Genie Simon MP Series Operator's Manual

Page 1

MODEL MP 60 Featuring "Simcon" Control System

Part No. 89-160402 • Initial Issue dated November, 1996 •

Page 2

Introduction
Machine Specifications	iv
Machine Diagrams	ν
Range Diagram	V
General Arrangement Diagram	vi
Gradeability Conversion Chart	vi

SAFETY

Safety Symbols
Safety Rules and Precautions
Safety-Related Decals
Safety and Control Decal Locations	1-16
Safety and Control Decal Identification	1-17

OPERATION

Unloading Procedures
Primary Machine Components
Operator Controls
Ground Controls
Remote Pendant Control	2-10
Platform Controls	2-14
Start-Up Procedures
Shift Checks
Machine Start-Up
Ground Operation and Checks
Platform Operation and Checks
Operation
Cold Weather Operation	2-31
Driving and Steering
Braking
Booms, Superstructure and Platform
Gasoline Engine Operation
Dual Fuel Engine Operation
Diesel Engine Operation
Shut-Down Procedures
Transporting the Machine
Towing Procedures
Truck or Trailer Transport
Emergency System and Procedures	0.40
Emergency Pump
Unpowered Emergency Movement
Emergency Lowering	2-42

Page 3

TABLE OF CONTENTS (CONTINUED)

MAINTENANCE

General Maintenance Tins	3-3
Shift Operational Checklist
Weekly Operation Checklist
Monthly Operational Checklist
Quarterly Operational Checklist	3-11
Semi-annual Operational Checklist
Lubrication Chart
Lubrication Diagram
Troubleshooting

INDEX

APPENDIX

Applicable Standards and Regulations	A-3
ANSI/ SIA A92.5-1980 (Partial)	A-5
11. Inspection and Maintenance	A-5
12. Training	A-5
13. Operation	A-5
14. Responsibilities of Manufacturer, Dealer, Purchaser,
and Operators	A-8
Simon Aerials Twelve Month Limited Warranty
Transfer of Ownership Notice (Business Reply Cards)
Catalog Comment Card (Business Reply Cards)

Page 4

NTRODUCTION

INTRODUCTION

This Operator's Manual has been designed to provide you with the instructions needed to properly and safely operate your Simon Self-Propelled Aerial Work Platform featuring SIMCON controls.

A DANGER

THIS OPERATOR'S MANUAL MUST BE READ AND UNDERSTOOD PRIOR TO OPERATING YOUR SIMON SELF-PROPELLED AERIAL WORK PLATFORM.

OPERATORS MUST BE AWARE OF AND COMPLY WITH ALL MANUFAC-TURER'S INSTRUCTIONS AND APPLICABLE OSHA/ANSI SAFETY GUIDE-LINES.

FAILURE TO COMPLY WITH MANUFACTURER'S INSTRUCTIONS AND OSHA/ANSI SAFETY GUIDELINES WILL RESULT IN SERIOUS INJURY OR DEATH.

Your Simon machine has been designed and built to provide many years of safe, dependable service. To obtain the full benefit of your machine, always follow the proper operating and maintenance procedures as outlined in this manual. Only trained, authorized personnel should be allowed to operate or service this machine. Service personnel should read and study this manual in order to gain a thorough understanding of the functions of the machine prior to making any repairs.

MODIFICATIONS OF THIS MACHINE FROM THE ORIGINAL DESIGN AND SPECIFICATION WITHOUT WRITTEN PERMISSION FROM SIMON AERIALS INC. ARE STRICTLY FORBIDDEN. A MODIFICATION MAY COMPROMISE THE SAFETY OF THE MACHINE, SUBJECTING USERS TO SERIOUS INJURY OR DEATH. ANY SUCH MODIFICATION WILL VOID ANY REMAINING WARRANTY.

Simon reserves the right to change, improve, modify or expand features of its equipment at any time. Specifications, models or equipment are subject to change without notice, and without incurring any obligations to change, improve, modify or expand features of previously delivered equipment.

All Simon 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.

Page 5

MACHINE SPECIFICATIONS

Working Height Platform Height Horizontal Reach (Boom Angle O°) Platform Capacity (Unrestricted) Platform Size	66 Ft/ 20.12 M 60 Ft/ 18.29 M 48 Ft 7 In./ 14.80 M 500 LBs./ 227 Kg 36 In. x 72 In. x 42 In./ 91 M x 1.83 M x 1.07 M
Stowed Length	25 Ft 8 In. / 7.82 M
Stowed Height	8 Ft 7 In./ 2.62 M
Machine Width	8 Ft. 0 In. / 2.44 M
Wheelbase	8 Ft 0 In./ 2.44 M
Outside Turning Radius	16 Ft 10 In. / 5.13 M
Maximum Travel Speed:
Boom Stowed (Note 1)	2.5 MPH / 4.0 KPH
Boom Extended	0.5 MPH/ 0.8 KPH
Ground Clearance	10.7 In./ 27.2 cm
Gross Weight (Approx.) (Note 1)	20,500 LBs. / 9,299 Kg
Gradeability (On Hard Surface) (Note 1)	15 °/ 27%
Platform Rotation	1 80 °
Superstructure Rotation	360° continuous, either direction
Tire Size	15 x 19.5 (14 Ply)
Tire Pressure (Disregard for foam filled tires)	105 PSI/ 7.24 Bar/ 7.38 Kg-cm ²
Wheel Lug Nut Torque (Drive Axle)	220 Ft LBs./ 298 Nm/ 30.4 Kg-m
Wheel Lug Nut Torque (Steer Axle)	220 Ft LBs./ 298 Nm/ 30.4 Kg-m
Swing Bearing Bolt Torque	320 Ft LBs. / 434 Nm/ 44.22 Kg-m
Drive Hub Bolt Torque	170 Ft LBs./ 231 Nm/ 23.49 Kg-m
Maximum Hydraulic Pressure	2500 PSI / 172 Bar/ 175 Kg-cm ²
Hydraulic Tank Capacity	35 Gal. / 132 Liters
Fuel Capacity:
Gas or Diesel	35 Gal. / 132 Liters
Propane	30 LBs./ 14 Kg
Electrical System	Two 12 Volt DC Batteries
Engine Availability:
Standard Wisconsin W41770, 35 HP (26.1 Kw), Air Co Optional Wisconsin V-465, 65 HP (48.5 Kw), Air Cool Ford LSG 423, 63 HP (47.0 Kw), Liquid Cool Deutz F3L 912, 55 HP (41 Kw), Air Cooled, Deutz F3L 1011, 42 HP (31.3 Kw), Air Coole Deutz F4L 1011, 56 HP (41.7 Kw), Air Coole Perkins 104.19, 43 HP (32.1 Kw), Liquid Cool Isuzu C-240, 56 HP (41.7 Kw), Liquid Coole	ooled, Gas (Dual Fuel - Optional) ed, Gas or Dual Fuel (Std. 4WD) ed, Gas or Dual Fuel Diesel ed, Diesel ed, Diesel ooled, Diesel d, Diesel

Note 1: Weight and performance shown represent typical machines, and should be used as a general guideline only. Many variables between machines can lead to significant differences in these factors. Accurate figures, when necessary for a particular application, can best be determined by testing of the specific machine.

Page iv

Page 6

MACHINE DIAGRAMS

RANGE DIAGRAM

ANGLE	-19°	0 °	15°	30 °	45°	60°	70 °
REACH	17' 8"	18' 7"	17' 5"	14' 8"	10' 7"	5' 5"	1' 7"
RETRACTED	5.38 M	5.66 M	5.30 M	4.47 M	3.22 M	1.65 M	.48 M
HEIGHT	2' 6"	10' 3"	16' 5"	22' 2"	26' 11"	30' 6"	32' 1"
RETRACTED	0.76 M	3.12 M	5.00 M	6.75 M	8.20 M	9.29 M	9.77 M
REACH	46' 1"	48' 7"	46' 5"	40' 8"	32' 11"	20' 5"	11' 11"
EXTENDED	14.04 M	14.80 M	14.14 M	12.39 M	9.70 M	6.22 M	3.63 M
HEIGHT	-7' 0"	10' 3"	24' 3"	37' 2"	48' 2"	56' 6"	60' 0"
EXTENDED	-2.13 M	3.12 M	7.39 M	11.32 M	14.68 M	17.22 M	18.28 M

Side reach measured from center of rotation.

Page 7

GENERAL ARRANGEMENT DIAGRAM

November 1996

Page 8

SECTION 1: SAFETY

Page 9

TABLE OF CONTENTS, SECTION 1

Safety Symbols
Safety Rules and Precautions
Safety-Related Decals
Safety and Control Decal Locations	1-16
Safety and Control Decal Descriptions	1-17

Page 10

SAFETY SYMBOL

SAFETY SYMBOLS

This manual contains important information on the safe use of your SIMON Self-Propelled Aerial Work Platform. Your failure to read, understand and follow all safety rules, warnings and instructions will unnecessarily expose you and others to dangerous situations. For your safety and the safety of those around you, you must operate your aerial work platform as instructed in this manual.

You, the operator, are the single most important factor for safety when using any piece of equipment. Learn to operate your work platform in a safe manner.

To help you recognize important safety information, we have identified warnings and instructions that directly impact on safety with the following signals:

A DANGER

"DANGER" INDICATES AN IMMINENTLY HAZARDOUS SITUATION WHICH, IF NOT AVOIDED, WILL RESULT IN DEATH OR SERIOUS INJURY. THIS SIGNAL WORD IS TO BE LIMITED TO THE MOST EXTREME SITUATIONS.

"WARNING" INDICATES A POTENTIALLY HAZARDOUS SITUATION WHICH, IF NOT AVOIDED, COULD RESULT IN DEATH OR SERIOUS INJURY.

A CAUTION

"Caution" indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. It is also used to alert against unsafe practices and for property-damage-only situations.

One final note: The best method to protect yourself and others from injury or death is to use common sense. If you are unsure of any operation, don't start until you are satisfied that it is safe to proceed.

Page 11

SAFETY RULES AND PRECAUTIONS

• 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 (3.05 M) 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 (30.5 cm) 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.

Read and understand all safety and control information found on the machine and in this manual before operating the machine.
Only trained, competent personnel should operate the aerial work platform.
Be aware of all Government and Local rules which may apply to this machine and its safe operation.
Approved safety belts must be worn at all times when operating the machine from the platform. In addition, approved headgear and other protective equipment must be worn as required. (In the U.S.A., OSHA approved equipment is required. For other countries, the appropriate equivalent government body should be consulted.)
NEVER fasten safety belt to an adjacent structure while on the work platform.
Make sure that entry gate to platform is secured before operating the machine from the platform.
DO NOT block the foot pedal or any function control in the operating position.
DO NOT exceed the platform capacity of the machine in any configuration. Review the section titled "MACHINE SPECIFICATIONS", earlier in this manual, regarding this model's capacities and dimensions.

Page 12

SAFETY RULES AND PRECAUTIONS

SAFETY RULES AND PRECAUTIONS (CONTINUED)

A DANGER

SECURE all tools and other loose items to prevent injury to persons working on or below the work platform.
DO NOT use scaffolding, ladders or similar items to extend your reach while on the work platform.
DO NOT attempt to climb down the boom assembly, if the machine fails while the operator's platform is raised or extended.
Since the machine may be operated from its ground controls, precautions should be taken to prevent unauthorized personnel from operating the work platform with the around controls while the platform is in use.
The "UNPOWERED EMERGENCY MOVEMENT" procedure (described later in this manual) requires releasing the torque hubs, which results in there being no means to stop the machine's travel. Simon recommends using this procedure only in cases of emergency, and only for a short distance. Be on guard against machine runaway on sloping surfaces. Movement speed shall not exceed 1 M.P.H. (1.6 K.P.H.).
DO NOT attempt to open any hydraulic line or component without first relieving all system pressures and shutting off fluid flow from the tank.
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.
DO NOT alter, modify or disable any safety devices or interlocks.
DO NOT refuel the machine near sparks or open flames. Gasoline and propane vapors, and Diesel fuel fumes are highly explosive.
DO NOT use the aerial work platform outdoors in electrical storms or in high wind situations.
DO NOT raise the aerial work platform unless the machine is on a firm, level surface.

Page 13

SAFETY RULES AND PRECAUTIONS (CONTINUED)

Use caution to prevent ropes, cords, hoses, etc. from becoming entangled in the machine's boom sections when being raised, lowered or repositioned.
Ensure that the area surrounding the mobile platform is clear of personnel and equipment before: driving the machine; or raising, lowering or extending the boom; or swinging the superstructure; or, rotating or tilting the platform.
Maintain a safe distance from overhead and ground obstacles, debris, drop-offs, holes, depressions, electrical wires and other hazards to travel.
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.
DO NOT sit, stand or climb on platform rails.
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.

Complete the "Operational Checklists" found in this manual (see Table of Contents) at designated intervals.
Ensure that the machine is in "LOW" drive speed while unloading from a truck or trailer.
Always attach the machine to a winch when loading or unloading from a truck or trailer. Simon does not recommend unassisted loading or unloading of any aerial work platform.
With the platform swung away from the stowed position, use caution when selecting travel or steering direction. Travel and steer direction will be opposite switch or lever movement. Refer to the large "FORWARD" arrows on the undercarriage of the machine or the location of the superstructure lockpin hole for travel orientation.

Page 14

SAFETY RULES AND PRECAUTIONS

SAFETY RULES AND PRECAUTIONS (CONTINUED)

Check fuel system for leaks or damaged fuel lines before operating the machine. If any damage is found, contact your supervisor immediately. Machine shall be removed from service until diagnosis and any necessary repairs have been completed.
Actuation of the red "EMERGENCY STOP" will apply brakes immediately, causing unexpected platform movement as the machine comes to a sudden stop. Brace yourself.
Whenever disengaging the drive torque hubs or before disconnection from towing vehicle, ensure that the machine cannot roll.
Immediately report any erratic noises, vibrations or malfunctions of the machine to your supervisor. Machine shall be removed from service until diagnosis and any necessary repairs have been completed.
Operating this equipment without all safety and control decals in place can be hazardous.

For transporting the machine, the platform must not be tied to the trailer bed in any way.
Be sure to turn all hydraulic valves back "ON" before starting the machine, or extensive pump damage will occur.
DO NOT exceed the maximum platform horizontal pull of 100 pounds (45.4 kg).
DO NOT use the boom or platform as a crane to lift oversized or hanging loads.
DO NOT raise, extend, retract, tilt, rotate, or lower the platform or booms into stationary objects, as this will cause damage to mechanical and hydraulic components.
DO NOT use the platform or boom functions to push or tow the machine or another vehicle.
Avoid sudden braking or steering, go slowly and leave more maneuvering room during cold weather operation until the machine is warm.

Page 15

SAFETY DELATED DECALS

10-145100 Decal "DANGER ELECTROCUTION"

10-130600 Decal, "DANGER" (ground station)

Page 1-8

Page 16

SAFFTY-RFI ATED DECALS (CONTINUED)

10-142100 Decal, "DANGER" (platform station)

Page 17

SAFETY-RELATED DECALS (CONTINUED)

10-272600 Decal, "CAUTION, Safety Belt Lanyard"

Page 18

SAFETY-RELATED DECALS (CONTINUED)

OPEN HYDRAULIC TANK VALVES BEFORE STARTING ENGINE

10012600

SAFETY RELATED DECALS

10-012600 Decal, "Open Hydraulic Tank Valves ."

ENSURE LOCKPIN IS DISENGAGED BEFORE OPERATING SWING FUNCTION

10-007200 Decal, "Ensure Lockpin Is Disengaged . "

10-012900 Decal, "FORWARD" Arrow

10-148300 Decal, Platform Capacity

Page 19

SAFETY-RELATED DECALS (CONTINUED)

HYDRAULIC FLUID ONLY 10151300

10-151300 Decal, "Hydraulic Fluid Only"

GASOLINE ONLY

10-117900 Decal, "Gasoline Only" (for versions with gasoline engines)

DIESEL FUEL ONLY

10-151100 Decal, "Diesel Fuel Only" (for versions with gasoline engines)

Page 1-12

SAFETY RELATED DECALS

Page 20

10-264200 Decal, Ground Electrical Controls

10-115800 Decal, "Glow Plug Indicator"

Page 21

SAFETY-RELATED DECALS (CONTINUED)

10-265200 Decal, Remote Pendant Control

10-272100 Decal, Function Power

Page 1-14

SAFETY RELATED DECALS

Page 22

SAFETY RELATED DECALS

SAFETY-RELATED DECALS (CONTINUED)

10-278100 Decal, Platform Controls

10-139800 Decal, "Operator's Manual Enclosed"

Page 23

SAFETY AND CONTROL DECAL LOCATIONS

OPERATING THIS EQUIPMENT WITHOUT ALL SAFETY AND CONTROL DECALS IN PLACE CAN BE HAZARDOUS.

If any of these items are damaged or missing, replace them immediately. Decals are shown for standard machine. Optional equipment may change the decal locations.

Page 24

SAFETY AND CONTROL DECAL DESCRIPTIONS

ltem No.	Part Number	Description	Qty.
			-
1	10-130600	Decal, "DANGER", Ground Station	1
2	10-145100	Decal, "DANGER", Electrocution	2
3	10-142100	Decal, "DANGER", Platform	1
4	10-272600	Decal, "CAUTION, Safety Belt Lanyard"	1
5	10-094700	Decal, "CAUTION, Hot Water "
		(for versions with liquid cooled engine)	1
6	10-094900	Decal, "CAUTION, Rotating Fan "
		(for versions with liquid cooled engine)	1
7	10-012600	Decal, "Open tank valves"	1
8	10-007200	Decal, "ENSURE LOCKPIN IS DISENGAGED "	2
9	10-264200	Placard, Ground Electrical Controls	1
10	10-148300	Decal, "CAPACITY 500 LBS (225 kg)", Small	2
11	10-265200	Placard, Remote Pendant Controls	1
12	10-272100	Decal, "Function Power"	1
13	10-115800	Decal, "Glow Plug Indicator"	1
14	10-151100	Decal, "DIESEL FUEL ONLY" (Diesel engine option)	1
	10-117900	Decal, "GASOLINE ONLY" (Gasoline engine option)	1
15	10-012900	Decal, "FORWARD" Arrow	2
16	10-151300	Decal, " Hydraulic Fluid Only "	1
17	10-278100	Placard, "Platform Control"	1
18	10-139800	Decal, "Operator's Manual Enclosed"	1
19	10-121600	Decal, "Made in U.S.A."	1

SAFETY AND CONTROL DECAL DESCRIPTIONS

Page 25

SAFETY AND CONTROL DECAL LOCATIONS (CONTINUED)

OPERATING THIS EQUIPMENT WITHOUT ALL SAFETY AND CONTROL DECALS IN PLACE CAN BE HAZARDOUS.

If any of these items are damaged or missing, replace them immediately. Decals are shown for standard machine. Optional equipment may change the decal locations.

Page 26

SAFETY AND CONTROL DECAL DESCRIPTIONS (CONTINUED)

ltem No.	Part Number	Description	Qty.
1	10-130600	Decal, "DANGER", Ground Station	1
2	10-145100	Decal, "DANGER", Electrocution	2
3	10-142100	Decal, "DANGER", Platform	1
4	10-272600	Decal, "CAUTION, Safety Belt Lanyard"	1
5	10-094700	Decal, "CAUTION, Hot Water"
		(for versions with liquid cooled engine)	1
6	10-094900	Decal, "CAUTION, Rotating Fan"
		(for versions with liquid cooled engine)	1
7	10-012600	Decal, "Open tank valves"	1
8	10-007200	Decal, "ENSURE LOCKPIN IS DISENGAGED"	2
9	10-264200	Placard, Ground Electrical Controls	1
10	10-148300	Decal, "CAPACITY 500 LBS (225 kg)", Small	2
11	10-265200	Placard, Remote Pendant Controls	1
12	10-272100	Decal, "Function Power"	1
13	10-115800	Decal, "Glow Plug Indicator"	1
14	10-151100	Decal, "DIESEL FUEL ONLY" (Diesel engine option)	1
	10-117900	Decal, "GASOLINE ONLY" (Gasoline engine option)	١
15	10-012900	Decal, "FORWARD" Arrow	2 .
16	10-151300	Decal, "Hydraulic Fluid Only "	1
17	10-278100	Placard, "Platform Control"	1
18	10-139800	Decal, "Operator's Manual Enclosed"	1
19	10-121600	Decal, "Made in U.S.A."	1

Page 27

OPERATION

SECTION 2: OPERATION

Page 28

Table of Contents, Section 2

Unloading Procedures Primary Machine Components	2-3 2-5
Ground Controls	2-6
Remote Pendant Control	2-10
Platform Controls	2-14
Start-Up Procedures
Shift Checks	2-20
Machine Start-Up	2-21
Ground Operation and Checks	2-22
Platform Operation and Checks	2-26
Operation	0.01
Cold Weather Operation	2-31
Driving and Steering	2-32
Braking	2-32
Booms, Superstructure and Platform	2-33
Gasoline Engine Operation	2-33
Dual Fuel Engine Operation	2-34
Diesei Engine Operation	Z-34
Shui-Down Plocedules	2-30
	2.36
Towing Plocedules	2-30
Emorgonov System and Drocedures	2-07
	2-40
Lincigency Fullip	2-40
Emergency Lowering	2-42

Page 2-2

Page 29

UNLOADING PROCEDURES

TO AVOID A SERIOUS PERSONAL INJURY OR DEATH, ENSURE THAT THE MACHINE IS IN "LOW" DRIVE SPEED WHILE UNLOADING FROM A TRUCK OR TRAILER.

Inspect the outside of the machine for damage (including the underside). Inspect all hoses, boom sections and cables for chafing or road damage. Confirm that all wheel lug nuts and swing bearing bolts are tight (refer to specifications).
Remove the pin that locks the superstructure to the undercarriage near the swing bearing. Stow the lock pin in the location provided nearby.
Unlock and open both side compartment doors. Inspect all fuel, electrical and hydraulic connections for damage and security.
Connect battery cables to batteries if required. Check electrolyte level.
Open the fuel tank valve and check fuel level.
Check engine oil level, and add as required per engine manufacturer's recommendations.
Check fluid level at the sight gauge on the hydraulic tank, and add fluid as required (see Lubrication Chart). Check that shutoff valves on the hydraulic tank are open.
Close side compartment doors.
Attach the machine to a winch for the unloading procedure.

ALWAYS ATTACH THE MACHINE TO A WINCH WHEN LOADING OR UNLOADING FROM A TRUCK OR TRAILER. CONNECT WINCH CABLE TO THE TIE DOWN LUGS ON THE UNDERCARRIAGE. UNASSISTED LOADING OR UNLOADING OF ANY MOBILE PLATFORM IS NOT RECOMMENDED.

READ AND UNDERSTAND ALL SAFETY, CONTROL AND OPERATING INFORMATION FOUND ON THE MACHINE AND IN THIS MANUAL BEFORE OPERATING THE MACHINE.

Page 30

UNLOADING PROCEDURES (CONTINUED)

• Switch the "GROUND/ PLATFORM" key switch to "GROUND". Start engine, using the ground controls.

NOTE: Refer to Startup Procedures and Operator Controls Descriptions in this section.

While pressing the "FUNCTION POWER" button on the remote pendant controls, press and hold a boom function toggle. This is called "deadheading", and will lead to maximum system pressure registering on the gauge at the ground control valve assembly. Check the hydraulic pressure (see Machine Specifications). Turn off engine.

Remove all machine tie downs (see Transporting the Machine). Remove wheel chocks, if used. Switch the "GROUND/ PLATFORM" key switch to "PLATFORM".
Enter the platform, and restart the engine using the platform controls. Select the "OPERATING" engine speed, and test all platform functions.
Raise the boom so that the platform will clear any obstacles as the machine is driven down the loading ramp.
Carefully drive the machine off the truck or trailer with the assistance of a winch.

NOTE: The brakes are automatically released for driving, and will automatically apply when the machine stops.

• Before placing the machine into service, all operators must read and understand the contents of this Operator's Manual.

Upon initial unloading of the machine the "Receipt Inspection Adjustment Report" or "Predelivery Inspection Adjustment Report" must be completed and returned in order to activate the Simon Limited Warranty.

An Operator's Manual and a "Receipt Inspection Adjustment Report" are included with each machine leaving the factory.

Page 31

Left Hand Side.

Page 32

OPERATOR CONTROLS

OPERATOR CONTROLS (GROUND CONTROLS)

Page 33

OPERATOR CONTROLS

OPERATOR CONTROLS DESCRIPTION (GROUND CONTROL)

ltem	Control	Location	Description
1.	Circuit Breaker	On Ground Console Panel	Pops out when the 12 Volt electrical circuit is over- loaded. Push in to reset.
2.	Choke/ Glow Plug Button	On Ground Console Panel	Choke button for gas or dual fuel engines. Press and hold while starting a cold engine.
			Glow plug button for some Diesels. Press and hold (if so equipped) to preheat combustion chamber before starting a cold engine.
3.	Main Power Key Switch	On Ground Console Panel	Three position main power "ON/ OFF" switch. Straight up position is "OFF".
			Turn key left (counterclockwise) one position to turn power "ON" for ground control operation. Turn key right (clockwise) one position to turn power "ON" for plat- form control operation.
			With key switch "OFF", the key may be removed to prevent unauthorized operation.
4.	Engine Start Button	On Ground Console Panel	Press push button to engage engine starter. Release button immediately upon engine start.
			NOTE: Main power key switch must be in "GROUND" position.
5.	Hour Meter	On Ground Console Panel	Indicates total elapsed time that the engine has been operated in hours and tenths.
6.	Volt Meter	On Ground Console Panel	Indicates electrical system voltage.
7.	Engine Oil Pres- sure Gauge	On Ground Console Panel	Indicates engine oil pressure.
8.	Hydraulic Fluid Pressure Gauge (Not shown)	Beneath Ground Valves	Indicates hydraulic fluid pressure.

Page 34

OPERATOR CONTROLS (GROUND CONTROLS, CONTINUED)

November 1996

Page 35

OPERATOR CONTROLS

OPERATOR CONTROLS DESCRIPTION (GROUND CONTROLS, CONTINUED)

ltem	Control	Location	Description
9.	Gas/ Off/ Propane Switch (Optional)	On Ground Console Panel	Flip toggle up to use gasoline, down to use propane. In "OFF" position, the engine does not get fuel supply.
10.	Engine Coolant Temperature Gauge (Not shown)	On Ground Console Panel	Indicates engine coolant temperature, if so equipped.
11.	Steer Wander Control Valve (Not shown)	Near Ground Console Panel	Available with optional tow package only. Pull valve knob out to allow the steering to be free wheeling. Push valve knob in to engage steering.
12.	Engine Throttle Switch	On Ground Console Panel	Flip toggle to down for low (idle) engine speed, up for mid range (operating) engine speed for generator use.

Page 36

OPERATOR CONTROLS

Page 2-10

OPERATOR CONTROLS (REMOTE PENDANT CONTROLS)

Control operation direction shown here in relation to "FORWARD" arrow on undercarriage. Superstructure and undercarriage lock pin holes line up when nightform controls face "FORWARD" ner arrow.

Page 37

DPERATOR CONTROLS

OPERATOR CONTROLS DESCRIPTION (REMOTE PENDANT CONTROLS)

ltem	Control	Location	Description
1.	Emergency Stop Button	On Remote Pendant Control	Used to stop all functions in an emergency. Push for emergency stop. Pull or rotate clockwise to reset, depending on style used.
2.	"Function Power" Button	On Remote Pendant Control	Press and hold to activate main hydraulic pump, enabling operation of hydraulic functions (drive, steer, or boom movement) from ground.
3.	Steer Toggle	On Remote Pendant Control	Push to left and hold to turn steer wheels to left, right to turn to right. To straighten wheels, push and hold switch in opposite direction.

WITH THE PLATFORM OVER THE STEERING WHEELS, USE CAUTION WHEN SELECTING THE STEERING DIRECTION. STEER DIRECTION WILL BE OPPOSITE SWITCH MOVEMENT. SEE DIAGRAM, FACING PAGE.

4. Drive Toggle On Remote Pendant Control Push up and hold to drive forward, and down to drive in reverse. Machine will travel at low speed with booms stowed, but only at slower "creep" speed when booms are raised or extended.

WHEN THE PLATFORM IS SWUNG OVER THE STEER-ING WHEELS, USE CAUTION WHEN SELECTING THE TRAVEL DIRECTION. TRAVEL DIRECTION WILL BE OPPOSITE SWITCH MOVEMENT. SEE DIAGRAM, FACING PAGE.

Page 38

OPERATOR CONTROLS

OPERATOR CONTROLS (REMOTE PENDANT CONTROLS, CONTINUED)

Control operation direction shown here in relation to "FORWARD" arrow on undercarriage. Superstructure and undercarriage lock pin holes line up when platform controls face "FORWARD" per arrow.

Page 39

OPERATOR CONTROLS

OPERATOR CONTROLS DESCRIPTION (REMOTE PENDANT CONTROLS, CONTINUED)

ltem	Control	Location	Description
5.	Emergency Pump Button	On Remote Pendant Control	Press down and hold to activate battery powered emergency hydraulic pump, allowing operation of hydraulic functions (drive, steer or boom movement) from the ground controls should the engine powered hydraulic pump be disabled.
6.	Swing Toggle	On Remote Pendant Control	Push and hold left to swing the superstructure left (counterclockwise) and to the right to swing the superstructure right (clockwise).
7.	Boom Extend/ Retract Toggle	On Remote Pendant Control	Push up and hold to extend main boom, and down to retract main boom.
8.	Main Boom Toggle	On Remote Pendant Control	Push down and hold to raise main boom, and up to lower main boom.

Page 40

November 1996

Page 41

Page 2-15

OPERATOR CONTROLS

MP 60 SIMCON OPERATOR'S MANUAL

OPERATOR CONTROLS DESCRIPTION (PLATFORM CONTROLS)

ltem	Control	Location	Description
1.	Emergency Stop Button	On Platform Console Panel	Used to stop all functions in an emergency. Push for emergency stop. Pull or rotate clockwise to reset, depending on style used.
			When the button is reset, the engine distress light will flash three times and the chassis tilt alarm will sound three times. If any of these indications do not occur at reset, do not operate machine
2.	Off/ On/ Start Toggle	On Platform Console Panel	Three position toggle switch. Up is "OFF". Move to center position to turn ignition "ON", down to engage starter. If the engine does not start within 10 seconds, switch must be turned off and then on again to start.
			IMPORTANT: Engine will not start with foot switch depressed.
3.	Glow Plug/ Choke/ Idle/ Operating Speed	On Platform Console Panel	Flip toggle to center position for low (idle) engine speed, up for mid range (operating) engine speed for generator use.
	(Engine Throttle)		Choke toggle for gas or dual fuel engines. Press and hold while starting a cold engine.
			Glow plug toggle for some Diesels. Press and hold (if so equipped) to preheat combustion chamber before starting a cold engine.
4.	Emergency Pump Push Button	On Platform Console Panel	Press and hold to activate battery powered hydraulic pump, allowing operation of boom or platform func- tions should the engine powered hydraulic pump be disabled.
5.	Engine Distress Light	On Platform Console Panel	Red light indicates low engine oil pressure, high engine coolant temperature or broken fan belt (if so equipped). Engine will shut down automatically if condition does not correct itself in approximately 10 seconds.

Page 42

Page 2-16

Page 43

OPERATOR CONTROLS

OPERATOR CONTROLS DESCRIPTION (PLATFORM CONTROLS, CONTINUED)

ltem	Control	Location	Description
6.	Boom Extend/ Retract Lever	On Platform Console Panel	Lever controls the boom extend/ retract function. Pull back to extend boom. Push forward to retract boom. Boom speed will be proportional to handle movement.
7.	Boom Lift and	On Platform Console Panel	Dual function lever.
	Swing Level		Push lever forward to raise main boom. Pull lever back to lower main boom. Boom speed will be proportional to handle movement.
			Push lever to right to swing superstructure to right (counterclockwise). Push lever to left to swing left (clockwise). Superstructure can rotate 360° continuously in either direction. Swing speed will be proportional to handle movement.
8.	Platform Rotate Toggle	On Platform Console Panel	Press and hold switch to left to rotate platform to left (counterclockwise). Press and hold switch to right to rotate platform right (clockwise). One speed only.
9.	Platform Leveling Toggle	On Platform Console Panel	Press and hold switch forward to tilt platform forward. Press and hold switch back to tilt platform backward. One speed only.
10.	Drive Lever	On Platform Console Panel	Lever controls forward and reverse travel of machine at a speed proportional to handle movement. (Engine

WITH PLATFORM SWUNG OVER STEERING WHEELS, USE CAUTION WHEN SELECTING THE TRAVEL DIRECTION. TRAVEL DIREC-TION WILL BE OPPOSITE DRIVE LEVER MOVEMENT.

Page 44

Page 2-18

Page 45

OPERATOR CONTROLS

OPERATOR CONTROLS DESCRIPTION (PLATFORM CONTROLS, CONTINUED)

ltem	Control	Location	Description
11.	Steer Switch	On end of Drive Lever	Move switch left and hold to turn steer wheels to left, and right to turn steer wheels to right. Push and hold in opposite direction to straighten wheels.
			WITH PLATFORM SWUNG OVER THE STEER- ING WHEELS, USE CAUTION WHEN SE- LECTING THE STEERING DIRECTION. STEER- ING DIRECTION WILL BE OPPOSITE STEER SWITCH MOVEMENT.
12.	Function Speed Toggle	On Platform Console Panel	Press toggle up for "HIGH" function speed, down for "LOW" function speed for all proportional functions (boom, swing, drive). High speed travel is available only while boom is below horizontal and extended less than 3 feet (0.9 Meters).
13.	Horn Button	On Platform Console Panel	Press button to sound warning horn.
14.	Light Toggle (Optional)	On Platform Console Panel	Flip toggle to turn head lights on and off (if so equipped).
15.	Sensor Override Button (Optional)	On Platform Console Panel	Press button to override the position sensor (if so equipped).
16.	Foot Switch	On Platform Floor	Must be depressed to activate main hydraulic pump, allowing operation of any hydraulic function (drive, steer, boom or platform movement) from the platform. Depress foot switch before selecting function. (Engine automatically shifts to mid range for all functions.)

Page 46

START-UP PROCEDURES

SHIFT CHECKS

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

Refer to checklists 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, flat or damaged tires, etc. Both compartment doors can be opened to inspect components inside.
Check engine oil and fuel levels.
Check engine coolant level (with liquid cooled engines).
____ Check volt meter on ground controls for battery condition, battery electrolyte level and wire connections.
Check hydraulic fluid level with booms fully retracted and lowered.
____ Check that all shutoff valves on the hydraulic tank are "OPEN". When open, valve handles will be parallel with the length of the valve.

The shutoff values on the hydraulic tank must be left open at all times, except during repairs or transport. If one or more of these values are closed when the machine is running, extensive pump damage will occur.

Check wheel lug nuts tightness. Check tire pressure (see Machine Specifications).
____ Check hoses for worn areas.
____ Check hose carrier to make sure that it is not bent or sagging.
____ Check platform rails and safety gate latch for damage.
____ Check pivot pins for security.
____ Check that all warning and instructional labels are legible and secure.

START-UP PROCEDURES

Page 47

MACHINE STADT-IID

MP 60 SIMCON OPERATOR'S MANUAL ERSTAND THE IANUAL PRIOR MUST BE PER-"SAFETY PULLES AND PRECALITIONS" SECTION OF THIS MANUAL PRIOR

A COMPLETE VISUAL INSPECTION OF THE MACHINE MUST BE PER-FORMED PRIOR TO OPERATIONAL CHECKS

Disengage lock nin before swinging the superstructure
Ensure that "EMERGENCY STOP" buttons on remote pendant control and platform control console panel are disenaaaed. Pull out or twist to reset, depending on style.
Turn the main power key switch to the "GROUND" position to energize the electrical svstem.
While starting a cold aasoline or dual fuel engine, press choke button.

For some optional Diesel engines, press alow plug button, and hold it there for 30 to 45 seconds prior to engaging starter motor.

Press and hold engine start button on around control box to start engine.
Press and hold the "FUNCTION POWER" button on the remote pendant control and "BOOM UP" togale. This is called "deadheadina", and will lead to maximum compensator setting of the pump system pressure registering on the gauge at the around control valve bank assembly.
Check that the hydraulic pressure on the gauge is as stated in the Machine Specifications of this manual.

Page 48

GROUND OPERATION AND CHECKS

BE SURE BOOM TRAVEL AREA IS CLEAR OF OBSTRUCTIONS.

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

Select "GROUND CONTROLS" with the "GROUND/ PLATFORM" key switch.
While pressing the "FUNCTION POWER" button on the remote control pendant, press and hold the "BOOM" toggle to the "UP" position to raise the boom to the horizontal position or slightly above. Release the "BOOM" toggle.
- ____ Listen for any unusual noises.
- Check for any vibration while the boom travels up.
- Check for uneven or jerky operation.
- Check for hydraulic leaks.
Press and hold the boom "EXTEND/ RETRACT" toggle on the remote control pendant to the "EXTEND" position. Extend the boom to the end of its travel.
- Listen for any unusual noises.
- Check for any vibration while the boom extends.
- Check for uneven or jerky operation.
- Check for hydraulic leaks.
Release the "FUNCTION POWER" button and "EXTEND/ RETRACT" toggle.
Inspect the boom sections visually for any damage along their entire lengths.
Push down on each of the three fastened corners of the tilt alarm located on the back side of the ground control bracket. The alarm should sound as each corner is pressed beyond 5 degrees.

START-UP PROCEDURES

Page 49

START-UP PROCEDURES

GROUND OPERATION AND CHECKS (CONTINUED)

While pressing the "FUNCTION POWER" button on the remote pendant control, press and hold "BOOM" toggle to the "UP" position. Raise the boom to the end of its travel. Then, release the "BOOM" toggle.
- Listen for any unusual noises.
- Check for any vibration while the boom travels up.
- Check for uneven or ierky operation.
- Check for hydraulic leaks.
- Visually confirm that the platform has remained level during boom travel.
- Report to supervisor and repair any problem.
Press and hold the "BOOM" toggle to lower the boom slightly.
Press the "EMERGENCY STOP" button. All machine functions must stop, including the engine. Pull the button out or twist to reset. Release the "FUNCTION POWER" button.

With the engine off,

Press the "EMERGENCY" button.
Press and hold the "BOOM" toggle to lower the boom slightly.
- ____ Listen for any unusual noises.
- Check for any vibration while the boom travels down.
- Check for uneven or jerky operation.
- Check for hydraulic leaks.
Once boom movement has been established using the emergency pump, release the "EMERGENCY" button and "BOOM" toggle. Restart engine.
Return the booms to their stowed positions by using the appropriate toggles for "RETRACT" and "DOWN" correspondingly, and the "FUNCTION POWER" button.
- _____ Listen for any unusual noises.
- Check for any vibration while the booms lower and retract.
- Check for uneven or jerky operation.
- Check for hydraulic leaks.
- _____ Report to supervisor and repair any problem.

Page 50

GROUND OPERATION AND CHECKS (CONTINUED)

Operate the "SWING" toggle in each direction while holding the 'FUNCTION POWER" button.
- Listen for any unusual noises.
- Check for any vibration while the machine rotates.
- Check for uneven or jerky operation.
- Check for hydraulic leaks.
- Report to supervisor and repair any problem.
Release the "SWING" toggle.

TAKE EXTREME CARE WHEN SELECTING ANY OF THE TRAVEL FUNCTIONS FROM THE REMOTE CONTROL PENDANT.

WITH THE PLATFORM SWUNG OVER THE STEERING WHEELS, TRAVEL AND STEERING DIRECTION WILL BE OPPOSITE TO DIRECTIONS INDI-CATED ON PLACARD.

Press the "DRIVE" toggle to the "DRIVE FORWARD" position. The machine will move forward.
- ____ Listen for any unusual noises.
- Check for any vibration while the machine travels.
- Check for uneven or jerky operation.
- Check for hydraulic leaks.
- ____ Report to supervisor and repair any problem.
Release the "DRIVE" toggle.

Page 2-24

START-UP PROCEDURES

Page 51

Push the "STEER" toggle in the left or right direction, and check for proper steering control. Note position of the platform to the steering wheels.
Return the wheels to the straight ahead position by pressing the "STEER" toggle in the opposite direction. When wheels are straight, release the "STEER" toggle and "DEADMAN" button.
Press the "EMERGENCY STOP" button. All functions (including the engine) must stop immediately. Pull the button out or twist to reset. Restart engine.
Press the "DRIVE" toggle to "DRIVE REVERSE" while holding the "FUNCTION POWER" button. The machine will move in the backward direction.
Release the "DRIVE" toggle. The unit must come to a complete stop.
Return the machine to the stowed position by pressing the appropriate toggle switches correspondingly, as well as the "FUNCTION POWER" button.
Shut the engine off.

Page 52

PLATFORM OPERATION AND CHECKS

Complete Ground Operation Checks before performing Platform Operation Checks.
Select "PLATFORM CONTROLS" with the "GROUND/ PLATFORM" key switch.
Enter the platform. Close gate securely.
Ensure that the "EMERGENCY STOP" button is released.
Move "OFF/ ON/ START" toggle to center position to turn ignition "ON", down to engage starter, then release it to the "ON" position.
Flip the "ENGINE THROTTLE" toggle to "OPERATING SPEED".

BE SURE BOOM TRAVEL AREA IS CLEAR OF OBSTRUCTIONS.

DO NOT OPERATE THE MACHINE IF THESE CHECKS REVEAL ANY DEFECT OR ABNORMALITY.

Press the "HORN" button briefly to check that the horn works. The horn also acts as a signal for the tilt alarm as well as its normal warning function.
Depress the foot switch mounted on the floor of the platform. (Activate foot switch to operate any of the machine functions.)
Slowly move the "BOOM/ SWING" lever forward to the "BOOM UP" position. The boom will start to rise. Function speed will be proportional to handle movement. Raise the boom to the horizontal position. Slowly return the lever to the center position.
Slowly move the "EXTEND/ RETRACT" lever back to the "EXTEND" position. Extend boom out a short distance. Extend speed will be proportional to handle movement.
- Listen for any unusual noises.
- Check for any vibration while the boom telescopes out.
- Check for uneven or jerky operation.
- Check for hydraulic leaks.
- Report to supervisor and repair any problem.

START-UP PROCEDURES

Page 53

START-UP PROCEDURES

PLATFORM OPERATION AND CHECKS (CONTINUED)

Slowly return the lever to the center position.
Slowly move "BOOM/SWING" lever forward to "BOOM UP" position. The boom will start to rise. Function speed will be proportional to handle movement.
- Listen for any unusual noises.
- Check for any vibration while the main boom travels up.
- Check for uneven or jerky operation.
- Check for hydraulic leaks.
- Report to supervisor and repair any problem.
Slowly return the lever to the center position.
Return the booms to the travel position by slowly operating the levers in the "RETRACT" and "BOOM DOWN" directions correspondingly.
- ____ Listen for any unusual noises.
- Check for any vibration while the booms lower and retract.
- Check for uneven or jerky operation.
- ____ Check for hydraulic leaks.
- Report to supervisor and repair any problem.
Slowly return the levers to their center positions.
Slowly move the "BOOM/ SWING" lever right to swing right (counterclockwise) and left to swing left (clockwise). Swing speed will be proportional to handle movement.
- Listen for any unusual noises.
- Check for any vibration while the superstructure rotates.
- ____ Check for uneven or jerky operation.
- Check for hydraulic leaks.
- Report to supervisor and repair any problem.
Slowly return the lever to the center position.
Operate the platform rotate function by moving the "PLATFORM ROTATE" toggle. Move the toggle in both directions.
- _____ Listen for any unusual noises.
- Check for any vibration while the platform rotates.
- ____ Check for uneven or jerky operation.
- Check for hydraulic leaks.
- ____ Report to supervisor and repair any problem.

Page 54

PLATFORM OPERATION AND CHECKS (CONTINUED)

Return the platform to the center position with the "PLATFORM ROTATE" togale.
Operate the platform level function by moving "PLATFORM LEVEL" toggle. Move the toggle in both directions.
- Listen for any unusual noises.
- Check for any vibration while the platform tilts forward or back.
- Check for uneven or jerky operation.
- Check for hydraulic leaks.
- Report to supervisor and repair any problem.
Return the platform to a level position with the "PLATFORM LEVEL" toggle.
Switch the machine "FUNCTION SPEED" toggle to "LOW".

WITH THE PLATFORM SWUNG OVER THE STEERING WHEELS, USE CAUTION WHEN SELECTING THE TRAVEL DIRECTION. TRAVEL AND STEERING DIRECTION WILL BE OPPOSITE CONTROL OPERATION.

• Slowly move the "DRIVE" lever forward. The machine should smoothly accelerate in the forward direction.

Movement alarm sounds whenever the machine is in motion.

____ Listen for any unusual noises.
Check for any vibration while the machine travels.
____ Check for uneven or jerky operation.
Check for hydraulic leaks.
Report to supervisor and repair any problem.

Page 55

Operate the "STEER" rocker switch and check for proper steering control. Note position of the platform to the steering wheels.
Return the wheels to the straight ahead position.
Slowly move the "DRIVE" lever backward. The machine will smoothly accelerate in the reverse direction.

Movement alarm sounds whenever the machine is in motion.

• Press "EMERGENCY STOP" button. All functions (including engine) must stop immediately.

BRACE YOURSELF FOR UNEXPECTED PLATFORM MOVEMENT BECAUSE THE MACHINE COMES TO A SUDDEN STOP.

ACTUATION OF THE "EMERGENCY STOP" BUTTON WILL APPLY BRAKES IMMEDIATELY!

• Reset "EMERGENCY STOP" button by turning or pulling, and restart engine.

Page 56

PLATFORM OPERATION AND CHECKS (CONTINUED)

• Raise the boom to above horizontal, and repeat the drive tests. Machine should travel a maximum of 0.5 M.P.H. (0.8 K.P.H.). This condition is referred to as "creep speed", and is the maximum rate of travel with the boom raised or extended.

NOTE: At "creep speed", a tire makes one complete revolution in approximately twenty (20) seconds. If one revolution takes much less than this time, the machine must be adjusted to bring the "creep speed" back down to 0.5 M.P.H (0.8 K.P.H.).

Return the machine to the straight ahead position, with boom below horizontal and fully retracted.
Switch the "MACHINE FUNCTION SPEED" toggle to "HIGH", and repeat the drive tests.
Move all levers and togales back to their neutral positions. Release the foot switch.

NOTE: All machine motion should stop upon release of the foot switch.

Move "OFF/ ON/ START" toggle to the "OFF" position to shut off the engine.
While pressing the "EMERGENCY PUMP" pushbutton, slightly raise the boom. Then return boom to stowed position.

Page 2-30

Page 57

DPERATION

OPERATION

DUE TO THE DESIGN OF THE SIMON MACHINE 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 ONLY ON THE TILT ALARM TO WARN YOU OF AN UNSAFE CONDITION.

SAFE OPERATION BEGINS WITH A SAFE OPERATOR.

Perform Start-Up Procedures. Remember to place the "GROUND/ PLATFORM" key switch in the "PLATFORM" position before entering the platform to operate the machine.

Enter platform, close and secure safety gate.

COLD WEATHER OPERATION

In below zero weather, the hydraulic fluid should be allowed to warm before full operation of the machine.
Check for water contamination of the fluid.
Check for and remove ice on the platform, swing gear teeth and steering linkage(s) prior to operation.
Check that all valve levers operate smoothly, and return freely to the neutral position.

Avoid sudden braking or steering, go slow and leave more maneuvering room during cold weather operation.

Page 58

DRIVING AND STEERING

ENSURE THAT THE ROUTE OF TRAVEL IS CLEAR OF PERSONNEL AND DEBRIS.

Depress the foot switch. Slowly push the "DRIVE" lever forward to provide forward travel, or pull the lever backward for reverse travel.

NOTE: The speed of the machine will be proportional to handle movement.

To steer, press the "STEER" rocker switch on the end of the drive lever to the left or right as required.

Although the machine can be driven with the platform positioned at either end of the machine, the operator may find driving easier when the platform is over the non-steering axle.

The stowed position can be identified by the large "Forward" arrows on the undercarriage, or by the line up of the lock pin holes. When driving with the platform over the opposite axle, remember that all directions given to the steer and drive controls will be reversed.

When descending a ramp (incline), it is necessary to control the travel speed. To slow the machine, move the drive lever slowly towards the center "neutral" position.

BRAKING

For parking, the brakes are automatically applied when the drive lever is in the center "neutral" position.

RELEASE OF THE DRIVE LEVER OR ACTUATION OF THE RED "EMERGENCY STOP" BUTTON WILL APPLY BRAKES IMMEDIATELY!

BRACE YOURSELF FOR UNEXPECTED PLATFORM MOVEMENT AS THE MACHINE COMES TO A SUDDEN STOP.

OPERATION

Page 59

DPERATION

BOOMS, SUPERSTRUCTURE AND PLATFORM

Depress the foot switch, then select the required function. Available functions are:

Boom UP or DOWN
Boom EXTEND or RETRACT
Superstructure swing LEFT or RIGHT
Platform level FORWARD or BACKWARD
Platform rotate LEFT or RIGHT

Each function can be selected by moving the appropriate lever or toggle in the proper direction.

NOTE: Function speeds will be proportional to the distance levers are moved.

Multiple control operation is possible by selecting more than one function at a time.

GASOLINE ENGINE OPERATION

• To start engine, press the "START" button and the "CHOKE" button (at ground station),

OR

press and hold the "ENGINE THROTTLE" toggle to "CHOKE" and the "OFF/ ON/ START" toggle to "START" (at platform).

• As soon as the engine starts, release both switches.

Page 60

DUAL FUEL ENGINE OPERATION

GASOLINE OPERATION

• Operate the machine as normal.

GASOLINE TO PROPANE SWITCHING

This switching can only be done from the ground controls. The machine should only be switched to propane while the engine is running.

Open valve on propane tank.
Turn dual "FUEL SELECTOR" switch on the ground controls to the "OFF" position. Allow the engine to run until it consumes the fuel in the carburetor bowl.
As soon as the engine starts to miss, turn the selector switch on the ground controls to the "PROPANE" position. Turn the fuel select control handle a quarter turn counterclockwise to unlock it, and push it in. Then, turn the handle clockwise to lock in position. The engine should run normally as soon as the switch engages and handle is pushed in.

PROPANE TO GASOLINE SWITCHING

This switching can only be done from the ground controls. The machine should only be switched to gasoline while the engine is running.

NOTE: When operating on propane, the engine will run for several seconds after the ignition is shut off. This allows the propane to clear the intake manifold.

Turn dual fuel selector switch on the ground control panel to the "OFF" position. Allow the engine to run until it consumes the propane in the intake manifold. ENGINE WILL STALL.
Turn the selector switch on the ground control panel to "GAS". Turn the fuel select control handle a quarter turn counterclockwise, and pull it out. Then turn it clockwise to lock in position, and restart engine. The engine will run normally.
Close valve on propane tank.

DIESEL ENGINE OPERATION

FOR DIESEL ENGINES EQUIPPED WITH GLOW PLUGS:

• Press the "GLOW PLUG" button (at platform or ground controls), and hold for 30 to 45 seconds (when the engine is cold) prior to engaging the starter motor.

Page 2-34

OPERATION

Page 61

SHUT-DOWN PROCEDURES

When finished with the machine, place the booms in the stowed position.
Park the machine on a level surface.
With all togales/ levers to "NEUTRAL" position, allow the engine to slow to idle speed.
Turn "OFF" the "GROUND/ PLATFORM" key switch. Remove key to prevent unauthorized operation.

Page 62

TRANSPORTING THE MACHINE

TOWING PROCEDURES

WITHOUT OPTIONAL TOWING PACKAGE:

• If optional towing package is not installed, refer to "UNPOWERED EMERGENCY MOVEMENT" in this section.

WITH OPTIONAL TOWING PACKAGE:

Securely attach the machine to a tow vehicle with the tow bar provided.
Disengage torque hubs:

WHENEVER DISENGAGING THE DRIVE TORQUE HUBS OR BEFORE DISCONNECTING FROM TOWING VEHICLE, ENSURE THAT THE MACHINE CANNOT ROLL.

Type 1: remove the plate in the center of the torque hub, turn the plate so that the boss faces in, then reinstall the plate.
Type 2: Push the plunger at the center of the torque hub in to disengage the hub. Two outer plungers will pop out.
Pull steer wander control valve, located near the ground controls, to allow steering wheels to track behind tow vehicle.

The tow vehicle must have sufficient braking capability in order to safely stop itself as well as the machine. Tow speed shall not exceed 3 MPH (4.8 KPH).

TRANSPORTING THE MACHINE

Page 63






Annual An		-

FRANSPORTING THE MACHINE

TRUCK OR TRAILER TRANSPORT

ALWAYS ATTACH THE MACHINE TO A WINCH WHEN LOADING OR UNLOADING FROM A TRUCK OR TRAILER. CONNECT WINCH CABLE TO THE TIE DOWN LUGS ON THE UNDERCARRIAGE.

UNASSISTED LOADING OR UNLOADING OF ANY MOBILE PLATFORM IS NOT RECOMMENDED.

1. Enter the platform, secure the safety gate, and start the engine using the platform controls. Select the engine "OPERATING SPEED".
2. Raise the boom to allow greater ground clearance so that the platform will clear any obstacles as the machine goes up the loading ramp.
3. Using a winch, carefully drive the machine onto the truck or trailer.
4. Lock the superstructure to the undercarriage by installing the lock pin provided.
5. Ensure that the boom is fully retracted and lowered. Next, use the platform level lever to rest the platform base on the bed of the truck or trailer, but do not apply pressure onto bed.

Page 64

TRUCK OR TRAILER TRANSPORT (CONTINUED)

To avoid damaging the machine, the platform MUST NOT be tied to the trailer bed in any way and should only REST on the bed.

6. The negative battery cables should be disconnected for long distance transport. It is recommended that the fuel and hydraulic tank values be closed as well.
7. Tie down locations are located on all four corners of the undercarriage. Use four (4) 1/2 inch, "Grade 7" chains from each of the tie down lugs, and run the chains as shown in the diagram below.

Ratchet type load binders are recommended. If using lever type load binders, wire or strap them shut, or wrap chains around them to prevent opening.

Page 65

Tie Down of Machine (Recommended Method).

Page 66

EMERGENCY SYSTEM AND PROCEDURES

IF THE MACHINE FAILS TO OPERATE WHEN THE PLATFORM IS RAISED OR EXTENDED, DO NOT ATTEMPT TO CLIMB DOWN THE BOOM ASSEMBLY. SERIOUS INJURY MAY RESULT.

EMERGENCY PUMP

The machine has an emergency pump which can be operated from the operator's platform or ground controls to safely return the platform to the ground position when the machine has lost engine/ pump power. Operation from the ground controls overrides platform controls .

Press and hold the "PUMP" toggle to "EMERGENCY" on the remote pendant control, OR
Press and hold the "EMERGENCY PUMP" button on the platform control console.

Select the proper function (boom retract, boom lower, or swing) as required to safely lower the platform to ground level.

To prevent the battery from completely discharging and the emergency pump from overheating, release the emergency pump button to allow a 30 second rest period after every 30 seconds of operation. Once the machine has been safely positioned, correct the cause of the failure before returning the machine to service.

UNPOWERED EMERGENCY MOVEMENT

• Every attempt should be made to restore engine/ pump power to the machine before using this procedure.

A DANGER

THIS PROCEDURE REQUIRES RELEASING THE VEHICLE BRAKES, WHICH RESULTS IN NO MEANS TO STOP THE MACHINE'S TRAVEL. SIMON RECOMMENDS USING THIS PROCEDURE ONLY IN CASES OF EMER-GENCY, AND ONLY A SHORT DISTANCE.

BE AWARE OF MACHINE RUNAWAY ON SLOPING SURFACES. MOVE-MENT SPEED SHALL NOT EXCEED 1 M.P.H. (1.6 K.P.H.).

Page 67

UNPOWERED EMERGENCY MOVEMENT (CONTINUED)

1. Secure the machine with chains or ropes.

The machine is equipped with the down lugs (front and rear of undercarriage) that can be used for towing the machine. The chains or ropes must be of sufficient capacity to move the machine.

ALWAYS CHOCK THE WHEELS BEFORE YOU RELEASE THE BRAKES TO PREVENT UNEXPECTED MACHINE MOVEMENT ON SLOPES.

2. Chock wheels.
3. Disengage torque hubs:

WHENEVER DISENGAGING THE DRIVE TORQUE HUBS OR BEFORE DIS-CONNECTION FROM TOWING VEHICLE, ENSURE THAT THE MACHINE CANNOT ROLL.

Type 1: remove the plate in the center of the torque hub, turn the plate so that the boss faces in, then reinstall the plate.
Type 2: Push the plunger at the center of the torque hub in to disengage the hub. Two outer plungers will pop out.
4. Disconnect steer cylinder.

After unchocking the wheels, the machine will be ready to be moved.

After engine/ pump power has been restored to the machine, engage the torque hubs, reset the brake circuit needle valve, and connect steer cylinder. The machine is now ready for normal operation.

Page 68

EMERGENCY LOWERING

It is not possible for us to foresee every emergency situation that could arise during operation of this machine. Information on the following pages describes three typical 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 ONE: Platform elevated, operator not incapacitated, but machine will not respond to platform controls.

POSSIBLE CONDITION:

One or more functions not operating correctly.
Machine movement from unselected lever.
Machine function will not stop unless power is switched off.

CORRECTIVE ACTION

1. Remove foot from foot switch.
2. Push the red "Emergency Stop" Button.
3. Evaluate the nature of the failure. Return to the ground, using the emergency pump and lowering procedure (see "Emergency Pump", earlier in this section).

A DANGER

DO NOT TRY TO CLIMB DOWN THE BOOM.

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

4. If unable to return to the ground using the platform controls and the emergency pump, contact an experienced operator to lower the machine with the emergency pump using the remote pendant controls (see "Emergency Pump", earlier in this section).
5. Report the incident to your supervisor immediately.

Page 69

SITUATION TWO: Platform elevated, with operator incapacitated at platform controls.

DO NOT TOUCH MACHINE !!!

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 the 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 (see "Emergency Pump", earlier in this section).
5. Render first aid to the operator.
6. Report the incident to your supervisor immediately.

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

Page 70

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

A DANGER

DO NOT TOUCH MACHINE !!!!

ELECTROCUTION HAZARD!!!

CORRECTIVE ACTION

1. Contact authorized personnel to disconnect power supply touching machine.
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 (see "Emergency Pump", earlier in this section).
5. Report the incident to your supervisor immediately.

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

Page 71

MAINTENANCE

SECTION 3: MAINTENANCE

Page 72

Table of Contents, Section 3


General Maintenance Tips	3-3
Shift Operational Checklist	3-4
Weekly Operation Checklist	3-7
Monthly Operational Checklist	3-9
Quarterly Operational Checklist	3-11
Semi-annual Operational Checklist	3-12
Lubrication Chart	3-14
Lubrication Diagram	3-15
Troubleshooting	3-16

Page 73

GENERAL MAINTENANCE TIPS

GENERAL MAINTENANCE TIPS

Never leave hydraulic components or hoses open. They must be protected from contamination (including rain) at all times.
Never open a hydraulic system or disassemble engine when there are contaminants in the air.
Use only recommended lubricants. Improper lubricants or incompatible lubricants may be as harmful as no lubrication (see Lubrication Chart).
ALWAYS clean the surrounding area before opening hydraulic system or disassembling engine 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 operator's, service, and repair manuals of the manufacturer.

Page 74

SHIFT OPERATIONAL CHECKLIST

All checks must be completed before operation of the machine.

These checklists can be copied as needed to aid in performing these inspections.

DATE: _____ INSPECTED BY: _____

MODEL NUMBER: SERIAL NUMBER:

GENERAL INFORMATION

1. Keep inspection records up-to-date.
2. Record and report all discrepancies to your supervisor.
3. A dirty machine cannot be properly inspected.

AWARNING

THIS CHECKLIST MUST BE USED AT DAILY INTERVALS OR AFTER EVERY 6 TO 8 HOURS OF USE, WHICHEVER IS SOONER. FAILURE TO DO SO COULD ENDANGER THE LIFE OF THE OPERATOR. ALWAYS REMEMBER, A LITTLE PREVENTIVE MAINTENANCE CAN SAVE MUCH MORE THAN IT COSTS.

INITIAL

DESCRIPTION

1. Check machine for any prior-shift or transportation damage, i.e. missing parts, torn or loose hoses, hydraulic fluid leaks, torn or disconnected wires, flat or damaged tires etc. The compartment doors on both sides can be opened to inspect components inside.
2. Check for machine damage, broken welds, improper or makeshift repairs.
3. Check hydraulic system for leaks, examine hoses for signs of excessive wear, chafing or twisting.
4. Check engine oil and fuel levels.
5. Check engine coolant level (liquid cooled engine only).

Continued on following page .

Page 75

SHIFT OPERATIONAL CHECKLIST

SHIFT OPERATIONAL CHECKLIST (CONTINUED)

INITIAL	DESC	RIPTION
	6.	Check battery electrolyte level. Check battery terminals for tight connec- tions and cleanliness.
	7.	Check hydraulic fluid level. The level should be at the line marked on the sight gauge with the machine in stowed position. Inspect condition of hydraulic fluid in the reservoir. Fluid should be a clear amber color.
	8.	Check that all shutoff valves on hydraulic tank are open (parallel to flow).
	9.	Check tires for proper inflation pressure (see Machine Specifications).
	10.	Check if wheel lug nuts are tight.
	11.	Check hoses for worn areas.
	12.	Check hose carrier to verify that it is not bent or sagging.
	13.	Inspect safety equipment as required by OSHA, government and local rules.
	14.	Check platform gate latch for damage.
	15.	Check pivot pins for security.
	16.	Check that no attempt had been made to override the drive interlock system by a previous operator.
	17.	Check that all warning and instructional decals are legible and secure.
	18.	Start engine. Check hydraulic pressure (see Machine Specifications).
	19.	Check that the tilt alarm is working properly.
	20.	When all pre-inspection checks have been completed, test the ground controls for proper operation.
	21.	Check emergency pumps for operation and pressure (see Machine Specifications).

Continued on following page .

Page 76

SHIFT OPERATIONAL CHECKLIST (CONTINUED)

22.	Check platform controls for proper operation.
23.	With the platform raised, check for the smooth operation of low speed drive.
24.	Follow engine daily service requirements. Refer to the Engine Mainte- nance Manual supplied with your machine.

ADDITIONAL MAINTENANCE REQUIREMENTS FOR SEVERE USAGE APPLICATIONS

NOTE: Do not lubricate wear pads or chains in dusty or sandblast environments. There are boots and guards available to extend machine life in these applications. Consult Simon Aerials Service Department.

NITI	AL

DESCRIPTION

20. Inspect cylinder boots, valve spool boots, etc., for cuts or other damage after every eight (8) hours of service. Repair or replace if necessary.
21. Check hydraulic system for leakage after every eight (8) hours of operation.
22. Follow engine severe usage service requirements. Refer to the Engine Maintenance Manual supplied with your Machine.

SHIFT OPERATIONAL CHECKLIST

Page 77

WEEKLY OPERATIONAL CHECKLIST

WEEKLY OPERATIONAL CHECKLIST

DATE: INSPECTED BY:

MODEL NUMBER: ______ SERIAL NUMBER: _____

These checklists can be copied as needed to aid in performing these inspections.

GENERAL INFORMATION

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

THIS CHECKLIST MUST BE USED AT WEEKLY INTERVALS OR EVERY 25 HOURS, WHICHEVER OCCURS FIRST. FAILURE TO DO SO COULD ENDANGER THE LIFE OF THE OPERATOR. ALWAYS REMEMBER, A LITTLE PREVENTIVE MAINTENANCE CAN SAVE MUCH MORE THAN IT COSTS.

INITIAL	DESCRIPTION
	1. Perform all checks listed on Shift Operational Checklist.
	2. Check wheel lug nut torque (see Machine Specifications).
	3. Check hydraulic connections for leaks, corrosion and wear.
	4. Lubricate swing bearing and drive pinion gear (see Lubrication Chart).
	Follow engine weekly service requirements. Refer to the Engine Mainte- nance Manual supplied with your machine.

Continued on following page .

Page 78

WEEKLY OPERATIONAL CHECKLIST (CONTINUED)

ADDITIONAL MAINTENANCE REQUIREMENTS FOR SEVERE USAGE APPLICATIONS

INITIAL	DESCRIPTION
	6. Lubricate all grease fittings (see Lubrication Chart).
	7. Check oil level in swing drive motor assembly (see Lubrication Chart).
	8. Check oil level in power hubs (see Lubrication Chart).
	Follow engine severe usage service requirements. Refer to the Engine Maintenance Manual supplied with your Machine.

Page 79

MONTHLY OPERATIONAL CHECKLIST

DATE: INSPECTED BY: _____

MODEL NUMBER: ______ SERIAL NUMBER: _____

These checklists can be copied as needed to aid in performing these inspections.

GENERAL INFORMATION

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

AWARNING

THIS CHECKLIST MUST BE USED AT MONTHLY INTERVALS OR EVERY 100 HOURS, WHICHEVER OCCURS FIRST. FAILURE TO DO SO COULD ENDANGER THE LIFE OF THE OPERATOR. ALWAYS REMEMBER, A LITTLE PREVENTIVE MAINTENANCE CAN SAVE MUCH MORE THAN IT COSTS.

INITIAL	DESCRIPTION
	1. Perform all checks listed on Shift and Weekly Operational Checklist.
	2. Lubricate all grease fittings (see Lubrication Chart).
	3. Lubricate all hydraulic valve spool linkages.
	4. Check hose and electrical wire routed from the boom to the platform for any damage.
	5. Check protective rubber cover around hoses at moving anchor, tip boom, boom hose passages, and at swing bearing.
	6. Check boom hose carrier for sag and damage. If damaged, have them repaired.
	7. Check torque of swing bearing bolts (see Machine Specifications).

Continued on following page .

Page 80

MONTHLY OPERATIONAL CHECKLIST (CONTINUED)

INITIAL	DESC	CRIPTION
	8.	Check adjustment and security of swing drive motor assembly. There should be a slight amount of backlash between the turntable and undercarriage when properly adjusted. Check torque of mounting bolts (see Machine Specifications).
	9.	Check oil level in swing drive gear box (see Lubrication Chart).
	10.	Check oil level in power hubs (see Lubrication Chart).
	11.	Check that tires are not leaning in or out.
	12.	Check that wheel spindles turn freely, with no end play.
	13.	Check drive wheel power hub mounting bolt torque (see "Machine Specifications").
	14.	Check that the boom does not drift with a full load, no hydraulic pres- sure (engine off) and the control valve in the "BOOM DOWN" position.
	15.	Inspect boom chains. Lubricate as required (see chart).
	16.	Check to make sure boom sections are not dented or bent.
	17.	Check that all adjustable flow valves are locked. Check settings if any are not locked.
	18.	Check fuel shutoff rack for proper operation. Loosen lever arm and lubricate with WD-40 or equivalent.
	19.	Follow engine monthly service requirements. Refer to the Engine Maintenance Manual supplied with your machine.

MONTHLY OPERATIONAL CHECKLIST

Page 81

QUARTERLY OPERATIONAL CHECKLIST

DATE: INSPECTED BY:

MODEL NUMBER: ______ SERIAL NUMBER: ______

These checklists can be copied as needed to aid in performing these inspections.

GENERAL INFORMATION

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

THIS CHECKLIST MUST BE USED AT MONTHLY INTERVALS OR EVERY 250 HOURS, WHICHEVER OCCURS FIRST. FAILURE TO DO SO COULD ENDANGER THE LIFE OF THE OPERATOR. ALWAYS REMEMBER, A LITTLE PREVENTIVE MAINTENANCE CAN SAVE MUCH MORE THAN IT COSTS.

INITIAL	DESCRIPTION
	1.	Perform all checks listed on Shift, Weekly and Monthly Operational Checklist.
ADDITIONAL MAINTENANCE REQUIREMENTS FOR SEVERE USAGE APPLICATIONS
INITIAL	DESC	RIPTION
	2.	Replace high pressure filter element.
	3.	Replace hydraulic return line filter element.
	4.	Replace emergency pump hydraulic filter.
	5.	Follow engine severe usage service requirements. Refer to the Engine

Maintenance Manual supplied with your Machine.

Page 82

SEMI-ANNUAL OPERATIONAL CHECKLIST

DATE: INSPECTED BY:

MODEL NUMBER: SERIAL NUMBER:

These checklists can be conied as needed to aid in performing these inspections

GENERAL INFORMATION

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

AWARNING

THIS CHECKLIST MUST BE USED AT SIX MONTH INTERVALS OR EVERY 500 HOURS, WHICHEVER IS SOONER. FAILURE TO DO SO COULD ENDANGER THE LIFE OF THE OPERATOR. ALWAYS REMEMBER, A LITTLE PREVENTIVE MAINTENANCE CAN SAVE MUCH MORE THAN IT COSTS

	INITIAL	DES	CRIPTION
-		1.	Perform all checks listed on Shift, Weekly, Monthly and Quarterl Operational Checklists.	y
-		2.	Have hydraulic fluid sample analyzed at a test laboratory. Com test results and recommendations to ensure long, trouble free or	ply with peration.
			NOTE: If hydraulic fluid has been regularly maintained, it should only require changing once every year, depending on maintenance, temperature, application, duty cycle, and atmospheric conditions.
-		3.	Clean and lubricate all electrical switches with an electrical cont cleaner and ensure that the switches operate freely in all positio	act ns.
-		4.	Check the electrical mounting and hardware connections for sec	urity.
-		5.	Replace high pressure filter element.
-		6.	Replace hydraulic return line filter element.
-		7.	Replace emergency pump hydraulic filter.
	Continued on follow	wing p	age
Page	3-12			November 19

Page 3-12

SEMI-ANNUAL OPERATIONAL CHECKLIST

lovember 1996

Page 83

SEMI-ANNUAL OPERATIONAL CHECKLIST

SEMI-ANNUAL OPERATIONAL CHECKLIST (CONTINUED)

INITIAL	DESCRIPTION
	8.	Drain and replace fluid from swing drive and power hubs. If badly contaminated, it may be necessary to disassemble and inspect components.
	9.	Clean and lubricate the standard open swing bearing gear teeth with dry moly lube spray.
	10.	Repack front wheel bearings.
	11.	Follow engine semi-annual service requirements. Refer to the Engine Maintenance Manual supplied with your machine.
	EVE	RY YEAR
	12.	Drain and replace fluid from hydraulic reservoir. Drain and replace fluid from drive wheel power hubs. If badly contaminated, it may be necessary to disassemble and inspect components.
	EVE	RY TWO YEARS
	13.	Drain and replace fluid from swing drive motor assembly. If badly contaminated, it may be necessary to disassemble and inspect components.
ADDITIONAL MAINTENANCE REQUIREMENTS FOR SEVERE USAGE APPLICATIONS
	EVE	RY SIX MONTHS

Drain and replace fluid from swing drive motor assembly and drive wheel power hubs.
Follow engine severe usage service requirements. Refer to the Engine Maintenance Manual supplied with your machine.

Page 84

LUBRICATION CHART

NO.	ITEM	SPECIFICATION AND QUANTITY	FREQUENCY OF LUBRICATION
1.	Hydraulic reservoir	Mobil DTE-13M to "Full" mark with all cylinders retracted.	Check level & condition each shift. Analyze 6 months or 500 hours. Change yearly or 1000 hours.
2.	Hydraulic high pressure filter	Filter element.	Change 6 months or 500 hours.**
3.	Hydraulic return line filter	Filter element.	Change 6 months or 500 hours.**
4.	Emergency pump hydraulic filter	Filter.	Change 6 months or 500 hours.**
5.	Swing bearing (standard open style)	Lithium N.L.G.I. #2 EP. Purge old grease.	Weekly or every 25 hours.**
6.	Exposed swing bearing gear teeth	Dry moly lube spray.	Every six (6) months or 500 hours.**
7.	Swing drive gear box	Fill to plug. SAE 140 EP or N.L.G.I. #00 EP oil.	Check monthly or every 100 hours.* ^† Change every two (2) years or 2,000 hours.*
8.	Boom pivot pins and Cylinder pins	Lithium N.L.G.I. #2 EP. Purge old grease.	Monthly or every 100 hours.**
9.	Wheel bearings	Lithium N.L.G.I. #2 EP. Clean and repack.	Change every six (6) months or 500 hours.* ^†
10.	Steering spindles	Lithium N.L.G.I. #2 EP. Purge old grease.	Monthly or every 100 hours.**
11.	Steering linkage	Lithium N.L.G.I. #2 EP. Purge old grease.	Monthly or every 100 hours.**
12.	Steering tie rod ends	Lithium N.L.G.I. #2 EP. Purge old grease.	Monthly or every 100 hours.**
13.	Drive wheel power hubs	SAE 80 W 90, SAE 90 or SAE 85-140, half full.	Change after first 50 hours. Check monthly or every 100 hours. Change yearly or 1,000 hours.
14.	Boom wear pads	Silicone spray.	Monthly or every 100 hours.**
15.	Valve spool linkage	WD 40 Spray or equivalent penetrating oil.	Monthly or every 100 hours.*
16.	Platform rotate mechanism	Hydraulic fluid.	Yearly.

* Whichever occurs first.

⁺ Different requirements for severe usage applications. See checklists.

LUBRICATION CHART

Page 3-14

Page 85

Page 86

TROUBLESHOOTING

SHOULD YOU EXPERIENCE ERRATIC OPERATION OR NOTICE ANY MAL-FUNCTION WHILE RUNNING YOUR MP 60, CONTINUE OPERATION ONLY LONG ENOUGH TO RETURN TO THE GROUND POSITION IF POSSIBLE.

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

WHAT TO CHECK IF UNIT WILL NOT START:

Is the key switch turned on?
Is the ground/ platform selector switch in the proper position?
Are all emergency stop buttons or switches released?
Are all battery cables connected?
Are the batteries charaed?
Are any wires pulled out or loose?
Is there proper fuel (gas, propane, or Diesel) in the fuel tank?
If equipped for propane fuel operation, is the propane tank valve open?
If equipped for dual fuel operation, is the fuel selector switch in the proper position?

WHAT TO CHECK IF FUNCTIONS WILL NOT OPERATE:

Is a function control lever or the platform foot pedal not activated?
Is the ground/ platform selector switch in the proper position?
Is the engine speed switch at the correct RPM (not at "IDLE" speed)?
Has the turntable lock pin not been removed?
Is there an obvious oil leak or damaged component?
Is the hydraulic fluid level low?
Are any wires pulled out or loose?
If equipped with manual descent valve option, are all three valves in the correct position?
If equipped with the tow package option, are the torque hubs or steering control valve disengaged?

IROUBLESHOOTING

Page 87

INDEX

A

ANSI/ SIA A92.5-1980 (Partial)	A-5
Applicable Standards and Regulations	A-3
Arrangement Diagram	vi
Auxiliary Pump Push Button	2-13

В

Boom, Su	perstructure and Platform	2-30
Braking

С

Choke Button
Circuit Breaker
Cold Weather Operation	2-28
Control Selector Switch

D

Diesel Engine Operation
Drive Control Lever
Drive Speed Switch
Drive Toggle Switch
Driving and Steering
Dual Fuel Engine Operatio	n2-30

E

	1 6
Electrical Storms	I-D
Electrocution Hazard	1-4
Emergency Descent Valves	2-9, 2-38
Emergency Descent Valves
Operation and Checks	2-27
Emergency Electrical Pumps	2-36
Emergency Lowering	2-38
Emergency Stop Button	2-7 , 2-13
Emergency System and Procedures	2-36
Engine Oil Pressure Gauge	2-9
Engine Speed (Throttle) Switch	2-7
Engine Warning Indicator	2-13

F

Foot Pedal Switch ......2-17

G

Gasoline Engine Operation Gasoline to Propane Switching	2-31
Glow Plug	2-7, 2-31
Operating Speed Switch	2-13
Gradeability Conversion Chart Ground Operation and Checks	vi 2-20

н

High Wind		1-5
	••••••
Horn Button
Hour Meter
Hydraulic Fluid Pres	ssure Gauge
Hydraulic Valves

I

Ignition Toggle	e Switch	2-7
Introduction		. iii

L

Lift and Swing Control Lever	2-15
Lift Lever
Lifting Procedure
Light Switch
Lubrication Chart

Μ

Machine Components	1-5
Machine Diagrams	V
Machine Startup2	-19
Main Power Key Switch	2-7
Maintenance	3-1
Maintenance,
Severe Usage Applications	3-8
Maintenance Tips	3-3
Monthly Operational Checklist	3-7

Page 88

0

Operation
Operator Controls
(Ground Electrical Panel)
Operator Controls
(Platform Controls)	2-12
Operator Controls
(Remote Control Pendant)

Ρ

Platform Leveling Lever
Platform Operation and Checks	2-23
Platform Rotate Lever
Propane Switch
Propane to Gasoline Switching	2-31
Pump Selector Toggle Switch	2-11

R

Ranae Diagram	۷
Range Diagram

S

Safety	1-1
Safety Rules and Precautions	1-4
Safety Symbols	1-3
Semi-Annual Operational Checklist	3-9
Shift Checks	-18
Shift Operational Checklist	3-4
Shut-Down Procedures	-32
Specifications	iv
Start Switch, On/ Off	-13
Startup Procedures	-18
Steer Switch	-17
Steer Toggle Switch	-11
Steer/ Wander Control Valve	2-9
Swing Lever	2-9

Т

Telescope Lever
Tie Down Locations (Recommended)	2-35
Towing Procedures
Transporting the Machine
Troubleshooting	3-11
Truck or Trailer Transport	2-34

U

Unloading Procedures
Unpowered Emergency Mov	vement2-37

۷

Page 89

OPERATOR'S MANUAL APPENDIX

APPENDIX

Page A-1

Page 90

Table of Contents, Appendix

Applicable Standards and Regulations	A-3
ANSI/SIA A92.5 - 1992 (Partial)	A-5
5. Responsibilities of Dealers	A-5
6. Responsibilities of Owners	A-7
7. Responsibilities of Users	A-10
8. Responsibilities of Operators	A-16
9. Responsibilities of Lessors	A-20
10. Responsibilities of Lessees	A-21
Simon Aerial's Twelve Month Limited Warranty
Transfer of Ownership Notice (Business Reply Cards)
Catalog Comment Card (Business Reply Cards)

Page 91

APPENDIX

APPLICABLE STANDARDS AND REGULATIONS

In addition to the operational instructions provided herein, various standards and governmental regulations also apply to the use and operation of your Simon Aerial Work Platform.

Attached hereto are copies of some of the applicable codes, regulations and standards with which you must comply if this unit is operated in the U.S.A. These standards were in effect (as attached) on the date your unit was manufactured. You must comply with these, or other applicable standards as defined by your governing bodies as they are updated over time.

For complete, current copies of U.S.A. standards, you must annually write to:

American National Standards Institute 1430 Broadway New York, NY 10018

Request: ANSI/ SIA A92.5 (current)

Specific state or local regulations may also apply. You must consult the appropriate regulating authority for the area in which the equipment will be operated in order to obtain current copies of these regulations.

Page 92

OPERATOR'S MANUAL APPENDIX

Page 93

ANSI/SIA A92.5 - 1992 (PARTIAL)

5. RESPONSIBILITIES OF DEALERS

5.1 Basic Principles. Sound principles of safety, training, inspection, maintenance, application and operation consistent with all data available regarding the parameters of intended use and expected environment shall be applied in the training of operators, in maintenance, application, safety provisions and operation of the aerial platform with due consideration of the knowledge that the unit will be carrying personnel.

5.2 Manuals. Dealers shall keep and maintain copy(ies) of the operating and maintenance manual(s) required in section 4.19 of this standard. Operating manual(s) shall be provided with each rental, lease, or sale delivery. These manual(s) shall be stored in the location required by section 4.20 of this standard. These manual(s) are considered an integral part of the aerial platform and are vital to communicate necessary safety information to users and operators. In addition, parts and maintenance manual(s) shall be provided with each sale delivery.

5.3 Predelivery Preparation. Aerial platforms shall be inspected, serviced and adjusted to manufacturer's requirements prior to each delivery by sale, lease or rental.

5.4 Maintenance Safety Precautions. Before adjustments and repairs are started on an aerial platform, the following precautions shall be taken as applicable:

(a) Powerplant stopped and starting means rendered inoperative.

(b) All controls in the "off" position and all operating systems secured from inadvertent motion by brakes, blocks, or other means.
(c) Boom and platform lowered to the full down position, if possible, or otherwise secured by blocking or cribbing to prevent dropping.
(d) Hydraulic oil pressure relieved from all hydraulic circuits before loosening or removing hydraulic components.
(e) Safety props or latches installed where applicable as prescribed by the manufacturer.

5.5 Replacement Parts . When parts or components are replaced, they shall be identical or equivalent to original aerial platform parts or components.

5.6 Training. Whenever a dealer directs or authorizes an individual to operate an aerial platform he shall ensure that the individual has been trained under the direction of a qualified person in accordance with the manufacturer's operating manual and requirements listed in section 8, of this standard, before operating the aerial platform.

5.6.1 Training on Delivery. Manufacturer's operating instruction and required training on the proper use and operation of the aerial platform shall be provided upon each delivery by sale, lease or rental.

Page 94

5. RESPONSIBILITIES OF DEALERS (CONTINUED)

5.7 Operation. When a dealer operates an aerial platform in sales demonstrations or otherwise for his beneficial use, he and his operating personnel shall assume the responsibilities of users as specified in section 7 and responsibilities of operators as specified in section 8 of this standard.

5.8 Assistance to Owners and Users. If a dealer is unable to answer an owner's or user's question relating to rated capacity, intended use, maintenance, repair, inspection or operation of the aerial platform, the dealer shall obtain the proper information from the manufacturer and provide that information to the owner or user.

5.9 Record Retention. Dealer(s) shall retain the following records for at least three years:

(a) Name and address of the purchaser of each aerial platform by serial number and date of delivery.
(b) Records of the person(s) trained upon each delivery of an aerial platform.
(c) Records of the predelivery preparation performed prior to each delivery.

5.10 Modifications. Modification or alteration of an aerial platform shall be made only with prior written permission of the manufacturer.

5.11 Manufacturers Safety Bulletins. The dealer shall comply with safety related bulletins as received from the manufacturer.

5.12 Ownership Records. When a change in ownership of an aerial device occurs, it shall be the responsibility of the seller to notify the manufacturer, or successor, of the unit, model and serial number and the name and address of the new owner within sixty (60) days.

Page 95

ANSI/ SIA A92.5-1992

6. RESPONSIBILITIES OF OWNERS

6.1 Basic Principles. Sound principles of safety, training, inspection, maintenance, application and operation consistent with all data available regarding the parameters of intended use and expected environment shall be applied in the performance of the responsibilities of owners with due consideration of the knowledge that the unit will be carrying personnel.

6.2 Manuals. Owners shall keep and maintain copy(ies) of the operating and maintenance manual(s) required in section 4.19 of this standard. Operating manual(s) shall be provided with each rental, lease or sale delivery. The operating manual(s) shall be stored in the location required in section 4.20 of this standard. These manual(s) are considered an integral part of the aerial platform and are vital to communicate the necessary safety information to users and operators. In addition, parts and maintenance manual(s) shall be provided with each sale delivery.

6.3 Predelivery Preparation. Aerial platforms shall be inspected, serviced and adjusted to manufacturer's requirements prior to each delivery by sale, lease or rental.

6.4 Maintenance. The owner of an aerial platform shall arrange that the maintenance specified in this standard is properly performed on a timely basis. The owner shall establish a preventive maintenance program in accordance with the manufacturer's recommendations and based on the environment and severity of use of the aerial platform. The owner shall arrange that frequent and annual inspections are performed. All malfunctions and problems identified shall be corrected before the aerial platform is returned to service.

6.5 Frequent Inspection. The owner of an aerial platform shall cause a frequent inspection to be performed on the aerial platform:

(a) That has been in service for three (3) months or 150 hours, whichever comes first.

(b) Before putting into service a machine which has been out of service for a period longer than three (3) months of time.

The inspection shall be made by a person qualified as a mechanic on the specific make and model of the aerial platform. The inspection shall include all items specified by the manufacturer for a frequent inspection and shall include but not be limited to the following:

(a) All functions and their controls for speed(s), smoothness and limits of motion.
(b) Lower controls including the provisions of overriding of upper controls.
(c) All chain and cable mechanisms for adjustment and worn or damaged parts.
(d) All emergency and safety devices.
(e) Lubrication of all moving parts, inspection of filter element(s), hydraulic oil, engine oil, and coolant as specified by the manufacturer.
(f) Visual inspection of structural components and other critical components such as fasteners, pins, shafts, turntable attachment bolts, and locking devices.
(g) Placard, warnings and control markings.

Page 96

6. RESPONSIBILITIES OF OWNERS (CONTINUED)

6.5 Frequent Inspection (continued).

(h) Additional items specified by the manufacturer.
(i) Correction of all malfunctions and problems identified and further inspection if necessary.
(j) After correction or replacement of any component, the unit shall be inspected and tested in accordance with above paragraph 6.5.

6.6 Annual Inspection. The owner of an aerial platform shall cause an annual inspection to be performed on the aerial platform no later than thirteen (13) months from the date of the prior annual inspection. The inspection shall be performed by a person(s) qualified as a mechanic on the specific make and model of the aerial platform. The inspection shall include all items specified by the manufacturer for an annual inspection.

6.7 Maintenance Safety Precautions. Before adjustments and repairs are started on an aerial platform, the following precautions shall be taken as applicable:

(a) Powerplant stopped and starting means rendered inoperative.

(b) All controls in the "off" position and all operating systems secured from inadvertent motion by brakes, blocks or other means.
(c) Elevating assembly and platform lowered to the full down position, if possible, or otherwise secured by blocking or cribbing to prevent dropping.
(d) Hydraulic oil pressure relieved from all hydraulic circuits before loosening or removing hydraulic components.
(e) Safety props or latches installed where applicable as prescribed by the manufacturer.

6.8 Replacement Parts. When parts or components are replaced, they shall be identical or equivalent to original aerial platform parts or components.

6.9 Maintenance Training. The owner shall train his maintenance personnel in inspection and maintenance of the aerial platform in accordance with sections 6.4, 6.5, 6.6, 6.7, 6.8 and 7.3.3 of this standard and with the manufacturer's recommendations.

6.10 Operator Training. Whenever an owner directs or authorizes an individual to operate an aerial platform, he shall ensure that the individual has been trained in accordance with the manufacturer's operating manual and requirements listed in section 8 of this standard before operating the aerial platform.

6.10.1 Training on Delivery. Manufacturer's operating instructions and required training on the proper use and operation of the aerial platform shall be provided upon each delivery by sale, lease or rental.

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6.11 Operation. When an owner operates an aerial platform, he shall have the responsibilities of users as specified in section 7 of this standard and his operating personnel shall have responsibilities of operators as specified in section 8 of this standard.

6.12 Assistance to Users and Operators. If an owner is unable to answer a user's or operator's questions relating to rated capacity, intended use, maintenance, repair, inspection or operation of the aerial platform, the owner shall obtain the proper information from the dealer or manufacturer and provide that information to the user or operator.

6.13 Record Retention. The owner shall retain the following records for at least three (3) years:

(a) Name and address of the purchaser of each aerial platform by serial number and date of delivery.
(b) Records of the person(s) trained upon each delivery of an aerial platform.
(c) Written records of the frequent and annual inspections shall be kept by the owner when he performs the inspection. The record shall include deficiencies found, corrective action and identification of the person(s) performing the inspection and repairs.
(d) Records of the predelivery preparation performed prior to each delivery.

6.14 Modifications. Modification or alteration of an aerial platform shall be made only with prior written permission of the manufacturer.

6.15 Manufacturer's Safety Bulletins. The owner shall comply with safety related bulletins as received from the manufacturer or dealer.

6.16 Ownership Records. When a change in ownership of an aerial device occurs, it shall be the responsibility of the seller to notify the manufacturer, or successor, of the unit, model and serial number and the name and address of the new owner within 60 days.

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7. RESPONSIBILITIES OF USERS

7.1 Basic Principles. The information in this standard must be supplemented by good job management, safety control and the application of sound principles of safety, training, inspection, maintenance, application and operation consistent with all data available and regarding the parameters of intended use and expected environment. Since the user has direct control over the application and operation of aerial platforms, conformance with good safety practices in this area is the responsibility of the user and his operating personnel including the operator. Decisions on the use and operation of the aerial platform must always be made with due consideration for the fact that the machine will be carrying personnel whose safety is dependent on those decisions.

7.2 Manuals. Users shall keep and maintain copy(ies) of the operating and maintenance manual(s) required in section 4.19 of this standard. The operating manual(s) shall be stored in the location required in section 4.20 of this standard. These manuals are considered an integral part of the aerial platform and are vital to communicate the necessary safety information to users and operators.

7.3 Inspection and Maintenance. Users shall inspect and maintain the aerial platform as required to ensure proper operation. The frequency of inspection and maintenance shall be determined by the manufacturer's recommendations and be compatible with operating conditions and the severity of the operating environment. Aerial platforms that are not in proper operating condition shall be immediately removed from service until repaired. Repairs shall be made by a qualified person and the repairs shall be in conformance with the manufacturer's recommendations.

7.3.1 Frequent Inspection. An inspection as outlined in section 6.5 of this standard shall be conducted.

7.3.2 Annual Inspection. An inspection as outlined in section 6.6 of this standard shall be conducted.

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7.3.3 Pre-start Inspection. Before use each day or at the beginning of each shift, the aerial platform shall be given a visual inspection and functional test including but not limited to the following:

(a) Operating and emergency controls.
(b) Safety devices.
(c) Personal protective devices, including fall protection.
(d) Air, hydraulic and fuel system leaks.
(e) Cables and wiring harness.
(f) Loose or missing parts.
(a) Tires and wheels.
(h) Placards, warnings, control markings and operating and safety manual(s).
(i) Outrigaers, stabilizers, extendible axles and other structures.
(i) Guardrail system.
(k) Items specified by the manufacturer.

7.3.4 Maintenance Safety Precautions. Before adjustments and repairs are started on an aerial platform, the following precautions shall be taken as applicable:

(a) Powerplant stopped and starting means rendered inoperative.
(b) All controls in the "off" position and all operating systems secured from inadvertent motion by brakes, blocks or other means.
(c) Boom and platform lowered to the full down position, if possible, or otherwise secured by blocking or cribbing to prevent dropping.
(d) Hydraulic oil pressure relieved from all hydraulic circuits before loosening or removing hydraulic components.
(e) Safety props or latches installed where applicable as prescribed by the manufacturer.
(f) Precautions specified by the manufacturer.

7.4 Replacement Parts. When parts or components are replaced, they shall be identical or equivalent to original aerial platform parts or components.

7.5 Maintenance Training. The user shall train his maintenance personnel in inspection and maintenance of the aerial platform in accordance with sections 7.3, 7.3.1, 7.3.2, 7.3.3 and 7.3.4 of this standard and with the manufacturer's recommendations.

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7. RESPONSIBILITIES OF USERS (CONTINUED)

7.6 Operator Training. Whenever a user directs or authorizes an individual to operate an aerial platform, he shall ensure that the individual has been trained in accordance with the manufacturer's operating and maintenance manual, the user's work instructions and requirements listed in section 8 of this standard before operating the aerial platform.

7.6.1 Model Training. The user shall be responsible for the operator being trained on the model of the aerial platform that he will be operating. Such training shall be in an area free of obstructions, under the direction of a qualified person for a time sufficient to determine that the trainee display proficiency in knowledge and actual operation of the aerial platform. Only properly trained and authorized personnel shall be permitted to operate the aerial platform.

7.6.2 Trainee Records. A record of the trainee's aerial platform instructions shall be maintained by the user for at least three (3) years.

7.7 Before Operation. Before authorizing an operator to operate an aerial platform, the user shall ensure that the operator has:

(a) Been instructed by a qualified person in the intended purpose and function of each control.
(b) Read and understood the manufacturer's operating instruction(s) and users safety rules, or been trained by a qualified person on the contents of the manufacturer's operating instruction(s) and users safety rules.
(c) Understood by reading or by having a qualified person explain all decals, warnings and instructions displayed on the aerial platform.
(d) Determine that the purpose for which the aerial platform is to be used is within the scope of the intended applications defined by the manufacturer.
(e) Been provided with approved fall protection devices and other safety gear for all personnel in the platform.

7.8 Work Place Inspection. Before the aerial platform is used and during use, the user shall check the area in which the aerial platform is to be used for possible hazards such as but not limited to:

(a) Drop-offs or holes.
(b) Bumps and floor obstructions.
(c) Debris
(d) Overhead obstructions and high voltage conductors.
(e) Hazardous locations.
(f) Inadequate surface and support to withstand all load forces imposed by the aerial platform in all operating configurations.
(g) Wind and weather conditions.
(h) Presence of unauthorized persons.
(i) Other possible unsafe conditions.

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