
Superstructure 5-1 O
Platform 5-11
Hoses and Cables 5-11
Miscellaneous Equipment 5-11
Boom 5-12
Boom Pivot Pin and Bushing Replacement 5-12
Wear Pads 5-13
Base Boom Top Wear Pad Replacement 5-13
Tip Boom Top Front Wear Pad Replacement 5-14
Moving Anchor Wear Pad Replacement 5-14
Boom Lift Cylinder 5-14
Lift Cylinder Pivot Pin Replacement 5-15
Lift Cylinder Seal Replacement (On Machine) 5-16
Bench Replacement Of Lift Cylinder Seals 5-17
Counterbalance Valve Inspection 5-18
Boom Telescope Cylinder 5-19
Telescope Boom Cylinder Pin Replacement 5-19
Telescope Cylinder Removal 5-20
Telescope Cylinder Seal Replacement 5-20
Telescope Cylinder Installation 5-21
Counterbalance Valve Inspection 5-21
Platform Level Cylinders 5-22
Platform Level Cylinder Pin Replacement 5-22
Level Cylinder Seal Replacement 5-23
Bleeding the Platform Leveling Circuit 5-24
Section 6: Maintenance Schedule
Maintenance Schedule 6-3
General Maintenance Tips 6-3
First Three Months of Operation 6-3
Routine Servicing 6-3
Daily Operational Checklist 6-6
Monthly Operational Checklist 6-9
Semi-Annual Operational Checklist 6-11
Section 7: Troubleshooting
General Troubleshooting Tips 7-3
Troubleshooting Chart 7-4
Index
Appendix

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