Genie Simon Falcon Series Operator's Manual

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SIMON AERIALS 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

IIFT

MODEL

SIMON

This manual is designed to instruct you in the proper operation of your Work Platform, and to make you aware of the many Safety Hazards that could affect the safe use and operation of your "FAL-CON" Vertical Lift.

IMPORTANT

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

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

PART NO. 89-755002

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INTRODUCTIONV
UNLOADING PROCEDURES
SECTION 1: DESCRIPTION
MACHINE SPECIFICATIONS1-3
GRADEABILITY CONVERSION CHART1-4
PRIMARY MACHINE COMPONENTS1-5
DECAL AND INFORMATION PLATE LOCATIONS1-6
SECTION 2: OPERATION
SAFETY RULES AND PRECAUTIONS2-3
OPERATOR CONTROLS2-6
GROUND CONTROLS2-6
CONTROL CONSOLE2-8
START-UP PROCEDURES2-10
DAILY CHECKS2-10
MACHINE STARTUP2-10
GROUND OPERATION AND CHECKS2-11
PLATFORM OPERATION AND CHECKS2-12

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TABLE OF CONTENTS (CONTINUED)

SECTION 2: OPERATION (CONTINUED)
OPERATION2-14
COLD WEATHER OPERATION2-14
DRIVING AND STEERING2-15
BRAKING2-15
ELEVATING THE PLATFORM2-16
LOWERING THE PLATFORM2-16
LOWERING THE GUARD RAILS2-17
RAISING THE GUARD RAILS2-17
SHUT-DOWN PROCEDURES2-18
RECHARGING BATTERIES2-18
TRANSPORTING THE UNIT
TOWING OF THE FALCON SERIES LIFT2-19
FORK LIFTING OF THE FALCON SERIES LIFT
TRUCK TRANSPORT OF THE FALCON SERIES LIFT
EMERGENCY SYSTEM AND PROCEDURES2-20
EMERGENCY LOWERING2-20
EMERGENCY DRIVE2-20
EMERGENCY PROCEDURES2-21

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TABLE OF CONTENTS (CONTINUED)

SECTION 3: MAINTENANCE


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

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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 2548 Self-Propelled Vertical Lift. 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.
Open 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.
Close 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 SPECIFICATIONS1-3
GRADEABILITY CONVERSION CHART1-4
PRIMARY MACHINE COMPONENTS1-5
DECAL AND INFORMATION PLATE LOCATIONS

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MACHINE SPECIFICATIONS

	31 FT (9.45 M) 25 FT (7.62 M)
GUARD RAILS IN PLACE	91.1 IN. (2.31 M) 75.3 IN. (1.91 M) 77.8 IN. (1.98 M)
PLATFORM CAPACITY (UNRESTRICTED): WITH STANDARD DECK	1,000 LBS. (454 KG) 900 LBS. (408 KG) 250 LBS. (115 KG)
W/ STANDARD DECK (or w/ optional deck stowed)	44.5 IN. (1.13 M) x 126 IN. (3.20 M) 44.5 IN. (1.13 M) x 158.5 IN. (4.03 M)
LENGTH (WITHOUT OPTIONAL DECK EXTENSION) (WITH OPTIONAL DECK EXTENSION) WIDTH WHEELBASE TRACK OUTSIDE TURNING RADIUS INSIDE TURNING RADIUS GROUND CLEARANCE GROSS WEIGHT (APPROX.)	126 IN. (3.20 M) 130.2 IN. (3.31 M) 48 IN. (1.22 M) 84 IN. (2.13 M) 42 IN. (1.07 M) 11 FT 1 IN. (3.39 M) 4 FT 5.5 IN. (1.36 M) 5.5 IN. (0.14 M) 5,300 LBS. (2,404 KG)
TRAVEL SPEED-PLATFORM STOWED TRAVEL SPEED-PLATFORM ELEVATED GRADEABILITY (on hard surface) (ref. next page) TIRES	1.9 MPH (3.1 KPH) 0.5 MPH (0.8 KPH) 14° (25%) 4" x 8" x 17.9" SOLID
HYDRAULIC FLUID CAPACITY	8.8 GAL. (33.3 L) 2500 PSI (172 BAR) 1500 PSI (104 BAR) 65-70 FT LBS. 24 VOLT DC (EIGHT 6 VOLT, 220 AMP/HR. LEAD-ACID BATTERIES)

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TABLE OF CONTENTS, SECTION 2: OPERATION

SAFETY RULES AND PRECAUTIONS
OPERATOR CONTROLS
GROUND CONTROLS2-6
CONTROL CONSOLE2-8
START-UP PROCEDURES
DAILY CHECKS2-10
MACHINE STARTUP2-10
GROUND OPERATION AND CHECKS2-11
PLATFORM OPERATION AND CHECKS2-12
OPERATION2-14
COLD WEATHER OPERATION2-14
DRIVING AND STEERING2-15
BRAKING2-15
ELEVATING THE PLATFORM2-16
LOWERING THE PLATFORM2-16
LOWERING THE GUARD RAILS2-17
RAISING THE GUARD RAILS2-17
SHUT-DOWN PROCEDURES2-18
RECHARGING BATTERIES2-18
TRANSPORTING THE UNIT2-19
TOWING OF THE FALCON SERIES LIFT2-19
FORK LIFTING OF THE FALCON SERIES LIFT2-19
TRUCK TRANSPORT OF THE FALCON SERIES LIFT2-19
EMERGENCY SYSTEM AND PROCEDURES
EMERGENCY LOWERING
EMERGENCY DRIVE2-20
EMERGENCY PROCEDURES2-21

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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 block the foot pedal in the depressed position.
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.

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SAFETY RULES AND PRECAUTIONS (CONTINUED)

SECURE all tools and other loose items to prevent injury to persons working on or below the work platform.
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.

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SAFETY RULES AND PRECAUTIONS (CONTINUED)

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.
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 (GROUND CONTROLS)

Item	Control	Location	Description
1.	Key Switch	Ground Control Panel	Main power disconnect. Also selects "GROUND" or "PLATFORM" operation. The key may be removed to prevent unauthorized operation.
2.	Lift/ Lower Switch	Ground Control Panel.	Toggle switch used to control the raising and lowering of the platform from the ground, when key switch is in the "GROUND" position.
			Speed of platform lift will be determined by the position of the Vehicle Lift/ Drive Speed Switch on the platform control console.
			Platform always lowers at low speed.
			Some very early units have a Lift Speed Switch above the Lift/ Lower Switch, used to select "HIGH" or "LOW" platform raising speed.
3.	Emergency Stop	Ground Control Panel.	Used to to stop all functions in an emergency. Push for emergency stop. Turn clockwise to reset.
4.	20 Amp Fuse	Ground Control Panel.	Electrical circuit protection.
5.	Low Speed Motor Selector Switch	Ground Control Panel.	Used to select "FRONT" or "REAR" electric motor operation for low speed lift, drive and steer functions. Both motors operate for high speed lift and drive.
6.	Battery Gauge	Ground Control Panel.	Indicates level of battery charge.
7.	Hour Meter (Option)	Ground Control Panel.	Indicates total elapsed time the machine has been operated in hours and tenths.

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OPERATOR CONTROLS DESCRIPTION (CONTROL CONSOLE)

item	Control	Location	Description
8.	Foot Pedal	Platform Floor	Must be depressed to activate main hydraulic pump, allowing operation of drive, steer, raise or lower functions from the platform.
9.	Lift/ Drive Selector (on earlier units)	Control Console	Selects "DRIVE" or "LIFT" function.
10.	Steering Switch	Control Console	Controls the steering wheels. On some earlier units, the Lift/ Drive Selector Switch must be in "DRIVE" position.
11.	Vehicle Lift/ Drive Speed Switch	Control Console	Shifts between "HIGH" and "LOW" speed drive, or platform raising speed.

			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.
12.	Emergency Stop	Control Console	Used to to stop all functions in an emergency. Push for emergency stop. Turn clockwise to reset.
13.	Lift Switch	Control Console	Used to control the raising and lowering of the platform. On some earlier units, the Lift/ Drive Selector Switch must be in the "LIFT" position.
14.	Drive Switch	Control Console	Used to select forward drive or reverse drive functions. On some earlier units, the Lift/ Drive Selector Switch must be in "DRIVE" position.
15.	Low Battery Light (on later units)	Control Console	Illuminates to indicate low battery condition. Return to ground as soon as possible. Sufficient battery power remains to safely lower the platform to the stowed position.
16.	Horn Button (on later units)	Control Console	Press button to sound warning horn.

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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 opened 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.

MACHINE STARTUP

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

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

Check that battery charger has been disconnected from the AC power source.
Ensure that emergency stop buttons on ground and platform panels are 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 ground panel to the "GROUND" position. Switch lift speed togale 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.

Switch the lift toggle on the ground 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.
- 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.
- ____ 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 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 lift switch when platform is approximately half way to stowed position.

Platform lowering should stop immediately upon release of lift switch.

• Lower platform to the stowed position.

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PLATFORM OPERATION AND CHECKS

Complete the Ground Operational Checks before you perform the Platform Checks.
Turn the key switch on the ground panel to the "PLATFORM" position.
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.

The foot pedal switch must be depressed to activate any of the machine functions using the platform controls.

_____ Turn the selector switch on the side of the control console to "LIFT" position (required only on earlier units).
_____ Switch the lift/ drive speed toggle to "LOW".
____ Depress the foot pedal switch.
_____ Switch the lift 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 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.

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Turn selector switch on the platform control to the "DRIVE" position (required only on earlier units).
Switch the drive toggle to the forward and reverse direction in turn to check for proper control. Machine should travel smoothly in the selected direction. Release the drive switch.

Machine travel should stop upon release of drive 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 steer switch "LEFT" and "RIGHT" to test proper steering control.
Exit the platform. Turn the key switch on the ground control panel "OFF".
Close the module covers on both sides 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.

The foot pedal switch must be depressed to activate any of the machine functions using the platform controls.

Turn the selector switch to the "DRIVE" position (required only on earlier units). Switch the lift/ drive speed toggle switch to "LOW". Move the drive 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 selector switch to the "LIFT" position (required only on earlier units). Switch the lift/ drive speed toggle switch to "LOW". Push the lift 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.


NOTE

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

LOWERING THE PLATFORM

Turn the key switch to the "LIFT" position (required only on earlier units). Switch the lift/ drive speed toggle switch to "LOW". Push the lift 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. The charger is fully automatic.
Charger light will turn on to indicate that the charger is operating. When the batteries are fully charged, the light will start flashing. The charger can be left connected for extended periods without damage to the batteries.
The minimum charge cycle is two hours. If the AC supply cord is unplugged, then reconnected, the charge cycle will start over.

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

WARNING !!!

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

The FALCON Model 2548 operates on 24 Volt DC power. However, the lowering valve operates on 12 Volts DC. Even if the batteries have discharged to the point that the unit will not function, enough power should remain to safely lower the platform, using the ground or platform controls.
Check to be sure that the key switch is turned to the proper position ("PLATFORM" or "GROUND").
If operating from the platform, ensure that the selector switch is in the "LIFT" position.
If the unit does not lower, check that the 20 Amp fuse on the ground control panel has not blown.
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:

Stav 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.

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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.

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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

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 conform-ance with the manufacturer's operating, maintenance, and repair manuals.

Page 39

DAILY OPERATIONAL CHECKLIST

All checks must be completed before operation of the Simon FAI CON

DATE INSPECTED BY

GENERAL INFORMATION

1 Keep inspection records up-to-date
2 Becord and report all discrepancies to your supervisor.
2 A dirty machine cannot be properly inspected. Keep vour Simon FALCON clean!!

THIS CHECKLIST MUST BE USED DAILY FAILURE TO DO SO COULD ENDANGER THE LIFE OF THE OPERATOR ALWAYS REMEMBER, A LITTLE PREVENTIVE MAINTENANCE CAN SAVE MUCH MORE THAN IT COSTS.

ΙΝΙΤΙΔΙ DESCRIPTION

1. Perform a visual inspection of all machine components, i.e. missing parts. torn 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 opened to inspect components inside.
2. Check battery charge level and connections.
- 3. 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.

ADDITIONAL MAINTENANCE REQUIREMENTS FOR SEVERE USAGE APPLICATIONS

INITIAL DESCRIPTION

11. Check hydraulic system for leakage after every eight (8) hours of operation.

Page 40

DATE INSPECTED BY

	GENERAL INFORMATION
1. 2. 3.	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!! WARNING !!!
TH CO RE MU	S CHECKLIST MUST BE USED WEEKLY. FAILURE T ULD ENDANGER THE LIFE OF THE OPERATOR. MEMBER, A LITTLE PREVENTIVE MAINTENANCE CA CH MORE THAN IT COSTS.	O DO SO ALWAYS AN SAVE
INITIAL	DESCRIPTION

	1. Perform all checks listed on Daily Operational Ch	ecklist.
	Perform all checks listed on Daily Operational Ch Check battery electrolyte level and specific gravit gravity should be 1.265).	ecklist. y (fully charged specific
	Perform all checks listed on Daily Operational Ch Check battery electrolyte level and specific gravit gravity should be 1.265). Check wheel lug nuts for proper torque (65-70 ft.	ecklist. y (fully charged specific lbs.).
	Perform all checks listed on Daily Operational Ch Check battery electrolyte level and specific gravit gravity should be 1.265). Check wheel lug nuts for proper torque (65-70 ft. Grease boom gears at mid post.	ecklist. y (fully charged specific lbs.).
ADDITIO	Perform all checks listed on Daily Operational Ch Check battery electrolyte level and specific gravit gravity should be 1.265). Check wheel lug nuts for proper torque (65-70 ft. Grease boom gears at mid post.	ecklist. y (fully charged specific lbs.). AGE APPLICATIONS
ADDITIO	Perform all checks listed on Daily Operational Ch Check battery electrolyte level and specific gravit gravity should be 1.265). Check wheel lug nuts for proper torque (65-70 ft. Grease boom gears at mid post. NAL MAINTENANCE REQUIREMENTS FOR SEVERE USA DESCRIPTION	ecklist. y (fully charged specific lbs.). AGE APPLICATIONS
ADDITIO	Perform all checks listed on Daily Operational Ch Check battery electrolyte level and specific gravit gravity should be 1.265). Check wheel lug nuts for proper torque (65-70 ft. Grease boom gears at mid post. NAL MAINTENANCE REQUIREMENTS FOR SEVERE USA DESCRIPTION 5. Inspect condition of hydraulic fluid in the reservoi amber color.	ecklist. y (fully charged specific lbs.). AGE APPLICATIONS r. Oil should have a clea
	Perform all checks listed on Daily Operational Ch Check battery electrolyte level and specific gravit gravity should be 1.265). Check wheel lug nuts for proper torque (65-70 ft. Grease boom gears at mid post. NAL MAINTENANCE REQUIREMENTS FOR SEVERE USA DESCRIPTION Inspect condition of hydraulic fluid in the reservoi amber color. Lubricate all grease fittings (see Lubrication Char	ecklist. y (fully charged specific lbs.). AGE APPLICATIONS r. Oil should have a clea t).
	Perform all checks listed on Daily Operational Ch Check battery electrolyte level and specific gravit gravity should be 1.265). Check wheel lug nuts for proper torque (65-70 ft. Grease boom gears at mid post. NAL MAINTENANCE REQUIREMENTS FOR SEVERE USA DESCRIPTION Inspect condition of hydraulic fluid in the reservoi amber color. Lubricate all grease fittings (see Lubrication Chail 7. Lubricate all steering linkages and pivot points.	ecklist. y (fully charged specific lbs.). AGE APPLICATIONS r. Oil should have a clea t).

Page 41

MONTHLY OPERATIONAL CHECKLIST
DATE INSPECTED BY


1. Keep i 2. Record 3. A dirty Keep	nspection records up-to-date. d and report all discrepancies to your supervisor. machine cannot be properly inspected. your Simon FALCON clean!! WARNING !!!
THIS CHECK SO COULD I REMEMBER MUCH MOR	KLIST MUST BE USED MONTHLY. FAILURE TO DO ENDANGER THE LIFE OF THE OPERATOR. ALWAYS 3, A LITTLE PREVENTIVE MAINTENANCE CAN SAVE E THAN IT COSTS.
INITIAL DES	CRIPTION
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 clear 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.
11.	Visually inspect power wheel mounting bolts. Bolts should be flush to retainer, with no gap between retainer and hub flange. Torque to 55-60 ft. lbs.

Page 42

DATE _		INSPECTED BY
MODEL	NUMBER _
·	1. Keej	GENERAL INFORMATION o inspection records up-to-date.
	2. Reco 3. A dir Kee	ty machine cannot be properly inspected. b your Simon FALCON clean!!

	THIS CHE FAILURE OPERATO MAINTEN	CKLIST MUST BE USED AT SIX MONTH INTERVALS. TO DO SO COULD ENDANGER THE LIFE OF THE R. ALWAYS REMEMBER, A LITTLE PREVENTIVE ANCE CAN SAVE MUCH MORE THAN IT COSTS.
INITIAL	DE	SCRIPTION
	1	Perform all checks listed on Daily, Weekly and Monthly Operational Che list.
	2	. Have hydraulic fluid sample analyzed at a test laboratory. Comply with results and recommendations to ensure long, trouble free operation.

		If hydraulic fluid has been regularly maintained, it should only require changing once every year, depending on main- tenance, temperature, application, duty cycle, and atmos- pheric conditions.
	3	. Check tightness of upper frame and linkage pins.
	4	. Check overall platform stability.
	5	. Check the electrical mounting and hardware connections for security.
	6	. Replace return filter element.
	7	. Repack front wheel bearings.

Page 43

TROUBLESHOOTING

WARNING !!!

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 position?
Emergency stop buttons at both ground and platform 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.	ІТЕМ	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.**
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.

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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

(2) the unit is ateled of repaired in soon a way as to another performance of remainly, of (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