Genie Simon RZB Series Operator's Manual

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

MODEL

R7R

SERIES

SIMON

IMPORTANT

This manual is designed to instruct you in the proper operation of your Aerial Platform, and to make you aware of the many Safety Hazards that could affect the safe use and operation of your "RZB" Trailer Mounted unit. Operators must be aware of and comply with all manufacturer's instructions OSHA / ANSI safety guidelines.

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

PART NO. 89-470002

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MACHINE SPECIFICATIONS
WORKING ENVELOPE 4
PRIMARY MACHINE COMPONENTS
SAFETY RULES AND PRECAUTIONS
GROUND CONTROLS
PLATFORM CONTROLS 13
OPERATOR CONTROLS DESCRIPTION AND FUNCTION
START-UP PROCEDURES
TOWING
SET-UP PROCEDURES 18
DAILY CHECKS 19

GROUND OPERATION AND CHECKS
EMERGENCY PUMP OPERATION AND CHECKS
EMERGENCY PUMP OPERATION AND CHECKS
GROUND OPERATION AND CHECKS 20 EMERGENCY PUMP OPERATION AND CHECKS 23 OPERATION 23 PLATFORM OPERATION 25
GROUND OPERATION AND CHECKS 20 EMERGENCY PUMP OPERATION AND CHECKS 23 OPERATION 23 OPERATION 25 EMERGENCY PUMP OPERATION 27
GROUND OPERATION AND CHECKS 20 EMERGENCY PUMP OPERATION AND CHECKS 23 OPERATION 23 OPERATION 25 EMERGENCY PUMP OPERATION 27 DUAL FUEL ENGINE OPERATION 28
GROUND OPERATION AND CHECKS20EMERGENCY PUMP OPERATION AND CHECKS23OPERATION23OPERATION25EMERGENCY PUMP OPERATION27DUAL FUEL ENGINE OPERATION28COLD WEATHER OPERATION28
GROUND OPERATION AND CHECKS 20 EMERGENCY PUMP OPERATION AND CHECKS 23 OPERATION 25 PLATFORM OPERATION 25 EMERGENCY PUMP OPERATION 27 DUAL FUEL ENGINE OPERATION 28 COLD WEATHER OPERATION 28 SHUT-DOWN PROCEDURES 28
GROUND OPERATION AND CHECKS 20 EMERGENCY PUMP OPERATION AND CHECKS 23 OPERATION 23 OPERATION 25 EMERGENCY PUMP OPERATION 25 EMERGENCY PUMP OPERATION 27 DUAL FUEL ENGINE OPERATION 28 COLD WEATHER OPERATION 28 SHUT-DOWN PROCEDURES 29
GROUND OPERATION AND CHECKS20EMERGENCY PUMP OPERATION AND CHECKS23OPERATION25PLATFORM OPERATION25EMERGENCY PUMP OPERATION27DUAL FUEL ENGINE OPERATION28COLD WEATHER OPERATION28SHUT-DOWN PROCEDURES29SHUT-DOWN30
GROUND OPERATION AND CHECKS20EMERGENCY PUMP OPERATION AND CHECKS23OPERATION25PLATFORM OPERATION25EMERGENCY PUMP OPERATION27DUAL FUEL ENGINE OPERATION28COLD WEATHER OPERATION28SHUT-DOWN PROCEDURES29SHUT-DOWN30EMERGENCY SYSTEM AND PROCEDURES
GROUND OPERATION AND CHECKS20EMERGENCY PUMP OPERATION AND CHECKS23OPERATION25PLATFORM OPERATION25EMERGENCY PUMP OPERATION27DUAL FUEL ENGINE OPERATION28COLD WEATHER OPERATION28SHUT-DOWN PROCEDURES29SHUT-DOWN30EMERGENCY SYSTEM AND PROCEDURES31

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TABLE OF CONTENTS (CONTINUED)

MAINTENANCE


GENERAL MAINTENANCE TIPS	35
DAILY OPERATIONAL CHECKLIST	36
	38
SEMI-ANNUAL OPERATIONAL CHECKLIST	40
TROUBLESHOOTING	43
	44
	45
WARRANTY	47

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MACHINE SPECIFICATIONS RZB 40, 50 AND 55

	RZB 40	RZB 50	RZB 55
WORKING HEIGHT	40 FT	51 FT	55 FT
PLATFORM HEIGHT	(12.19 M)	(15.56 M)	(16.76 M)
	34 FT	45 FT	49 FT 2 IN.
	(10.26 M)	(12 72 M)	(14.99 M)
HORIZONTAL OUTREACH	18 FT 10.5 IN. (5 75 M)	19 FT 6 IN. (5 94 M)	(14.99 M) 21 FT 10 IN. (6 65 M)
PLATFORM CAPACITY (UNRESTRICTED)	400 LBS.	400 LBS.	400 LBS.
	(180 KG)	(180 KG)	(180 KG)
PLATFORM DIMENSIONS	60 IN. x 30 IN.	60 IN. x 30 IN.	60 IN. x 30 IN.
	(1.5 M x .76 M)	(1.5 M x .76 M)	(1.5 M x .76 M)
STOWED LENGTH	18 FT 5 IN.	18 FT 7 IN.	18 FT 7 IN.
	(5.61 M)	(5.66 M)	(5.66 M)
STOWED HEIGHT	8 FT 3 IN.	9 FT 9 IN.	9 FT 9 IN.
	(2.50 M)	(2.97 M)	(2.97 M)
WIDTH	6 FT 1 IN.	6 FT 5 IN.	6 FT 5 IN.
	(1.85 M)	(1.95 M)	(1.95 M)
STABILIZER SPREAD	9' 10" x 9' 10"	10' 6" x 10' 6"	10' 6" x 10' 6"
	(3 M x 3 M)	(3.2 M x 3.2 M)	(3.2 M x 3.2 M)
GROUND CLEARANCE	9 IN. (0.23 M)	9 IN. (0.23 M)	9 IN. (0.23 M)
	3,800 LBS	5,780 LBS	6,000 LBS
	(1725 KG)	(2620 KG)	(2720 KG)
TIRES	7.00 x 15"	9.50 x 16.5"	9.50 x 16.5"
	8 PLY	10 PLY	10 PLY
TIRE PRESSURE	60 PSI	75 PSI	75 PSI
	2610 PSI	2610 PSI	2610 PSI
	(180 BAR)	(180 BAR)	(180 BAR)
SWING BEARING TORQUE	83 FT LBS.	196 FT LBS.	196 FT LBS.
	150 FT LBS.	150 FT LBS.	150 FT LBS.
	360°	360°	360°
	CONTINUOUS	CONTINUOUS	CONTINUOUS
POWER SYSTEM - ELECTRIC STANDARD ELECTRIC MODEL	24 VOLT DC (4) 12 VOLT, 105 AMP/ HR	24 VOLT DC (4) 12 VOLT, 105 AMP/ HR	24 VOLT DC (4) 12 VOLT, 105 AMP/ HR
OPTIONAL FUEL POWERED MODEL	BATTERIES 12 VOLT BATTERY (95 AMP/ HR)	BATTERIES 12 VOLT BATTERY (95 AMP/ HR)	12 VOLT BATTERY (95 AMP/ HR)
OPTIONAL ENGINE	8 HP	8 HP	8 HP
BRIGGS GAS/ DUAL FUEL	3000 RPM	3000 RPM	3000 RPM

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SAFETY RULES AND PRECAUTIONS

This manual is designed to instruct you in the proper operation of your Aerial Platform, and to make you aware of the many Safety Hazards that could affect the safe use and operation of your RZB. Operators must be aware of and comply with all manufacturer's instructions and OSHA/ ANSI safety guidelines.

This Operator's Manual must be read prior to operating your trailer mounted RZB Aerial Platform.

DO NOT tow the RZB if it is not in roadworthy condition.
A suitable tow vehicle must be used in accordance with the appropriate state and local legislation when towing the RZB.
Some state or local laws require trailers to be licensed, and to have a spare tire or other equipment when being towed on roads and highways. It is the owners responsibility to verify that the unit complies with the legislation of the area through which it is being towed.

SIMON offers a spare tire as an optional feature.

Superstructure, platform and booms must be in the stowed position before towing the RZB.
DO NOT tow the RZB with the platform occupied, or allow persons to ride on the trailer.
Only trained, competent personnel should operate the RZB.
The operator should complete the "Daily Operational Checklist" found in this manual (see Table of Contents) prior to placing the unit in service.
The operator shall ensure that the area surrounding the aerial lift is clear of personnel and equipment before raising or lowering the booms.
The operator shall use caution to prevent ropes, cords, hoses, etc. from becoming entangled in the unit's boom sections when being elevated, lowered or repositioned.
DO NOT alter, modify or disable any safety devices or interlocks.
DO NOT exceed the safe working load of the RZB in any configuration. Review this manual's specification data sheet regarding your particular model's capacities and dimensions.

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SAFETY RULES AND PRECAUTIONS

DO NOT exceed the maximum platform horizontal pull of 150 lbs.
DO NOT use the RZB as a crane or hoist to lift oversized or hanging loads.
DO NOT sit, stand or climb on platform rails.
DO NOT use scaffolding, ladders or similar items to extend the RZB's reach.
DO NOT use the RZB in electrical storms or in high wind situations.
OSHA approved safety belts and safety hats must be worn at all times when operating the RZB. Make sure that the entry bar to the platform is secured before operating.
Since the machine may be operated from its ground controls, precautions should be taken to prevent unauthorized personnel from operating the work platform from the ground controls while the platform is in use.
DO NOT raise or swing the boom sections unless you have:
- positioned the RZB on ground that is level (not to exceed a 1.5 degree slope), well compacted and capable of taking the weight transferred to it by the outriggers in ALL stages of lift operation;
- disconnected the RZB from the towing vehicle and set the parking brake on the unit;
- fully extended the outriggers, with safety interlocks engaged;
- cranked the outrigger jacks down to carry the weight of the RZB while leaving the tires in contact with the ground.
- checked the leveling gauge to verify that the unit is level on the outrigger jacks.
DO NOT swing the superstructure until the lower boom is raised sufficently to clear the trailer and outriggers. DAMAGE TO THE OUTRIGGERS MAY OCCUR.
When lowering the RZB boom sections, take care not to descend on the outriggers or trailer chassis causing injury or damage.
The operator should immediately report any noises, vibrations or malfunctions of the RZB to supervisors.

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SAFETY RULES AND PRECAUTIONS

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

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

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

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

BEWARE OF STRONG AND/ OR GUSTY WIND CONDITIONS. Wind will cause both the work platform and electrical wires to sway.

ELECTRICAL UNITS

DO NOT operate the RZB if the batteries are not at a reasonably charged rate or if the unit is sluggish in operation.
DO NOT recharge the batteries near sparks or open flames as batteries emit highly explosive hydrogen gas when being charged.

GAS OR DUAL FUEL UNITS

The operator should check fuel system for leaks or damaged fuel lines before operating unit.
DO NOT refuel the RZB near sparks or open flames. Gasoline and propane vapors are highly explosive.

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OPERATOR CONTROLS DESCRIPTION AND FUNCTION

Item	Control	Location	Description
1	Boom Telescope (Extend) Lever	Ground Panel/ Platform Console	Valve handle which allows the telescoping upper boom to extend and retract, giving the operator access over obstacles.
2	Swing Lever	Ground Panel/ Platform Console	Valve handle which controls the rotation of the superstructure on the undercarriage. The superstructure can rotate a full 360 degrees continuous in each direction.
			Since damage to the outriggers may occur if the lower boom section does not clear the outriggers when rotating, DO NOT rotate the RZB superstructure if the lower boom section is not elevated at least three feet from the stowed position. When lowering the RZB boom sections, take care not to descend on the outrig- gers or trailer chassis causing personal injury or unit damage.
3	Lower Boom Lever	Ground Panel/ Platform Console	Valve handle used to control the raising and lowering of the lower boom section. Each boom section can be independently controlled.
4	Middle Boom Lever (RZB 50 and RZB 55 only)	Ground Panel/ Platform Console	Valve handle used to control the raising and lowering of the middle boom section. Each boom section can be independently controlled.
5	Upper Boom Lever	Ground Panel/ Platform Console	Valve handle used to control the raising and lowering of the upper boom section. Each boom section can be independently controlled.

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OP	OPERATOR CONTROLS DESCRIPTION AND FUNCTION
Item	Control	Location	Description
6	Emergency Stop Button	Platform Console	Used to stop all functions at platform and ground in an emergency. Push to stop. Turn clockwise to reset.
			Emergency pump on gas/ dual fuel units remains operational.
7	Ignition Switch	Ground Panel/ Platform Console	Three position switch. Full left position is "OFF". Center position is ignition "ON", full right engages the starter.
8	Engine Throttle	Ground Panel/ Platform Console	Three position switch. Full left position for "HIGH" RPM. Center position for "LOW" (idle) RPM. Full right position for engine "CHOKE".
9	Emergency Pump Switch	Ground Panel/ Platform Console	Permits operation of any boom function should the engine powered hydraulics become inoperable.
10	Main Power Key Switch	Ground Panel	Main power disconnect. The key may be removed to prevent unauthorized operation.
11	Ground/Platform Control Selector	Ground Panel	Selects "GROUND" or "PLATFORM" control of unit.
12	Dual Fuel Selector (if so equipped)	Ground Panel	Selects the type of fuel ("GAS" or "PROPANE") used by the engine.
			This switch has an "OFF" position which should be used to clear the carburetor bowl of gaso- line when changing from gasoline to L.P.
13	Power Control	Ground Panel	Electric units, push to operate all controls on the ground panel.
			Gas units, rotate to operate all controls on the ground panel.

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OPERATOR CONTROLS DESCRIPTION AND FUNCTION

Item	Control	Location	Description
14	Platform Level Lever	Platform Console	Valve handle which allows the platform to be manually leveled, or tilted forward and back.
15	Foot Pedal	Platform Floor	Pedal must be depressed to operate all controls on the platform console.
16	Hour Meter	Ground Panel	Indicates the number of hours the machine has been operated in hours and tenths.
17	Ampmeter	Ground Panel	Indicates the current charge or discharge rate in amps.
18	Circuit Breaker	Ground Panel	Pops out when there is excessive electrical load in the 12 volt control circuit. Push in to reset.
19	Main Power Light (electric operated RZB 40 only)	Platform Console	Indicates when power is being supplied to the platform controls.
	Boom Indicator Light (RZB 50 and 55 only)	Platform Console	Indicates when lower boom is raised enough for swinging superstructure to clear trailer.

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START-UP PROCEDURES

TOWING

Follow state and local regulations for towing.
Towing vehicle must have sufficient braking capability to stop itself as well as the RZB.
Check that superstructure, platform, booms and outriggers are in the stowed position.
Check tire pressure (refer to "Machine Specifications").
Check the surge brake before towing.
Release the parking brake.
Connect the breakaway cable to the towing vehicle.
Towing speed not to exceed 55 MPH.
When at destination, check for towing damage.

Trailer brakes do not function when backing up.

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SET-UP PROCEDURE

OPERATOR'S MANUA

TIPPING HAZARD!

GROUND UNDER OUTRIGGER JACKS MUST BE WELL COM-PACTED, LEVEL AND CAPABLE OF TAKING THE WEIGHT TRANSFERRED TO IT BY THE OUTRIGGERS IN ALL STAGES OF LIFT OPERATION.

Position trailer at worksite. Apply parking brake and disconnect tow hitch.
Fully extend the four outriggers.
- Unlock the outrigger by raising the lock pin ball handle up and over.
- Pull the outrigger out a short distance, then return the lock pin ball handle to the center position where it will drop slightly.
- Continue to pull out the outriggers (uncovering white strip) until lock pin ball drops down, locking the outrigger.
- Shake outrigger to check that the lock pins are fully down and the safety interlocks engaged.
Crank outrigger jacks down to carry the weight of the unit, but leave the tires in contact with the ground.
Level the unit using the level gauge provided.

Outriggers must be fully extended, resting on a firm level surface, with safety interlocks engaged.

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DAILY CHECKS

Before the RZB is put into use each day, or cold-started after an extended period during use, the following checks should be completed to ensure that the machine is safe and in good condition:

Perform a visual inspection of all machine components; i.e. missing parts, torn or loose hoses, hydraulic oil leaks, torn or disconnected wires, flat or damaged tires etc. The superstructure cover can be raised to inspect components inside.
Check engine oil and fuel tank levels (fuel powered units only).
Check battery electrolyte level and connections.
Check battery charger to verify that charge is adequate (electric units only).
Check hydraulic fluid level.
Check tires for damage.
Check tire pressure (60 psi, RZB 40; 75 psi, RZB 50 and 55).
____ Check hoses for worn areas.
Check hose carrier to verify that it is not bent or sagging.
Check safety belt connections and worn areas on the belt.
Check platform rails and gate latch for damage.
Check pivot pins for security. Ensure that all snap rings and securing bolts are in place on each pin.
____ Check that all labels are legible and secure.
____ Check outrigger locking pins for proper operation and signs of fatigue.
Check the safety outrigger interlocks to verify proper engagement.
Check that the safety interlock switches have not been disconnected.
Check the leveling gauge to verify leveling accuracy.
Check tow hitch for signs of damage or loosening.
____ Check the brake linkage.
____ Check that no attempt had been made to override the interlock system by a previous operator.

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GROUND OPERATION AND CHECKS

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

Set-up procedures and daily checks must be completed prior to operational checks.

ELECTRIC UNITS

• Turn the key switch to "ON" to activate the unit. The main power light at the platform should illuminate (RZB 40 only).

If the power light does not illuminate, turn the emergency stop button clockwise at the platform control console. When this button is depressed, all functions at ground and platform control consoles automatically become inoperative.

Select the "GROUND" position on the ground/ platform selector switch.

FUEL POWERED UNITS

Turn the key switch to "ON" to energize the machine's electrical system.
Select the "GROUND" position on the ground/ platform selector switch.
Turn the ignition switch to "START" while engaging the "CHOKE" with the choke switch. As soon as the engine starts, allow both switches to return to their center positions. See "Engine Operation" in "Operation" section for propane operation on dual fuel versions.
After a brief warm up period, select the "HI" engine RPM setting.

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FUNCTION OPERATION (ELECTRIC AND FUEL POWERED UNITS)

WARNING!!!

BE AWARE OF OBSTACLES AND HAZARDS ABOVE, BELOW AND AROUND THE BOOM TRAVEL AREA.

DO NOT OPERATE THIS UNIT FROM THE GROUND CONTROLS WITH PERSONNEL IN THE PLATFORM, EXCEPT IN AN EMERGENCY.

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

Function Operation

Actuate and hold the power switch on the ground control console to activate hydraulic system.
Slowly move the appropriate function lever in the desired direction.
Slowly return the function lever to the central position, then release the power switch.
Operate only one function at a time.

Function Checks

Telescope upper boom in to disengage boom lock.
Raise the lower boom to the end of its movement.
- _____ Listen for any unusual noises.
- _____ Check for any vibration while the boom travels up or down.
- Check for uneven or jerky operation.
- Check for hydraulic leaks.
Return the lower boom to its stowed position by slowly moving the control lever to the down direction.
Individually raise and lower the middle and upper booms in the same way.
- _____ Listen for any unusual noises.
- Check for any vibration while the boom travels up or down.
- Check for uneven or jerky operation.
- Check for hydraulic leaks.
- Check that the platform remains level during upper boom operation.

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RZB	SER	IES

٠	Raise the lower boom until all parts of the superstructure will clear trailer when swing- ing. (RZB 50 and 55 models are equipped with a red indicator light on the underside of the platform control console, visible from the ground control panel, that illuminates when the trailer is cleared.
٠	Swing the superstructure a full 360°.

	Do not trip over trailer components or other obstacles as you operate the swing function from the ground control console.
	Listen for any unusual noises. Check for any vibration while the superstructure swings. Check for uneven or jerky operation. Check for hydraulic leaks.
• .	Swing to align platform with boom lock bracket.
٠	Return the lower boom to its stowed position.
•	Raise the upper boom to the horizontal position.
٠	Telescope upper boom out to the end of its movement.
	Listen for any unusual noises. Check for any vibration while the boom travels in or out. Check for uneven or jerky operation. Check for hydraulic leaks.
٠	Telescope upper boom in fully.
•	Lower the upper boom fully.
٠	Telescope upper boom out to engage boom lock (additional swing alignment of plat- form may be necessary to engage lock).
٠	Release the power switch.
٠	Electric units:
	Turn the key switch to "OFF" to de-activate the unit.
٠	Fuel powered units:
	Select the "LOW" engine RPM setting. Allow the engine to slow to idle speed. Turn the ignition switch to "OFF" to shut the engine off. Turn the key switch to "OFF" to de-activate the unit.

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EMERGENCY PUMP OPERATION AND CHECK

ELECTRIC UNITS

Raise superstructure cover.
Locate the emergency hand pump bleed valve "T" handle, located behind the emergency pump towards the back wall.
Close the hand pump bleed valve by turning the "T" handle clockwise approximately 180°.

Emergency Hand Pump Function Operation

Operate and hold the appropriate function lever in the desired direction.
Pump the hand pump handle up and down as required to allow function movement.

Machine function will be very slow when using the emergency hand pump.

The emergency pump is designed for emergency descent only and should not be operated for extended periods of time.

Emergency Hand Pump Function Checks

Telescope upper boom in to disengage boom lock.
Raise the lower boom a few inches.
Lower the lower boom fully and telescope upper boom out to engage boom lock.
Open the hand pump bleed valve by turning the "T" handle counterclockwise approximately 180° (bleed valve must be open for normal operation).

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FUEL POWERED UNITS

With engine off:

Turn the key switch to "ON" position.
Actuate and hold the emergency pump switch.
Telescope upper boom in to disengage boom lock.
Raise the lower boom a few inches.
Return the lower boom to its stowed position by slowly moving the control lever to the down direction.
Telescope upper boom out to engage boom lock.
Release the emergency pump switch.
Turn the key switch to "OFF" position.

The emergency pump is designed for emergency descent only and should not be operated for extended periods of time.

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OPERATION

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

Set-up procedures, daily checks and ground operation checks must be completed prior to operation from platform.

PLATFORM OPERATION

ELECTRIC UNITS

• Turn key switch to "ON" to activate unit. The main power light should now be illuminated (RZB 40 only).

Turn the ground/ platform selector switch to "PLATFORM".
Enter platform, close safety gate and attach safety belt.

FUEL POWERED UNITS

Turn key switch to "ON" to energize the machine's electrical system.
Turn the ground/ platform selector switch to "PLATFORM".
Enter platform, close safety gate and attach safety belt.
Turn the ignition switch to "START" while engaging the "CHOKE" with the choke switch. As soon as engine starts, allow both switches to return to their center positions. See "DUAL FUEL ENGINE OPERATION" later in this section for propane operation on dual fuel versions.
After a brief warm-up period, select "HI" engine RPM setting.

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FUNCTION OPERATION (ELECTRIC AND FUEL POWERED UNITS)
WARNING !!!
BE AWARE OF THE OBSTACLES AND HAZARDS ABOVE, BE- LOW AND AROUND THE BOOM TRAVEL AREA.

Depress and hold the foot pedal on platform floor to activate hydraulic system.
NOTE
The foot pedal power switch must be fully depressed during platform operation.
Slowly operate the appropriate function lever in the desired direction. Available functions are:
Lower boom "UP" or "DOWN"
Middle boom "UP" or "DOWN" (RZB 50 and 55 only)
Upper boom "UP" or "DOWN"
Telescope (extend) boom "IN" or "OUT"
Superstructure swing "LEFT" or "RIGHT"
Platform level "FORWARD" or "BACKWARD"
WARNING !!!
TELESCOPE UPPER BOOM IN TO DISENGAGE BOOM LOCK BEFORE ATTEMPTING TO RAISE ANY BOOM SECTION OR SWING SUPERSTRUCTURE.
DO NOT SWING THE SUPERSTRUCTURE UNTIL THE LOWER BOOM IS RAISED SUFFICIENTLY TO CLEAR THE TRAILER AND OUTRIGGERS. DAMAGE TO THE OUTRIGGERS MAY OCCUR.
NOTE
RZB 50 and 55 models are equipped with a blue indicator light on the control console that illuminates when the lower boom is raised enough to clear trailer.

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DUAL FUEL ENGINE OPERATION

Change from gasoline to propane or propane to gasoline can only be performed at the ground control panel.

GASOLINE OPERATION

• Turn the dual fuel switch to "GAS" and operate the machine as normal.

GASOLINE TO PROPANE SWITCHING

The machine should only be switched to propane while the engine is running.

Engine RPM switch should be in "HIGH" position.
Turn dual fuel selector switch 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 to "PROPANE". The engine should run normally as soon as the switch engages.

PROPANE TO GASOLINE SWITCHING

• Turn the fuel selector switch to "GAS". No special procedures are required.

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.

COLD WEATHER OPERATION

In below zero weather, the hydraulic fluid should be allowed to warm before full operation of the unit.
Check for water contamination of the fluid.
Check for ice on the platform and rotation teeth.
Check that all valves operate smoothly and return freely to the neutral position.

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SHUT-DOWN PROCEDURES

BOOM LOCK AND STORAGE INSTRUCTIONS

RZB 40 MODEL

Telescope upper boom in fully.
Swing to align platform with boom lock bracket.
Lower all booms fully, taking care not to descend on the outriggers or trailer chassis.
Telescope upper boom out to engage boom lock (additional swing alignment of the platform may be necessary to engage lock).

RZB 50 AND 55 MODELS

Telescope upper boom in fully.
Lower all booms as far as possible (the lower boom can not be fully lowered using the platform controls).
Swing platform to slightly clear either side of trailer hitch.
Telescope upper boom out until platform reaches a safe exit height. Proceed to ground controls to continue boom lock and storage.
At ground control panel, turn ignition switch to "ON", and turn engine RPM switch to "HIGH" position (fuel powered units only). Turn ground/ platform selector switch to "GROUND".
Telescope upper boom in fully.
Swing to align platform with boom lock bracket.
Lower all booms fully taking care not to descend on the outriggers or trailer chassis.
Telescope upper boom out to engage boom lock (additional swing alignment of the platform may be necessary to engage lock).

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SHUT-DOWN

ELECTRIC UNIT SHUT-DOWN

Turn ground/ platform selector switch to "GROUND" position.
Turn key switch to "OFF" position. Remove key to prevent unauthorized operation of the RZB.
Park the unit on level ground and secure against vandalism and to discourage children from climbing or playing on it.

FUEL POWERED UNIT SHUT-DOWN

Turn engine RPM switch to "LOW" position. Allow engine to slow to idle speed.
Turn ignition switch to "OFF" position.
Turn ground/ platform selector switch to "GROUND" position.
Turn key switch to "OFF" position. Remove key to prevent unauthorized operation of the RZB.
Park the unit on level ground and secure against vandalism and to discourage children from climbing or playing on it.

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EMERGENCY SYSTEM AND PROCEDURES

WARNING!!!

IF THE RZB'S POWER SOURCE FAILS WHILE THE OPERATOR'S PLATFORM IS RAISED OR EXTENDED, DO NOT ATTEMPT TO CLIMB DOWN THE BOOM ASSEMBLY. SERIOUS INJURY MAY RESULT.

EMERGENCY PUMP

Each RZB has an emergency pump which can be operated to safely return the platform to the ground position.

ELECTRIC UNITS

Electric units have an emergency hand pump which can be operated only from the ground control panel. The pump is operated with a handle located on the side of the hydraulic tank.

Raise superstructure cover.
Locate the emergency hand pump bleed valve "T" handle, located behind the emergency pump towards the back wall.
Close the hand pump bleed valve by turning the "T" handle clockwise approximately 180°.

Emergency Hand Pump Function Operation

Operate and hold the appropriate function lever in the desired direction.
Pump the hand pump handle up and down to allow function movement.

Machine function will be very slow when using the emergency hand pump.

The emergency pump is designed for emergency descent only and should not be operated for extended periods of time.

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FUEL POWERED UNITS

Fuel powered units have an electric emergency pump which can be operated from the operator's platform or at the ground control station.

With engine off:

Turn the key switch to "ON" position.
Actuate and hold the emergency pump switch.
Operate and hold the appropriate function lever in the desired direction.
Release the emergency pump switch.
Turn the key switch to "OFF" position.

The emergency pump is designed for emergency descent only and should not be operated for extended periods of time.

Page 33

EMERGENCY SITUATION AND LOWERING

SITUATION: Platform elevated, operator not incapacitated, but unit will not respond to platform controls.

DO NOT TRY TO CLIMB DOWN THE BOOM.

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

CORRECTIVE ACTION

1. Remove foot from foot pedal.
2. Push "Emergency Stop" button.
3. Evaluate the nature of the failure. Return to the ground, using the emergency pump and lowering procedure (see "Emergency Pump" on previous pages).
4. If unable to return to the ground using the platform controls, contact an experienced operator to lower the machine using the ground control panel.
5. Report the incident to your supervisor immediately.

Page 34

SITUATION: Unit elevated, with operator incapacitated at platform controls.

DANGER!!! DO NOT TOUCH UNIT !!!

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

CORRECTIVE ACTION

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

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

DANGER!!! DO NOT TOUCH UNIT!!!!

CORRECTIVE ACTION

1. Contact authorized personnel to disconnect power supply touching unit.
2. Have someone summon first aid or rescue squad.
3. If operator is unconscious, check to see if he is in a pinned position, or would be endangered if machine 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" on previous pages).

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

Page 35

MAINTENANCE

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 engine when there are contaminants in the air.
Use only recommended lubricants. Improper lubricants or incompatible lubricants may be as harmful as no lubrication.
ALWAYS clean the surrounding area before opening hydraulic or 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 manufacturer's operating, maintenance, and repair manuals.

Page 36

DAILY OPERATIONAL CHECKLIST

All checks must be completed before operation of the Simon BZB

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. Keen vour Simon BZB clean!!

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


1.	Perform a visual inspection of all machine components, i.e. missing parts, torn or loose hoses, hydraulic oil leaks, torn or disconnected wires, flat or damaged tires etc. Check for transportation damage. The superstructure cover can be raised to inspect components inside.
2.	Check engine oil and fuel tank levels (fuel powered units only).
3.	Check battery electrolyte level and connections.
4.	Check battery charger (electric units only) to verify that charge is adequate.
5.	Check hydraulic fluid level with all cylinder retracted.
6.	Check tires for damage.
7.	Check tire pressure (60 psi, RZB 40; 75 psi, RZB 50 and 55).
8.	Check hoses for worn areas.
9.	Check for bent or sagging hose track.
10.	Check safety belts and connections.
11.	Check platform and gate for damage.
12.	Check pivot pins for security. Ensure that all snap rings and securing bolts are in place on each pin.
13.	Check warning and operating instruction decals for legibility.
14.	Check outrigger locking pins for proper operation and signs of fatigue.

Page 37


NITIAL	DESCRIPTION
	15. Check the safety outrigger interlocks to verify proper engagement.
	16. Check the leveling gauge to verify leveling accuracy.
	17. Check tow hitch for signs of damage or loosening.
	Check the brake linkage. Check operation of surge brake before towing the RZB on public roadways.
	Check that no attempt had been made to override the interlock system by previous operator.
	20. If all pre-inspection checks have been completed, the operator is ready to test the Simon RZB's ground control station for proper operation.
	Unplug battery charger before placing the RZB into operation (electric units only).
,	21. Check emergency pump for operation.
	22. Follow engine daily service requirements. Refer to the Engine Mainte- nance Manual supplied with your fuel powered RZB.
	AL MAINTENANCE REQUIREMENTS FOR SEVERE USAGE APPLICATIONS
INITIAL	DESCRIPTION
	DAILY
	23. Inspect cylinder boots, valve spool boots, etc., for cuts or other damage after every eight hours of service. Repair or replace if necessary.
	24. Check hydraulic system for leakage after every eight hours of operation.
	WEEKLY
	25. Inspect condition of hydraulic fluid. Fluid should have a clear amber colo

	26. Lubricate all grease fittings.

Page 38

I	ONTHLY OPERATIONAL CHECKLIST
DATE	INSPECTED BY

	GENERAL INFORMATION
1. 2. 3.	Keep inspection records up-to-date. Record and report all discrepancies to your supervisor. A dirty machine cannot be properly inspected. Keep your Simon RZB clean!!
THIS CHEC SO COULD LITTLE PR	LIST MUST BE USED AT MONTHLY INTERVALS. FAILURE TO DO NDANGER THE LIFE OF THE OPERATOR. ALWAYS REMEMBER, A /ENTIVE MAINTENANCE CAN SAVE MUCH MORE THAN IT COSTS.
INITIAL	DESCRIPTION
	1. Perform all checks listed on Daily Operational Checklist.
	2. Lubricate all grease fittings.
	3. Inspect condition of hydraulic fluid in the reservoir. Fluid should have a clear amber color.
	Check hydraulic system for leaks. Examine hoses for signs of excessive wear, chafing or twisting. Replace worn hoses if necessary.
	5. Clean and lubricate all valve spool linkages.
	6. Check tires for cracks and other damage.
	7. Check wheel lug nuts for tightness (150 ft. lbs.).
	8. Check for unit damage, broken welds, improper or makeshift repairs.
	9. Torque nuts on U-bolts used for axle mounting to 55 ft. lbs.
	10. Check protective rubber cover around hoses at moving anchor tip boom support posts, boom hose passages and at swing bearing.
	Check torque of swing bearing bolts. The correct torque is 83 ft. lbs. for RZB 40. The correct torque is 196 ft. lbs. for RZB 50 and 55.
	12. Check adjustment and security of swing drive. Correct torque of mountin bolts is 80 ft/lbs. There should be a slight amount of backlash between th superstructure and trailer when properly adjusted.

Page 39

MONTHLY OPERATIONAL CHECKLIST
INITIAL	DESCRIPTION
	13. Lubricate swing bearings.
	14. Follow engine monthly service requirements. Refer to the Engine Mainte- nance Manual supplied with your fuel powered RZB.
ADDITIONAL	MAINTENANCE REQUIREMENTS FOR SEVERE USAGE APPLICATIONS
INITIAL	DESCRIPTION
	90 DAYS
	15. Replace return filter element.
	Change engine oil and filter (fuel powered units only), and follow all other engine severe usage requirements. Refer to the Engine Maintenance Manual supplied with your RZB.

Page 40

SEMI - ANNUAL OPERATIONAL CHECKLIST
DATE	INSPECTED BY

	GENERAL INFORMATION
1. 2. 3.	Keep inspection records up-to-date. Record and report all discrepancies to your supervisor. A dirty machine cannot be properly inspected. Keep your Simon RZB clean!!
THIS CH DO SO C REMEMI MORE T	ECKLIST MUST BE USED AT 6 MONTH INTERVALS. FAILURE TO OULD ENDANGER THE LIFE OF THE OPERATOR. ALWAYS BER, A LITTLE PREVENTIVE MAINTENANCE CAN SAVE MUCH HAN IT COSTS.
INITIAL	DESCRIPTION
	1. Perform all checks listed on Daily and Monthly Operation Checklists.
	Have hydraulic fluid sample analyzed at a test laboratory. Follow trecommendations of test results. 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. Check operating speeds to ensure they are within specified limits.
	Clean and lubricate all pushbutton switches with an electrical contact cleaner and ensure that the switches operate freely in all positions.
	5. Check all electrical mounting and hardware connections for security.
	Check that engine RPM is as stated on data plate (fuel powered units only).
	7. Replace return filter element.
	8. Inspect entire machine for worn or damaged components. Replace as necessary.
	Tune engine (fuel powered units only), and follow all other engine semi- annual service requirements. Refer to the Engine Maintenance Manual supplied with your RZB.

Page 41

SEMI - ANNUAL OPERATIONAL CHECKLIST

ADDITIONAL MAINTENANCE REQUIREMENTS FOR SEVERE USAGE APPLICATIONS

INITIAL DESCRIPTION

10. Replace fuel filter (fuel powered units only), and follow all other engine severe usage requirements. Refer to the Engine Maintenance Manual supplied with your RZB.

Page 42

TROUBLESHOOTING

! WARNING!!!

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

IMMEDIATELY REPORT THE INCIDENT TO YOUR SUPERVISOR AND DISCONTINUE USING THE UNIT UNTIL IT HAS BEEN CHECKED BY A TRAINED EQUIPMENT MAINTENANCE PERSON.

WHAT TO CHECK IF UNIT WILL NOT START:

Key switch turned on?
Ground/ platform selector switch in proper position?
Emergency Stop Button on platform control released? (Twist to release.)
Battery or batteries fully charged?
Battery cables connected?
Fuel in fuel tank gas or propane (fuel powered units)?
Propane tank valve open, if so equipped (dual fuel powered units)?
Fuel selector switch in proper position (dual fuel powered units)?
Wires pulled out or loose?
Key switch turned to "OFF" position prior to a restart attempt in order to reset delay relay?

WHAT TO CHECK IF FUNCTIONS WILL NOT OPERATE:

Ground/ platform selector switch in proper position?
Power switch or platform foot pedal not activated?
Hydraulic fluid level low?
Outriggers fully extended with safety interlocks properly engaged?
Engine switch at correct RPM (fuel powered units)?
Obvious oil leak or damaged component?
Wire connections pulled out or loose?
Are the hydraulic tank ball valves open?

Page 43

Page 44

RZB SERIES

LUBRICATION CHART

NO. ON DIAGRAM	ITEM	SPECIFICATION AND QUANTITY	FREQUENCY OF LUBRICATION
1	CONTROL VALVE HANDLE PIVOT PINS	WD 40 SPRAY	MONTHLY OR EVERY 100 HRS.
2	HYDRAULIC RESERVOIR	MOBIL DTE-15 TO FULL MARK W / ALL CYLINDERS RETRACTED	CHECK DAILY, ANALYZE EVERY 6 MONTHS, CHANGE YEARLY.
3	HYDRAULIC FILTER	FILTER ELEMENT	CHANGE EVERY 6 MONTHS
4	BOOM WEAR PADS	SILICONE SPRAY	MONTHLY OR EVERY 100 HRS
5	SWING BEARING	LITHIUM N.L.G.I. #2 EP (PURGE OLD GREASE)	MONTHLY OR EVERY 100 HRS.*
6	PIVOT PINS	LITHIUM N.L.G.I. #2 EP (PURGE OLD GREASE)	MONTHLY OR EVERY 100 HRS.*
7	SWING BEARING GEAR TEETH	DRI MOLY-LUBE	EVERY 6 MONTHS OR 500 HRS.*
8	HUB AND DRUM	REPACK WITH SAE 90 GREASE	YEARLY
9	BRAKE FLUID RESERVOIR	DOT 3 BRAKE FLUID	CHECK BEFORE TOWING UNIT
10	COUPLER ROLLERS	MOTOR OIL	AFTER PROLONGED USE OR STORAGE
11	OUTRIGGER JACKS	LITHIUM N.L.G.I. #2 EP GREASE	EVERY SIX MONTHS
12	OUTRIGGER BEAMS	DRI MOLY-LUBE	EVERY SIX MONTHS
13	INNER TELESCOPIC BOOM	SAE 90 GREASE	MONTHLY OR EVERY 100 HRS.*

* WHICHEVER OCCURS FIRST.

Page 45

Vergleglegle

Six Month Limited Warranty

n Aerials Inc. (the "Company") warrants, to the original Buver only.

anufactured and sold by it conform to the Company's publish

ufactured by it shall be free from defects in material or workmanship for s from the date the unit is first placed in service; and

ufactured by the Company shall be free from d d hy the Compa

ariod a failure to conform to specifications or a it notice of such co n to the Comp ty period. enection by factory Qual rt(s) are judged to be not in co

ed by shipment, misuse of the unit (including op meh ravors not cover dam tion limits), failure to properly service and maintain the unit in accordance with the Com anv's Manuai or Factory Service Bulletins, all and shall be void if ration of the unit or natural disasters (such as fire, flood, wi

(1) the unit is altered or repaired contrary to the Company's authorized instructions, (2) the unit is altered or repaired in such a way as to affect its performance or reliability of the unit is altered or repaired in such a way as to affect its performance or reliability of the unit is altered or repaired in such a way as to affect its performance or reliability of the unit is altered or repaired in such a way as to affect its performance or reliability of the unit is altered or repaired in such a way as to affect its performance or reliability of the unit is altered or repaired in such a way as to affect its performance or reliability of the unit is altered or repaired in such a way as to affect its performance or reliability of the unit is altered or repaired in such a way as to affect its performance or reliability of the unit is altered or repaired in such a way as to affect its performance or reliability of the unit is altered or repaired in such a way as to affect its performance or reliability of the unit is altered or repaired in such a way as to affect its performance or reliability of the unit is altered or repaired in such a way as to affect its performance or reliability of the unit is altered or repaired in such a way as to affect its performance or reliability of the unit is a such as the unit is a such as the unit is a such as the unit is a such as the unit is a such as the unit is a such as the unit is a such as the unit is a such as the unit is a such as the unit is a such as the unit is a such as the unit is a such as the unit is a such as the unit is a such as the unit is a such as the unit is a such as the unit is a such as the unit is a such as the unit is a such as the unit is a such as the unit is a such as the unit is a such as the unit is a such as the unit is a such as the unit is a such as the unit is a such as the unit is a such as the unit is a such as the unit is a such as the unit is a such as the unit is a such as the unit is a such as the unit is a such as the unit is a such a

(3) the unit is mount d on a chassis or carrier which does not meet the Company's rul requirements.

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

eld repair or parts rec lacement is ne tors for direct labor costs incurred for said repairs according to the Company's current authorized field ice rate, providing that advance approval for said work be gran d by Simon A rials Service Der all the Company he li idence strict h of contract neal in tort or any other legal theory. This les the risks of product failure betw ized by both parties and is reflected in the price of the

ranty is understood to be the complete and exclusive agreement bet s, oral or written and all other communications bet n the parties relating to t matter of this warranty. No employee, agent or distributor of the Company or any other person is doitional warranties on behalf of the Company, nor to assume for the Company te or imply any ad ty in connection with any of its products, unless made in writing and signed by an officer of the

SIMON AERIALS INC. Milwaukee. WI