Genie Simon Falcon Series Operator's Manual

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SIMON AFRIALS INC 10600 W Brown Deer Road Milwaukee, Wisconsin 53224 Phone (414) 355-0802 TWX 910-262-3310 FAX (414) 355-0832 Cable SIMON MIL

FAI CON

SERIES

VERTICAL

I IFT

MODEL 2034

SIMON

that could affect the safe use and operation of your "FAL-CON" Vertical Lift Operators must be aware of and comply with all manufacturer's instructions and OSHA / ANSI safety auidalinas

This Operator's Manual must be read prior to operating your Simon "FALCON" Work Platform

Note: Earlier versions of the "FALCON - 2034" Vertical Lift are identified on nameplates, decals and accompanying publications as "L-2034E"

Both names refer to the same model, which is identified throughout this publication by its current name, "FALCON"

PART NO. 89-750002

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INTRODUCTIONV
UNLOADING PROCEDURES
SECTION 1: DESCRIPTION
MACHINE SPECIFICATIONS1-3
GRADEABILITY CONVERSION CHART1-4
PRIMARY MACHINE COMPONENTS
DECAL AND INFORMATION PLATE LOCATIONS1-6
SECTION 2: OPERATION
SAFETY RULES AND PRECAUTIONS2-3
OPERATOR CONTROLS2-6
START-UP PROCEDURES2-8
DAILY CHECKS2-8
MACHINE STARTUP2-9
GROUND OPERATION AND CHECKS2-10
EMERGENCY VALVE OPERATION AND CHECK
PLATFORM OPERATION AND CHECKS2-12

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TABLE OF CONTENTS (CONTINUED)

SECTION 2: OPERATION (CONTINUED)

OPERATION
COLD WEATHER OPERATION2-13
DRIVING AND STEERING2-14
BRAKING2-14
ELEVATING THE PLATFORM2-15
LOWERING THE PLATFORM2-15
LOWERING THE GUARD RAILS
RAISING THE GUARD RAILS
SHUT-DOWN PROCEDURES
RECHARGING BATTERIES2-17
TRANSPORTING THE UNIT
TOWING OF THE FALCON SERIES LIFT
FORK LIFTING OF THE FALCON SERIES LIFT
TRUCK TRANSPORT OF THE FALCON SERIES LIFT
EMERGENCY SYSTEM AND PROCEDURES
EMERGENCY LOWERING2-19
EMERGENCY DRIVE
EMERGENCY PROCEDURES2-21

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TABLE OF CONTENTS (CONTINUED)

SECTION 3: MAINTENANCE

GENERAL MAINTENANCE TIPS	3
DAILY OPERATIONAL CHECKLIST	4
VEEKLY OPERATIONAL CHECKLIST	5
MONTHLY OPERATIONAL CHECKLIST	6
SEMI - ANNUAL OPERATIONAL CHECKLIST	7
ROUBLESHOOTING	9
UBRICATION CHART	0
WARRANTY	3

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INTRODUCTION

This Operator's Manual is designed to provide you with the instructions needed to properly operate the SIMON AERIALS INC FALCON MODEL 2034 Self-Propelled Vertical Lift The "FALCON" MODEL 2034 includes earlier models identified as "L-2034E This Manual is also meant to inform you of the many Safety Hazards that can affect the safe use and operation of the unit

This Operator's Manual MUST BE READ AND UNDERSTOOD prior to operating the FALCON Self-Propelled Vertical Lift.

Operators must be aware of and comply with ALL manufacturer's instructions and OSHA / ANSI safety guidelines.

Simon Aerials FALCON Series Self-Propelled Vertical Lifts are designed and built to provide many years of safe, dependable service. To obtain full benefits from your FALCON, always follow the proper operating and maintenance procedures Only trained, authorized personnel should be allowed to operate or service this machine. Service personnel should read and study this Operator's Manual in order to gain a thorough understanding of the functioning of the unit prior to making any repairs

Machine operators must understand and comply with all warnings and instructional decals on the body of the machine, and at the ground and platform control stations

MODIFICATIONS OF THIS MACHINE FROM THE ORIGINAL DE-SIGN WITHOUT WRITTEN PERMISSION FROM SIMON AERIALS INC. ARE STRICTLY FORBIDDEN, AND WILL VOID ANY REMAIN-ING WARRANTY.

SIMON AERIALS INC reserves the right to change, improve, modify or expand features of its equipment. Therefore, specifications, models or equipment are subject to change without notice, and without incurring obligation to change, improve, modify or expand features of previously delivered equipment

All SIMON AERIALS INC manuals are periodically updated to reflect changes that occur in the equipment Please contact the factory with any questions you may have regarding your machine, or the availability of more recent manuals

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UNLOADING PROCEDURES

UNLOADING THE UNIT

Inspect the outside of the unit for damage Inspect all hoses, boom sections and cables for chafing or road damage Confirm that all wheel lug nuts are tight
Unlock and remove both side compartment covers Inspect all electrical and hydraulic connections for damage and security
Connect battery cables to batteries if required Check electrolyte level
Check fluid level in the hydraulic tank, and add fluid as required (see Lubrication Chart) Check that shutoff valve on the hydraulic tank is open
Replace side compartment covers

UNITS NOT EQUIPPED WITH TOW PACKAGE OPTION:

• Ensure that lift truck used has adequate capacity to lift the machine (see "Machine Specifications" for weight) Lift the Simon FALCON Vertical Lift from the sides only Position forks under the modules, between the front and rear wheels and as near to the rear (driving) wheels as possible

Do not use tie down lugs to lift the FALCON.

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UNITS EQUIPPED WITH TOW PACKAGE OPTION:

The FALCON Vertical Lift may be winched off the transporting vehicle IF THE UNIT IS EQUIPPED WITH THE TOW PACKAGE OPTION Locate the tow brake and motor release valves located below the lift cylinder To unload the unit
Fully close the brake release valve by turning the knob clockwise Fully open the motor release valve by turning the knob counterclockwise
Momentarily operate the drive function to disengage the brake cylinder The unit is now ready to unload
Remove machine tie downs Remove wheel chocks, if used
Carefully unload the unit off the truck or trailer
Return both tow valves to normal operating position (engaging the brake) when the unit has been removed from the transporting vehicle.

ALL UNITS:

• Before placing the unit into service, all operators must read and understand the contents of this Operator's Manual Upon initial unloading of the machine the Predelivery Inspection Report must be completed and returned in order to activate the Simon Limited Warranty An Operator's Manual and a Predelivery Inspection Report are included with each machine leaving the factory

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SECTION 1: DESCRIPTION

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TABLE OF CONTENTS, SECTION 1: DESCRIPTION

MACHINE SPECIFICATIONS
GRADEABILITY CONVERSION CHART
PRIMARY MACHINE COMPONENTS
DECAL AND INFORMATION PLATE LOCATIONS

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MACHINE SPECIFICATIONS

	26 FT (7 93 M) 20 FT (6 10 M)
GUARD RAILS IN PLACE	89 6 IN (2 28 M) 75 2 IN (1 91 M) 78 0 IN. (1 98 M)
PLATFORM CAPACITY (UNRESTRICTED) ^. WITH STANDARD DECK	750 LBS. (340 KG) 650 LBS (295 KG) 250 LBS (115 KG)
W/ STANDARD DECK (or w/ optional deck stowed)	30 5 IN. (0 77 M) x 96 IN (2 44 M) 30 5 IN (0.77 M) x 128 5 IN (3 26 M)
LENGTH (WITHOUT OPTIONAL DECK EXTENSION)	96 IN. (2 44 M) 100 2 IN (2 54 M) 34 IN (0 86 M) 66 IN (1 67 M) 28 6 IN (0 73 M) 8 FT 6 IN (2 59 M) 3 FT 5 IN. (1 04 M) 4 IN (0 10 M) 3,200 LBS (1,452 KG)
TRAVEL SPEED-PLATFORM STOWEDTRAVEL SPEED-PLATFORM ELEVATEDGRADEABILITY (on hard surface) (ref next page)TIRES	2 MPH (3 2 KPH) 0 5 MPH (0.8 KPH) 11 3 ° (20%) 4" x 8" x 16" SOLID
HYDRAULIC FLUID CAPACITY	4 GAL (15 1 L) 2600 PSI (179 BAR) 65-70 FT LBS 24 VOLT DC (FOUR 6 VOLT, 220 AMP/HR LEAD-ACID BATTERIES IN SERIES )

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DECAL AND INFORMATION PLATE LOCATIONS WARNING !!! OPFRATING THIS EQUIPMENT WITHOUT ALL SAFETY AND CONTROL DECALS IN PLACE CAN BE HAZARDOUS. Locations of the various decals and plates on the Simon Falcon 2034 Aerial Platform are shown here If any of these items are damaged or missing, refer to your Parts Catalog for correct replacement part number. - O DOWN STEE THEN MACHINE YELL KILL YOU MACHINE IN COLUMN AND AND MACHINE ELECTROCUTION HAZARDI TEU HUR HADITADI A CLEARNER D' AT LEAST TO THE BETTERS AND TANK IP THE INCIDE OF IT'S LOAD AND IN LEASTING LIKE OF ATTACKING CARTING TO THE 295 KG OVERLOAD DEATH OR SERIOLS INJURY 10 A BLIFE OF BUILDE LOUIS. THE THEN INCOME LIALING YOU HAVE NOT SED THE OPERATES AND INVESTY HAULAL AND III DO NOT PERFORM ANY SERVICE ON MACHINE UN BATTERIER ARE DISCONNECTED FROM MACHINE ΛΟΓ DANCE 5 PERFORM ANY GERVICE ON NACHINE Is fully lowered or before b DAR PLITCH AN HOUSE IN THE COL אות האות האות היו אות היו אות האות היו אות היו ה היו אינו אות הבנאות, זה היו אינו אות היו אות היו 650 LBS MAXIMUN 295 KGB FALCON -2034 L-2034E NANGFR Ŵ ELECTROCUTION HAZARD ANGE ſ, OR SERIOUS INJURY w

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SAFETY RULES AND PRECAUTIONS
OPERATOR CONTROLS
START-UP PROCEDURES
DAILY CHECKS
MACHINE STARTUP
GROUND OPERATION AND CHECKS
EMERGENCY VALVE OPERATION AND CHECK
PLATFORM OPERATION AND CHECKS
OPERATION
COLD WEATHER OPERATION
DRIVING AND STEERING 2-14
BRAKING
ELEVATING THE PLATFORM
LOWERING THE PLATFORM
LOWERING THE GUARD RAILS
RAISING THE GUARD RAILS
SHUT-DOWN PROCEDURES
RECHARGING BATTERIES
TRANSPORTING THE UNIT
TOWING OF THE FALCON SERIES LIFT
FORK LIFTING OF THE FALCON SERIES LIFT
TRUCK TRANSPORT OF THE FALCON SERIES LIFT
EMERGENCY SYSTEM AND PROCEDURES
EMERGENCY LOWERING
EMERGENCY DRIVE
EMERGENCY PROCEDURES

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SAFETY RULES AND PRECAUTIONS

Only trained, competent personnel should operate the FALCON Vertical Lift
Read and understand all safety and control information found on the machine and in this manual before operating the unit.
Be aware of all Federal, State and Local rules which may apply to this machine and its safe operation
DO NOT operate this machine while under the influence of any drugs or alcohol
DO NOT operate this machine if you are bothered by heights, seizures, or dizzy spells.
DO NOT indulge in stunt driving or horseplay while operating this machine
DO NOT exceed the safe working load of the unit in any configuration Review the section titled "MACHINE SPECIFICATIONS", earlier in this manual, regarding this model's capacities and dimensions
DO NOT exceed platform rated capacity when transferring live loads to or from the work platform.
USE EXTREME CAUTION when transferring live loads to or from the platform while the work platform is in a raised position.
DO NOT raise the work platform unless the unit is on a firm, level surface
DO NOT exceed the maximum platform horizontal pull of 150 pounds
DO NOT alter, modify or disable any safety devices or interlocks
DO NOT perform any service on the unit unless the batteries are disconnected The platform must be fully lowered, or blocking must be in place between lower boom and base of unit before performing any service
DO NOT use the FALCON vertical lift as a crane to lift oversized or hanging loads
DO NOT sit, stand or climb on platform rails.
DO NOT use scaffolding, ladders or similar items to extend your reach while on the work platform.
SECURE all tools and other loose items to prevent injury to persons working on or below the work platform.

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SAFETY RULES AND PRECAUTIONS (CONTINUED)

DO NOT use the work platform or booms to push or tow another vehicle.
DO NOT raise or lower the platform into stationary objects, as this will cause damage to mechanical and hydraulic components.
DO NOT use the Falcon outdoors in electrical storms or in high wind situations
OSHA approved safety belts and safety hats must be worn at all times when operating the unit
NEVER fasten safety belt to an adjacent structure while on the work platform
DO NOT elevate the platform unless all railings are securely locked in their raised position. Make sure that the entry chain to the platform is secured before operating the unit from the platform.
Since the platform may be lowered from its ground controls, precautions should be taken to prevent unauthorized personnel from operating the ground controls while the platform is in use.
DO NOT allow anyone to tamper with, service or operate the machine from the ground control station while personnel are on the platform, except in an emergency.
The operator must complete the "Daily Operational Checklist" found in this manual (see Table of Contents) prior to each day's usage
The operator shall immediately report any noises, vibrations or malfunctions of the unit to supervisor Machine shall be removed from service until diagnosis and any necessary repairs have been completed.
The operator should note that the travel speed automatically decreases whenever the platform is elevated
The operator shall ensure that the area surrounding the FALCON is clear of personnel and equipment before driving the unit, raising or lowering the platform.
The operator shall maintain a safe distance from overhead and ground obstacles, debris, drop-offs, holes, depressions, electrical wires and other hazards to travel
The operator shall limit travel speed according to conditions of the ground surface, congestion, slope, location of personnel or any other factors that could cause hazard of collision or injury to personnel
The operator shall use caution to prevent ropes, cords, hoses, etc. from becoming entangled in the unit's boom sections when being raised, lowered or repositioned.

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SAFETY RULES AND PRECAUTIONS (CONTINUED)

The operator should check level of battery charge before operating unit If the unit is sluggish in operation, DO NOT USE before recharging
DO NOT recharge the batteries near sparks or open flames Lead-acid batteries generate EXPLOSIVE HYDROGEN GAS Always wear safety glasses.

ELECTROCUTION HAZARD!!

THIS MACHINE IS NOT INSULATED!!

Maintain safe clearance from electrical lines and apparatus. You must allow for machine sway (side to side movement) when elevated, and electrical line movement. This machine does not provide protection from contact with or proximity to an electrically charged conductor.

You must AVOID CONTACT between any part of the machine, or its load, and any electrical line or apparatus carrying up to 300 volts.

You must maintain a CLEARANCE OF AT LEAST 10 FEET between any part of the machine, or its load, and any electrical line or apparatus carrying over 300 volts up to 50,000 volts. One foot additional clearance is required for every additional 30,000 volts.

DEATH OR SERIOUS INJURY will result from contact with, or inadequate clearance from, any electrically charged conductor.

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OPERATOR CONTROLS DESCRIPTION

ltem	Control	Location	Description
1.	Steering Switch	Control Console	Controls the steering wheels when Key Switch is turned to the "DRIVE" position
2	Vehicle Lift/ Drive (Function) Speed	Control Console	Shifts between "HIGH" and "LOW" speed drive, or platform raising speed
	Switch		AUTION
			High speed drive should be used only on firm, level surfaces.
			NOTE
			Drive is limited to "LOW" speed and gradeabil- ity will be reduced whenever the platform is elevated
3	Emergency Stop	Control Console	Used to to stop all functions in an emergency Push for emergency stop Turn clockwise to reset.
4	Lift/ Drive Switch	Control Console	Used to control the raising and lowering of the platform when the Key Switch is turned to the "LIFT" position.
			Used to select forward drive or reverse drive functions when the Key Switch is turned to the "DRIVE" position.
5	Key Switch	Control Console	Main power disconnect Also selects "DRIVE" or "LIFT" function. The key may be removed to prevent unauthorized operation
6	Emergency Lowering Valve	Ground Valve Bank in Enclosure	Push red knob in and turn full counterclockwise to permit lowering of platform should the plat- form controls become inoperable Push and turn full clockwise to release
7	Lift/ Lower Switch	Ground Panel	Toggle switch used to control the raising and lowering of the platform from the ground.
8	20 Amp Fuse	Ground Panel Panel	Electrical circuit protection

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START-UP PROCEDURES

DAILY CHECKS

Before the Simon FALCON Vertical Lift is put into use each day, the following checks should be completed to make sure that the machine is safe and in good condition

Refer to check lists at back of this manual for periodic maintenance requirements and additional procedures for severe duty applications

_____ Visually inspect all machine components, i.e missing parts, torn or loose hoses, hydraulic fluid leaks, torn or disconnected wires, damaged tires, etc The module covers on both sides can be removed to inspect components inside
____ Check battery electrolyte level, charge level and connections.
____ Check hydraulic fluid level with platform fully lowered
____ Check tires for damage.
____ Check wheel lug nuts for tightness.
____ Check hoses and cables for worn areas
Inspect safety belt connections and check for worn areas on the belts.
____ Check platform rails and safety chains for damage.
____ Check pivot pins for security.
____ Check that all warning and instructional labels are legible and secure.

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MACHINE STARTUP

All operators must thoroughly read and understand the "Safety Rules and Precautions" section of this manual prior to operating this machine.

A complete visual inspection of the machine must be performed prior to operational checks.

Check to be sure that battery charger has been disconnected from the AC power source Unhook the control console from the platform guard rail, and hold console while standing on the ground, alongside the machine, to perform these checks

Stand clear of the machine, and keep control console cable away from mechanism while performing these checks.

Ensure that emergency stop button is disengaged Turn clockwise to reset.
Push down on each of the three fastened corners of the tilt alarm (if so equipped) and hold After a three second delay, the alarm should sound as each corner is pressed

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GROUND OPERATION AND CHECKS

Turn the key switch on the platform control to the "DRIVE" position Switch lift/ drive speed toggle to "LOW"
Switch forward/ reverse toggle in each direction to check for proper control Machine should travel smoothly in the selected direction. Release the forward/ reverse switch.

Machine travel should stop upon release of forward/ reverse switch.

Switch the lift/ drive speed toggle to "HIGH", and repeat forward and reverse tests Check for appropriate drive speed of unit in "HIGH" and "LOW" toggle position.
Test the "Emergency Stop" function. While travelling, press the red button on the platform control.

Machine travel should stop upon actuation of emergency stop button. Beware of unsecured items on platform.

Turn emergency stop button clockwise to reset.
Move steering switch "LEFT" and "RIGHT" to test proper steering control
Turn the key switch on the platform control to the "LIFT" position Switch lift/ drive speed toggle to "LOW".

BE SURE AREA ABOVE UNIT IS CLEAR OF OBSTRUCTIONS, TO ALLOW FULL ELEVATION OF PLATFORM.

DO NOT OPERATE THE MACHINE IF THE FOLLOWING CHECKS REVEAL A DEFECT.

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Hook the control console to the platform guard rail Switch the lift/ lower toggle on the around panel "UP" to raise the platform to the end of its movement
- Listen for any unusual noises.
- Check for any vibration while the platform travels up.
- Check for uneven or jerky operation
- ____ Check for hydraulic leaks
- Check pivot pin security Ensure that all snap rings and keeper pins are in place at each pin locking point
Lower the platform about half way by switching the lift/ lower toggle on the ground panel "DOWN". Note operation of audible "down alarm" during lowering procedure.
- ____ Listen for any unusual noises.
- ____ Check for any vibration while the platform travels down
- ____ Check for uneven or jerky operation
- ____ Check for hydraulic leaks
- Check pivot pin security. Ensure that all snap rings and keeper pins are in place at each pin locking point.
Release the raise/ lower switch when platform is approximately half way to stowed position

Platform lowering should stop immediately upon release of raise/ lower switch.

• Turn the key switch off

EMERGENCY VALVE OPERATION AND CHECK

With power off.

Open the emergency lowering valve by pushing knurled red "manual override" knob (located inside and below the compartment opening) in. Turn knob counterclockwise approximately 180°, then release. The knob will pop out and the platform will lower to the stowed position
Close the emergency lowering valve. Push red knob in, turn clockwise approximately 180° and release. The knob will be held in by a detent. Platform cannot be raised when emergency lowering valve is open.

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PLATFORM OPERATION AND CHECKS

Complete the Ground Operational Checks before you perform the Platform Checks
Enter platform and close entry safety chain. Check that all end railings are in position, and railing pins are all in place
For machines with optional deck extension, manually lower extension into working position. Check that front guard rails are in position, and railing pins are all in place

BE SURE AREA ABOVE UNIT IS CLEAR OF OBSTRUCTIONS, TO ALLOW FULL ELEVATION OF PLATFORM.

DO NOT OPERATE THE MACHINE IF THE FOLLOWING CHECKS REVEAL A DEFECT.

____ Turn the key switch on the side of the control console to the "LIFT" position
Switch the lift/ drive toggle "UP" to raise the platform part way
Test the "Emergency Stop" function While platform is moving, press the red button Platform should stop
_____ Reset button by turning clockwise to continue platform operation
Switch the lift/ drive toggle "DOWN" to lower the platform to the stowed position.

IF PLATFORM SHOULD FAIL TO LOWER, DO NOT ATTEMPT TO CLIMB DOWN THE BOOM. SERIOUS INJURY MAY RESULT.

• Replace module covers on both side of the machine.

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OPERATION

DUE TO THE DESIGN OF THE FALCON LIFT, IT IS POSSIBLE TO DRIVE THROUGH LOCATIONS IN WHICH IT WOULD BE UNSAFE TO RAISE THE PLATFORM.

THE OPERATOR MUST BE AWARE OF THE ENVIRONMENT. DO NOT RAISE THE PLATFORM IF THE MACHINE IS NOT ON A FIRM LEVEL SURFACE!

DO NOT RELY ON THE TILT ALARM TO WARN YOU OF AN UNSAFE CONDITION.

SAFE OPERATION BEGINS WITH A SAFE OPERATOR.

Perform Start-up Procedures After satisfactory completion of all preliminary checks, enter platform, close safety chain, and attach safety belt Check that front end guard rails are also in position, and railing pins are all in place.

COLD WEATHER OPERATION

In below zero weather, the hydraulic fluid should be allowed to warm before full operation of the unit
Check for water contamination of the hydraulic fluid.
Check for and remove ice on steps, platform and steering linkage prior to operation
Check that all controls operate freely in all positions

Go slow and leave more maneuvering room during cold weather operation.

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DRIVING AND STEERING

Check that the route of travel to be taken is clear of persons, obstructions, debris, holes and dropoffs, and is capable of supporting the machine.

Turn the key switch to the "DRIVE" position. Switch the lift/drive speed toggle switch to "LOW" Push the forward/ reverse toggle switch to select the desired travel direction. IF CONDITIONS PERMIT, switch the lift/ drive speed toggle switch to "HIGH" to allow faster travel

Steering is achieved by pressing the steer toggle switch to the left or right as required

Steer wheels will not center themselves after a turn, and must be returned to the straight-ahead position with the steer toggle switch.

Although the control panel may be positioned anywhere on the platform rail, the operator may find driving easier if facing the "steering" end of the machine If driving is attempted while facing the "non-steering" end, it must be remembered that all directions given to the steer and drive controls will be reversed

When descending a ramp (incline), switch the lift/ drive speed toggle switch to "LOW"

BRAKING

For parking, the brake is automatically applied when the forward/ reverse toggle switch is positioned in the center (neutral) position.

ACTUATION OF THE PLATFORM "EMERGENCY STOP" SWITCH WILL APPLY BRAKES IMMEDIATELY!

BRACE YOURSELF AND SECURE LOOSE OBJECTS ON PLAT-FORM, AS THIS WILL CAUSE MACHINE TO COME TO A SUDDEN STOP.

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ELEVATING THE PLATFORM

Turn the key switch to the "LIFT" position Switch the lift/ drive speed toggle switch to "LOW" Push the up/ down toggle switch to the "UP" position. If desired, switch the lift/ drive speed toggle switch to "HIGH" to allow faster rise.

TRAVEL WITH PLATFORM ELEVATED ONLY ON HARD, LEVEL SURFACES.

The machine will travel only at the slower speed when platform is raised.

LOWERING THE PLATFORM

Turn the key switch to the "LIFT" position Switch the lift/ drive speed toggle switch to "LOW" Push the up/ down toggle switch to the "DOWN" position

The platform will only descend at "LOW" speed, regardless of the position of the lift/ drive speed toggle switch

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LOWERING THE GUARD RAILS

USE THIS PROCEDURE ONLY TO PERMIT DRIVING THE UNIT THROUGH DOORWAYS OR OPENINGS TOO SMALL TO OTHER-WISE ALLOW ACCESS.

Unpin control console from platform side rail. Set aside to prevent damage Fold down the deck extension (if so equipped)
Unpin the front and rear end railings on one side, and unhook the safety chain
Swing end railings over to side rail, and insert pins to hold end rails in place
Swing upper side rails inward onto platform. Fold up the deck extension (if so equipped)

OPERATE MACHINE FROM GROUND ONLY, USING PLATFORM CONTROL CONSOLE, WHILE GUARD RAILS ARE IN LOWERED POSITION.

RAISING THE GUARD RAILS

GUARD RAILS MUST BE SECURELY FASTENED IN THEIR PROPER POSITION BEFORE ENTERING THE PLATFORM.

Fold down the deck extension (if so equipped). Swing upper side rails to upright position.
Unpin end railings from side rail, swing into position and pin to opposite side rail
Connect rear midrail chain. Place control console in desired position on top rail, and pin in place.

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SHUT-DOWN PROCEDURES

When finished with the unit, place the platform in the stowed position.
Park the unit on level ground (preferably protected from weather) Secure to prevent vandalism and to discourage children at play.
Turn off the key switch, and remove key to prevent unauthorized operation
Plug in the battery charger to recharge the batteries

RECHARGING BATTERIES

Recharge the batteries of the FALCON Vertical Lift each day after use

LEAD-ACID BATTERIES GENERATE EXPLOSIVE GASES. KEEP SPARKS AND FLAME AWAY FROM BATTERIES. NO SMOKING!

Plug the charger into a 115 Volt, 60 Hz AC outlet, using a #12 AWG grounded extension cord
Set timer on charger to
- 16 hours for fully discharged batteries,
- 7 to 9 hours if batteries are lightly discharged.

Timer will shut off the charger automatically at the end of this time

To determine if the batteries are fully charged, plug the charger in, and set the timer for 1 hour A drop in the charge rate (shown on the ammeter) to 1-4 amps within a few minutes indicates that the batteries are fully charged

DO NOT OPERATE THE UNIT WHILE CHARGING.

Be sure to disconnect the charger from the outlet before moving the FALCON

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TRANSPORTING THE UNIT

Platform should be in the stowed position when the unit is being transported Do not operate the unit while it is being transported

TOWING OF THE FALCON SERIES LIFT:

If your FALCON is equipped with the TOW PACKAGE OPTION, it can be towed MAXIMUM TOWING SPEED IS 6 MPH (9.6 KPH). The tow brake and motor release valves are located below the lift cylinder. To tow the unit

Fully close the brake release valve by turning the knob clockwise. Fully open the motor release valve by turning the knob counterclockwise.
Momentarily operate the drive function to disengage the brake cylinder. The unit is now ready to tow.

To return to normal operation, fully open the brake release valve by turning the knob counterclockwise Fully close the motor release valve by turning the knob clockwise.

FORK LIFTING OF THE FALCON SERIES LIFT:

Lift the Simon FALCON Vertical Lift from the sides only. Position forks under the modules, between the front and rear wheels and as near to the rear (driving) wheels as possible Ensure that lift truck used has adequate capacity to lift the machine (see "Machine Specifications" for weight).

Do not use tie down lugs to lift the FALCON.

TRUCK TRANSPORT OF THE FALCON SERIES LIFT:

The FALCON Vertical Lift may be winched onto a transporting vehicle IF THE UNIT IS EQUIPPED WITH THE TOW PACKAGE OPTION. Return both tow valves to normal operating position (engaging the brake) when the unit is on the transporting vehicle
Securely attach the machine to the transporting vehicle using the tie down lugs, located at the center front and center rear of the undercarriage Ensure that chains or straps have adequate load capacity, and DO NOT OVERTIGHTEN

Do not use tie down lugs to lift the FALCON.

Always chock the wheels of the unit while on the transporting vehicle

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EMERGENCY SYSTEM AND PROCEDURES

IF PLATFORM SHOULD FAIL TO LOWER, DO NOT ATTEMPT TO CLIMB DOWN THE BOOM ASSEMBLY. SERIOUS INJURY MAY RESULT.

HAVE AN EXPERIENCED OPERATOR USE THE EMERGENCY LOWERING PROCEDURE TO SAFELY LOWER THE PLATFORM.

THIS MACHINE IS NOT INSULATED AND EXTREME CARE MUST BE TAKEN WHEN WORKING AROUND POWER LINES.

DO NOT TOUCH THE UNIT IF THERE IS A CHANCE IT IS IN CONTACT WITH POWER LINES. WAIT UNTIL THE POWER TO THE LINES HAS BEEN SHUT OFF.

EMERGENCY LOWERING

DO NOT REMOVE THE VELOCITY FUSE WHILE THE PLATFORM IS RAISED.

Remove wire #7 from the high speed valve. The high speed valve is located to the left of the emergency lowering valve inside and below the ground control opening
Hold the lift/ lower toggle in the "LIFT" position. The pump should run.
Open the emergency lowering valve by pushing knurled red "manual override" knob (on the emergency lowering valve) in. Turn knob counterclockwise approximately 180°, then release The knob will pop out, you should hear pressure being relieved, and the platform will lower to the stowed position.

Drive and steer functions are not available when using the emergency lowering valve

The emergency lowering system is designed to be used only for emergency descent.

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Once the platform has been fully lowered, close the emergency lowering valve Push red knob in, turn clockwise approximately 180° and release The knob will be held in by a detent.

Platform will not elevate if this valve is open.

Reconnect wire #7 to the high speed valve.
Report the incident to your supervisor immediately.

EMERGENCY DRIVE

The emergency lowering system will not provide control or operation of the drive or steering functions Should it be necessary to move the unit, see "Transporting the Unit", earlier in this Manual

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EMERGENCY PROCEDURES

It is not possible for us to foresee every emergency situation that could arise during operation of this machine. The following information describes three such emergency situations, and lists appropriate actions that can be taken.

When faced with an emergency, above all please remember

Stay calm
Think through the situation before operating the machine
Get help if necessary

SITUATION: Platform elevated, operator not incapacitated, but unit will not respond to control console.

DO NOT TRY TO CLIMB DOWN THE BOOM ASSEMBLY. SERIOUS INJURY MAY RESULT

HAVE AN EXPERIENCED OPERATOR USE THE EMERGENCY LOWERING PROCEDURE TO SAFELY LOWER THE PLATFORM.

REPORT THE INCIDENT TO YOUR SUPERVISOR IMMEDIATELY.

POSSIBLE CONDITION:

One or more functions not operating correctly
Unit movement from unselected control
Unit function will not stop unless power is switched off

CORRECTIVE ACTION

1 Contact an experienced operator to lower the machine using the emergency descent lowering procedure.
2 Report the incident to your supervisor immediately.

Page 35

SITUATION: Unit elevated, with operator incapacitated at controls.

DO NOT TOUCH UNIT !!!

DETERMINE THE CAUSE OF THE PROBLEM BEFORE YOU TOUCH THE MACHINE.

CORRECTIVE ACTION

1 Have someone summon first aid or rescue squad.
2. Attempt to talk to operator before taking any rescue measures.
3 Check to see if operator is in a pinned position, or would be endangered if platform is moved, before attempting emergency lowering procedure.
4 After establishing that the machine is not in contact with live power lines, lower the platform using the emergency lowering procedure.
5 Render first aid to the operator

SITUATION: Platform in contact with live power lines and operator incapacitated.

CORRECTIVE ACTION

1 Contact authorized personnel to disconnect power supply touching unit.
2. Have someone summon first aid or rescue squad.
3 If operator is unconscious, check to see if he is in a pinned position, or would be endangered if platform is moved.
4 AFTER POWER IS CUT, use the emergency lowering procedure to bring platform with operator to a safe location to render first aid.

Any incident involving personal injury must be immediately reported to the local Simon Aerials Distributorship as well as to Simon Aerials Inc.

Page 36

SECTION 3: MAINTENANCE

Page 37

TABLE OF CONTENTS, SECTION 3: MAINTENANCE

GENERAL MAINTENANCE TIPS
DAILY OPERATIONAL CHECKLIST
WEEKLY OPERATIONAL CHECKLIST
MONTHLY OPERATIONAL CHECKLIST
SEMI - ANNUAL OPERATIONAL CHECKLIST
TROUBLESHOOTING
LUBRICATION CHART
WARRANTY

Page 38

MAINTENANCE

GENERAL MAINTENANCE TIPS

WARNING !!!

NEVER PERFORM SERVICE ON THE UNIT (WITH PLATFORM ELEVATED) WITHOUT FIRST BLOCKING THE ELEVATING ASSEMBLY IN PLACE !

USE 4" X 4" WOOD POSTS OR SIMILAR MATERIAL WITH SUFFI-CIENT STRENGTH TO HOLD PLATFORM AND BOOM.

BLOCK BETWEEN LOWER BOOM OR MIDPOST AND CHASSIS. DO NOT BLOCK BETWEEN MIDPOST AND GROUND, AS RE-TRACTING CYLINDER MAY CAUSE STEER END OF UNIT TO RISE OFF THE GROUND.

Never leave hydraulic components or hoses open. They must be protected from contamination (including rain) at all times.
Never open a hydraulic system when there are contaminants in the air
Use only recommended lubricants. Improper lubricants or incompatible lubricants may be as harmful as no lubrication.
ALWAYS clean the surrounding area before opening hydraulic systems
Watch for makeshift "fixes" which can jeopardize safety as well as lead to more costly repairs.
Any work platform found not to be in safe operating condition should be removed from service until repaired. All repairs should be made by authorized personnel in conformance with the manufacturer's operating, maintenance, and repair manuals

Page 39

DAILY OPERATIONAL CHECKLIST

DATE		INSPECTED BY

		GENERAL INFORMATION
Keep inspection records up-to-date Record and report all discrepancies to your supervisor A dirty machine cannot be properly inspected Keep your Simon FALCON clean!!
TH CC RE MU	IIS CHEC OULD EN MEMBEI JCH MOF	EXLIST MUST BE USED DAILY. FAILURE TO DO SO DANGER THE LIFE OF THE OPERATOR. ALWAYS R, A LITTLE PREVENTIVE MAINTENANCE CAN SAVE RE THAN IT COSTS.
NITIAL	DES	SCRIPTION
1. Per torn dan cov		Perform a visual inspection of all machine components, i e missing parts forn or loose hoses, hydraulic fluid leaks, torn or disconnected wires, damaged tires etc Replace components as necessary. The module covers on both sides can be removed to inspect components inside
	2	Check battery charge level and connections.
	З.	Check hydraulic fluid level with the unit in stowed position.
	4.	Check that all shutoff valves on hydraulic tank are open (parallel to flow)
	5	Check tires for damage.
	6	Check hoses and cables for worn areas
	7.	Inspect safety belt connections, and check for worn areas on the belts.
	8.	Check platform rails and safety chains for damage
	9	Check pivot pins for security.
	10	Check that all warning and instructional labels are legible and secure
ADDITIC		NTENANCE REQUIREMENTS FOR SEVERE USAGE APPLICATIONS
NITIAL	DES	SCRIPTION
	11.	Check hydraulic system for leakage after every eight (8) hours of operation

Page 40

WEEKLY OPERATIONAL CHECKLIST

DATE INSPECTED BY

		GENERAL INFORMATION
1 2 3	. Keep Reco A dirt Keep	inspection records up-to-date rd and report all discrepancies to your supervisor. y machine cannot be properly inspected. your Simon FALCON clean!! WARNING !!!
T C F N	THIS CHEC COULD EN REMEMBEI NUCH MOF	KLIST MUST BE USED WEEKLY. FAILURE TO DO SO DANGER THE LIFE OF THE OPERATOR. ALWAYS R, A LITTLE PREVENTIVE MAINTENANCE CAN SAVE RE THAN IT COSTS.
INITIAL	DES	SCRIPTION
	. 1.	Perform all checks listed on Daily Operational Checklist
	2.	Check battery electrolyte level and specific gravity (fully charged specific gravity should be 1.265).
	3	Check wheel lug nuts for proper torque (65-70 ft lbs).
	4.	Grease boom gears at mid post.
ADDIT		NTENANCE REQUIREMENTS FOR SEVERE USAGE APPLICATIONS
	DES	SCRIPTION
INITIAL	5	Inspect condition of hydraulic fluid in the reservoir Oil should have a clear amber color
INITIAL
	6.	Lubricate all grease fittings (see Lubrication Chart)
	6. 7.	Lubricate all grease fittings (see Lubrication Chart) Lubricate all steering linkages and pivot points.
	6. . 7.	Lubricate all grease fittings (see Lubrication Chart) Lubricate all steering linkages and pivot points.

Page 41

MONTHLY OPERATIONAL CHECKLIST

DATE
DATE
		GENERAL INFORMATION
Keep inspection records up-to-date. Record and report all discrepancies to your supervisor A dirty machine cannot be properly inspected. Keep your Simon FALCON clean!!
THIS SOC REM MUC	CHEC OULD EMBEI	KLIST MUST BE USED MONTHLY. FAILURE TO DO ENDANGER THE LIFE OF THE OPERATOR. ALWAYS R, A LITTLE PREVENTIVE MAINTENANCE CAN SAVE RE THAN IT COSTS.
INITIAL	DES	SCRIPTION
	1.	Perform all checks listed on Daily and Weekly Operational Checklists
	2	Lubricate all grease fittings (see Lubrication Chart).
	3	Lubricate all steering linkages and pivot points.
	4	Lubricate deck extension pivot pin (if so equipped)
	5	Inspect condition of hydraulic fluid in the reservoir Oil should have a clea amber color
	6	Inspect the entire machine for signs of damage, broken welds, loose bolts improper or makeshift repairs
	7.	Check the electric motor brushes
	8	Check pin joints and retaining bolts for security.
	9.	Check hydraulic system pressure.

	10	Check left and right spindles for free turning with no end play.

Page 42

DATE _	INSPECTED BY
MODEL	NUMBER
	1 Keep 2 Reco 3 A dirt Keep	GENERAL INFORMATION inspection records up-to-date rd and report all discrepancies to your supervisor y machine cannot be properly inspected your Simon FALCON clean!!
	THIS CHEC FAILURE 1 OPERATOR MAINTENA	CKLIST MUST BE USED AT SIX MONTH INTERVALS. TO DO SO COULD ENDANGER THE LIFE OF THE R. ALWAYS REMEMBER, A LITTLE PREVENTIVE NCE CAN SAVE MUCH MORE THAN IT COSTS.
INITIAL	DE	SCRIPTION
	1.	Perform all checks listed on Daily, Weekly and Monthly Operational Check list.
	2	Have hydraulic fluid sample analyzed at a test laboratory Comply with test results and recommendations to ensure long, trouble free operation
	3.	Check tightness of upper frame and linkage pins.

	4	Check overall platform stability
	4 5.	Check the electrical mounting and hardware connections for security
	4 5. 6	Check overall platform stability Check the electrical mounting and hardware connections for security Replace return filter element.

Page 43

TROUBLESHOOTING

SHOULD YOU EXPERIENCE ERRATIC OPERATION OR NOTICE ANY MALFUNCTION WHILE RUNNING THIS UNIT, CONTINUE OPERATION ONLY LONG ENOUGH TO RETURN TO THE GROUND POSITION IF POSSIBLE.

IMMEDIATELY REPORT THE INCIDENT TO YOUR SUPERVI-SORS, AND DISCONTINUE USING THE UNIT UNTIL IT HAS BEEN CHECKED BY A TRAINED, QUALIFIED MECHANIC.

WHAT TO CHECK IF UNIT WILL NOT OPERATE:

Key switch turned to proper mode?
Emergency stop button released? (Twist to release.)
Batteries fully charged?
Battery cables connected?
Wires pulled out or loose?
Hydraulic fluid level low?
Obvious fluid leak or damaged component?

Page 44

LUBRICATION CHART


NO.	ITEM	SPECIFICATION AND QUANTITY	FREQUENCY OF LUBRICATION
1.	Hydraulic reservoir	Mobil DTE-15 to 2" from top of tank with platform retracted	Check daily, Analyze every 6 months or 500 hrs * ^† , Change yearly or every 1,000 hrs * ^†
2	Hydraulic return filter	Filter element	Chg. every 6 months or 500 hrs *†
3	Pivot pins	Mobilgrease Special or equivalent (NLGI #2 Lithium plus EP & Moly). Purge old grease.	Weekly or every 25 hrs.*†
4	Steering spindles	Lithium N.L.G I #2 EP. Purge old grease.	Monthly or every 100 hrs.*1
5	Steering hubs	Lithium N.L.G I #2 EP Clean and repack.	Every 6 months or 500 hrs.*
6	Steering linkage	Silicone spray or penetrating oil	Monthly or every 100 hrs.* ^†
7	Boom gears	"Keystone - Moly 29 Open Gear Compound" Coat gear faces	Weekly or every 25 hrs.* ^†
8	Deck extension pivot pin	Silicone spray or penetrating oil.	Monthly or every 100 hrs.*1

* Whichever occurs first

^† Different requirements for severe duty applications See check lists

Page 45

Page 46

Twelve Month Limited Warranty

Simon Aerials Inc. (the "Company") warrants, to the original Buyer only,

(a) that the units of equipment manufactured and sold by it conform to the Company's published specifications;

(b) that all component parts manufactured by it shall be free from defects in material or workmanship for 12 months from the date the unit is first placed in service; and

(c) that component parts not manufactured by the Company shall be free from defects in material or workmanship for the period warranted by the Company's vendor.

If the Buyer discovers within the warranty period a failure to conform to specifications or a defect in material or workmanship, it must promptly submit notice of such condition to the Company and return the nonconforming part(s) to the factory, freight prepaid, together with a properly completed Simon Aerials Inc. Warranty Claim Form as furnished by the Company. In no event shall such notice be received later than 30 days following expiration of the applicable warranty period. If, after inspection by factory Quality Assurance personnel, the returned part(s) are judged to be not in conformity with specifications or defective in material or workmanship, the Company will correct such condition by delivering repaired or new replacement part(s) to the Buyer, free of charge. This remedy is the Buyer's exclusive remedy for breach of warranty.

This warranty does not cover damage caused by shipment, misuse of the unit (including operation beyond unit specification limits), failure to properly service and maintain the unit in accordance with the Company's Manual or Factory Service Bulletins, alteration of the unit, or natural disasters (such as fire, flood, wind and lightning) and shall be void if

(1) the unit is altered or repaired contrary to the Company's authorized instructions,

(2) the unit is altered or repaired in such a way as to affect its performance or reliability, or

(3) the unit is mounted on a chassis or carrier which does not meet the Company's published minimum requirements.

THE FOREGOING WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE.

If field repair or parts replacement is necessary on warranted components, Simon Aerials will reimburse distributors for direct labor costs incurred for said repairs according to the Company's current authorized field service rate, providing that advance approval for said work be granted by Simon Aerials Service Department. In no case shall the Company be liable for any special incidental or consequential damage (including without limitation loss of profits, loss of revenue, cost of capital, cost of substitute equipment, downtime, claims of third parties and injury to person or property) based upon breach of warranty, breach of contract, negligence, strict liability in tort, or any other legal theory. This limited warranty allocates the risks of product failure between the Company and the Buyer, and that allocation is recognized by both parties and is reflected in the price of the goods.

This written warranty is understood to be the complete and exclusive agreement between the parties, superceding all prior agreements, oral or written and all other communications between the parties relating to the subject matter of this warranty. No employee, agent or distributor of the Company or any other person is authorized to state or imply any additional warranties on behalf of the Company, nor to assume for the Company any other liability in connection with any of its products, unless made in writing and signed by an officer of the Company.

SIMON AERIALS INC. Milwaukee, WI