Genie Simon Skyhawk 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

MODFI

SKYHAWK

SIMON

OPERATOR'S MANUAL

SERIES 2031E 2234E 2234E 2248E 2248E 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 SKYHAWK Work Platform. Operators must be aware of and comply with all manufac-

This Operator's Manual must be read prior to operating your Simon SKYHAWK Platform.

turer's instructions and OSHA / ANSI safety guidelines.

PART NO. 89-790002

MARCH, 1990

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	3
MACHINE SPECIFICATIONS	4
GRADEABILITY CONVERSION CHART	5
PRIMARY MACHINE COMPONENTS	6
DECAL AND INFORMATION PLATE LOCATIONS	7
SAFETY RULES AND PRECAUTIONS	8
OPERATOR CONTROL DIAGRAM	10
OPERATOR CONTROL DESCRIPTION AND FUNCTION	11
START-UP PROCEDURES
DAILY CHECKS	13
OPERATION AND CHECKS	14
	16
OPERATION
	17
BRAKING	18
	18
	18
	19
RAISING THE GUARD RAILS	19
SHUT-DOWN PROCEDURES	20
RECHARGING BATTERIES	20

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TABLE OF CONTENTS (CONTINUED)

TRANSPORTING THE UNIT
TOWING OF THE WORK PLATFORM 2	21
FORK LIFTING OF THE WORK PLATFORM	21
TRUCK TRANSPORT OF THE WORK PLATFORM	21
EMERGENCY SYSTEM AND PROCEDURES
EMERGENCY LOWERING 2	22
EMERGENCY DRIVE	22
EMERGENCY PROCEDURES 2	23
MAINTENANCE
GENERAL MAINTENANCE TIPS 2	25
DAILY OPERATIONAL CHECKLIST	26
WEEKLY OPERATIONAL CHECKLIST 2	27
MONTHLY OPERATIONAL CHECKLIST 2	28
SEMI-ANNUAL OPERATIONAL CHECKLIST	29
TROUBLESHOOTING	31
LUBRICATION DIAGRAM	32
LUBRICATION CHART	33
WARRANTY	35

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INTRODUCTION

This Operator's Manual is designed to provide you with the instructions needed to properly operate the SIMON AERIALS INC. SKYHAWK Self-Propelled Work Platform. This Manual is also meant to inform you of the many Safety Hazards that can affect the safe use and operation of the unit.

This Operator's Manual MUST BE READ AND UNDERSTOOD prior to operating the self-propelled SKYHAWK Work Platform.

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

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

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

MODIFICATIONS OF THIS MACHINE FROM THE ORIGINAL DESIGN WITH-OUT WRITTEN PERMISSION FROM SIMON AERIALS INC. ARE STRICTLY FORBIDDEN, AND WILL VOID ANY REMAINING WARRANTY.

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

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MACHINE SPECIFICATIONS SKYHAWK SERIES

	2031E	2234E	2248E
	25 FT 6 IN. (7.77 M)	27 FT 6 IN. (8.38 M)	27 FT 6 IN. (8.38 M)
PLATFORM HEIGHT	19 FT 6 IN. (6.10 M)	21 FT 6 IN. (6.55 M)	21 FT 6 IN. (6.55 M)
STOWED HEIGHT:
GUARD RAILS IN PLACE	95 IN. (2.41 M)	95 IN. (2.41 M)	95 IN. (2.41 M)
	74 IN. (1.88 M)	74 IN. (1.88 M)	74 IN. (1.88 M)
	56.5 IN. (1.43 M)	56.5 IN. (1.43 M)	56.5 IN. (1.43 M)
	750 LBS.	750 I BS.	1000 LBS
	(340 KG)	(340 KG)	(454 KG)
PLATFORM DIMENSIONS	26 IN. x 95 IN.	29 IN. x 104 IN.	48 IN. x 104 IN.
	(0.66 M x 2.41 M)	(0.74 M x 2.64 M)	(1.22 M x 2.64 M)
LENGTH	101 IN. (2.57 M)	118 IN. (3.00 M)	118 IN. (3.00 M)
	31 IN. (0.79 M)	34 IN. (0.86 M)	48 IN. (1.22 M)
	84 IN. (2.13 M) 26 IN. (0.66 M)	87 IN. (2.21 IVI) 29 5 IN. (0.75 M)	87 IN. (2.21 IVI) 42 INI (1.07 M)
	12 FT	12 FT 9 IN.	13 FT 6 IN.
	(3.66 M)	(3.89 M)	(4.12 M)
	7 FT	7 FT 9 IN.	7 FT 9 IN.
	(2.13 M)	(2.36 M)	(2.36 M)
	7 IN. (0.18 M)	7 IN. (0.18 M)	/ IN. (0.18 M)
	4,200 LBS (1 905 KG)	4,400 LDS (1 995 KG)	4,000 LBS
TRAVEL SPEED-STOWED	2 MPH (3.2 KPH)	2 MPH (3.2 KPH)	2 MPH (3.2 KPH)
TRAVEL SPEED-ELEVATED	0.5 MPH	0.5 MPH	0.5 MPH
	(0.8 KPH)	(0.8 KPH)	(0.8 KPH)
GRADEABILITY
	8 ° (14%) 4" × 9" × 10"	8 ° (14%) 4" x 8" x 16"	8 ° (14%) 4" x 8" x 10"
	4 X 8 X 16 7 5 GAL (28 L)	4 X 0 X 10 75 GAL (281)	4 X 0 X 10 7 5 GAL (28 L)
HYD. OPERATING PRESSURE:		7.0 G/(E. (20 E)
LIFT/ HIGH DRIVE	2600 PSI	2600 PSI	2600 PSI
	(179 BAR)	(179 BAR)	(179 BAR)
	. 1600 PSI	1600 PSI	1600 PSI


	(FOUR 6 VOLT.	(FOUR 6 VOLT.	(FOUR 6 VOLT.
	220 AMP/HR.	220 AMP/HR.	220 AMP/HR.
	LEAD-ACID	LEAD-ACID	LEAD-ACID
	BATTERIES	BATTERIES	BATTERIES
	IN SERIES.)	IN SERIES.)	IN SERIES.)
BATTERY CHARGER	25 AMP	25 AMP	25 AMP

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SAFETY RULES AND PRECAUTIONS

Only trained, competent personnel should operate the SKYHAWK Work Platform.
Read and understand all safety and control information found on the machine and in this manual before operating the unit.
DO NOT exceed the safe working load of the unit in any configuration. Review this manual's specification data sheet regarding your particular model's capacities and dimensions.
DO NOT raise the Work Platform unless the unit is on a firm, level surface.
DO NOT alter, modify or disable any safety devices or interlocks.
DO NOT use the SKYHAWK 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 your reach while on the Work Platform.
DO NOT use the platform to push or tow the unit or another vehicle.
DO NOT use the unit in electrical storms or in high wind situations.
It is recommended that OSHA approved safety belts and safety hats be worn at all times when operating the Work Platform.
DO NOT elevate the platform unless all railings are securely locked in their raised position. Make sure that entry chains to the platform are secured before operating.
The operator must complete the "Daily Operational Checklist" found in this manual (see Table of Contents) prior to each day's usage.
The operator should immediately report any noises, vibrations or malfunctions of the unit to supervisors.
The operator should note that the travel speed automatically decreases whenever the boom is elevated.
Fork lift pockets under the chassis of the SKYHAWK Work Platform are to be used ONLY for transporting the unit. Do not operate the unit while it is being transported.
The operator shall ensure that the area surrounding the Work Platform is clear of personnel and equipment before driving the unit, raising or lowering the platform.

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SAFETY RULES AND PRECAUTIONS

The operator shall maintain a safe distance from overhead and ground obstacles, debris, drop-offs, holes, depressions, electrical wires and other hazards to travel.
The operator shall limit travel speed according to conditions of the ground surface, congestion, slope, location of personnel or any other factors that could cause hazard of collision or injury to personnel.
The operator shall use caution to prevent ropes, cords, hoses, etc. from becoming entangled in the unit's boom sections when being elevated, lowered, or repositioned.
The operator should check level of battery charge before operating unit. If the unit is sluggish in operation, DO NOT USE before recharging.
DO NOT recharge the batteries near sparks or open flames. Lead-acid batteries generate EXPLOSIVE HYDROGEN GAS. Always wear safety glasses.

ELECTROCUTION HAZARD!! THIS MACHINE IS NOT INSULATED!!

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

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

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

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

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OPERATOR CONTROL DESCRIPTION AND FUNCTION

ltem No.	Control	Location	Description
1	Lower Boom Lever	Control Console	Control lever used to raise or lower the lower boom section. Each bom section can be controlled independently.
2	Upper Boom Lever	Control Console	Control lever used to raise or lower the upper boom section. Each boom section can be controlled independently.
			maximum ground speed and gradeability.
3	Steer Switch	Control Console	Controls the steering wheels.
4	Drive Controller	Control Console	Controls all forward and reverse drive functions at a speed proportional to handle movement.
5	Main Power Key Switch	Control Console	Main power disconnect. The key may be removed to prevent unauthorized operation.
6	Platform Control Power Switch	Control Console	Press and hold to permit operation of all lift and drive functions from the platform position.
7	Ground Control Power Switch	Control Console	Press and hold to permit operation of all lift and drive functions (at low speed) from the ground position.
			WHEN OPERATING THE CONTROL CONSOLE FROM THE GROUND POSITION, USE EXTREME CAUTION. TRAVEL AND STEER DIRECTION WILL BE OPPOSITE DRIVE CONTROLLER MOVEMENT.
8	Emergency Hand Pump Handle	Undercarriage Hydraulic Tank	Permits lowering of the boom sections in an emergency.

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OPERATOR CONTROL DESCRIPTION AND FUNCTION

ltem No.	Control	Location	Description
9	Emergency Hand Pump Control	Undercarriage Hydraulic Tank	Turn clockwise to close, allowing emergency hand pump operation. Turn counterclockwise to open, allowing normal operation.
10	Lower Boom Control	Undercarriage Hydraulic Tank	Turn counterclockwise to open, allowing lowering of the lower boom with the emergency hand pump.
11	Upper Boom Control	Undercarriage Hydraulic Tank	Turn counterclockwise to open, allowing lowering of the upper boom with the emergency hand pump.
12	Hour Meter (Not Shown) (Optional)	Undercarriage Front of Hyd. Module	Indicates the number of hours the machine has been operated in hours and tenths.
13	Battery Indicator (Not Shown) (Optional)		Indicates the charge on the batteries.

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START-UP PROCEDURES

DAILY CHECKS

Before the Simon SKYHAWK Work Platform is put into use each day, or before being started up 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, damaged tires etc. The module covers on both sides can be removed to inspect components inside.
____ Check battery electrolyte level, charge level, and connections. Replenish electrolyte, if necessary, WITH DISTILLED WATER ONLY. Do not overfill.
Check hydraulic fluid level with platform fully lowered.
____ Check tires for damage.
____ Check hoses for worn areas.
____ Check operator supplied safety belts and connections.
_____ Check platform rails and safety chains for damage. Guard rails should be up, with pins and safety chains in place.
____ Check pivot pins for security.
____ Check that all warning and instructional labels are legible and secure.

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OPERATION AND CHECKS

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

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

Check to be sure that battery charger has been disconnected from the AC power source.

Batteries are not at full voltage capacity when new. An undetermined number of charging cycles are required to attain full voltage capacity of the batteries.

A charging cycle is the discharge and then charging of the battery. Ideally the battery must be discharged 20 percent.

Turn the key switch to the "ON" position to energize the electrical system. Note operation of rotating beacon (if so equipped).
Individually push down on each of the three fastened corners of the tilt alarm (if so equipped). The alarm should sound as each corner is pressed (may be a brief delay).
Press and hold the power control toggle switch to activate the pump motor. Move the drive controller forward or backward to move in the desired direction. Drive speed is proportional to the amount of movement of the lever from its center position. Note operation of audible "movement alarm" (if so equipped) when driving.

If machine is equipped with any optional alarms, DO NOT disable these alarms. The optional alarms are offered for your protection and the protection of persons in the immediate area. Disabling any of these devices may result in an accident.

When the unit is driven, the brake will automatically release allowing movement. When the drive control is returned to neutral (center position) the brake engages.

When the platform is raised, drive speed is automatically reduced to slow speed.

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The rocker switch on top of the drive controller is used to steer the unit left or right.

WARNING!!!

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

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

Press and hold the power control switch to activate hydraulic pump motor, move lower boom control lever up to raise lower boom section. The speed of the boom movement is determined by how far the control lever is moved from its center position.
- _____ Listen for any unusual noises.
- _____ Check for any vibration while the platform travels up.
- _____ Check for uneven or jerky operation.
- _____ Check for hydraulic leaks.
Return the lower boom to the stowed position by slowly moving the control lever in the down direction. Note operation of descent alarm (if so equipped) as platform descends. Raise the boom a few inches to enable later test of the emergency pump.
Operate the upper boom the same way.
- _____ Listen for any unusual noises.
- _____ Check for any vibration while the platform travels down.
- _____ Check for uneven or jerky operation.
- _____ Check for hydraulic leaks.
Return the upper boom to the stowed position by slowly moving the control lever in the down direction. Note operation of descent alarm (if so equipped) as platform descends. Raise the boom a few inches.
Release the power switch.

All machine operations should stop immediately upon release of the power switch.

Turn the key switch off.
Carefully dismount the platform, placing your feet only on the steps provided.

____ Check pivot pin security. Ensure that all securing bolts are in place at each pin locking point.

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EMERGENCY PUMP OPERATION AND CHECK

With power off:

Locate emergency hand pump on side of hydraulic reservoir.
Close the emergency hand pump control valve by turning the "T" handle clockwise until it fully seats.
Open the lower or upper boom control on the hydraulic reservoir by turning counterclockwise. Boom can be lowered together.
Pump the hand pump handle up and down as required to allow the boom section to lower to the stowed position.
- _____ Listen for any unusual noises.
- Check for any vibration while using the emergency pump.
- _____ Check for hydraulic leaks.
- Ensure that boom lowers using emergency pump.

Machine lowering will be slow when using the emergency hand pump.

Open the emergency hand pump control valve by turning the "T" handle approximately 180° counterclockwise to relieve pressure in the circuit. Close the valve.
Close the boom control valve on the hydraulic reservoir and open the remaining boom control valve.
Pump the hand pump handle up and down as required to allow the boom section to lower to its stowed position.
- _____ Listen for any unusual noises.
- Check for any vibration while using the emergency pump.
- _____ Check for hydraulic leaks.
- _____ Ensure that boom lowers using emergency pump.
Open the emergency hand pump control valve (control valve must be open for normal operation).
Close the boom control valve on the hydraulic reservoir (both boom control valves must be closed for normal operation).

•

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OPERATION

Perform Start-up Procedures. After satisfactory completion of all preliminary checks, the unit is ready for use. Position front gate and control console in the desired location (up for platform control or down for ground control).

WHEN OPERATING THE SKYHAWK FROM THE GROUND, USE ONLY THE "GROUND CONTROL" POWER SWITCH.

USE EXTREME CAUTION. TRAVEL AND STEER DIRECTION WILL BE OPPOSITE DRIVE CONTROLLER MOVEMENT, AND YOUR ABIL-ITY TO RAISE THE PLATFORM WILL BE LIMITED.

DO NOT STAND ON THE UNDERCARRIAGE WHILE OPERATING THE UNIT.

Enter platform, close safety chain and attach operator supplied safety belt. Check that front guard rails are also in position, and rail keeper pins are all in place. Normal operation of the SKYHAWK is done from the platform.

DRIVING AND STEERING

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

Turn the key switch to the "ON" position. Press and hold the power control switch to activate the pump motor. Push the drive controller forward to travel in that direction and pull the drive controller backward for reverse travel.

Drive speed is proportionally controlled by the amount of movement from its center position.

When the platform is raised, drive speed is automatically reduced to slow speed.

Steering is achieved by the rocker switch on top of the drive controller. Press to the left or right as required.

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

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BRAKING

For parking, the brake is automatically applied when the drive controller is positioned in the center (neutral) position.

ELEVATING PLATFORM

Press and hold the power control switch to activate hydraulic pump motor, move appropriate boom control lever up to raise the desired boom section.

NOTE

The speed of the boom movement is determined by how far the control lever is moved from its center position.

TRAVEL WITH PLATFORM ELEVATED ONLY ON HARD, LEVEL SURFACES.

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

LOWERING PLATFORM

Press and hold the power control switch to activate hydraulic pump motor, move appropriate boom control lever down to lower the desired boom section.

The speed of the boom movement is determined by how far the control lever is moved from its center position.

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LOWERING THE GUARD RAILS

WARNING !!!

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

Unpin the front end gate and swing it down. Hold gate in place with gate stop arm.
Unhook the safety chain.
Unpin the rear end post on one side.
Swing one rear post down.
Swing one upper side rail inward onto platform.
Repeat procedure for other side.

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

RAISING THE GUARD RAILS

Swing one upper side rail to upright position.
Swing one rear post up.
Pin rear end post on one side.
Repeat procedure for other side.
Release gate stop arm. Push up front end gate and pin gate in position.

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SHUT-DOWN PROCEDURES

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

RECHARGING BATTERIES

Recharge the batteries of the SKYHAWK platform each day after use.

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

Plug the charger into a 115 Volt, 60 Hz AC outlet, using a #12 AWG grounded extension cord.
When batteries are fully charged, the charger automatically shuts off.

DO NOT OPERATE THE UNIT WHILE CHARGING.

• When batteries are fully charged, disconnect the charger from the approved power.

Be sure charger is disconnected from the outlet before moving the SKYHAWK platform.

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TRANSPORTING THE UNIT

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

TOWING of the Work Platform:

If the SKYHAWK platform is equipped with the TOW PACKAGE OPTION, it can be towed. MAXIMUM TOWING SPEED IS 6 MPH (9.6 KPH). The brake actuation levers are located on the rear axle mounting tube and the motor cross port valve lever is located next to the hydraulic tank. To tow the unit:

Release brake by turning brake actuation lever (1) to "CLOSED" position. "OPEN" brake actuation lever (2).
Close emergency pump control valve. Activate pump handle one to two strokes.
Turn motor cross port valve lever to "OPEN". The unit is now ready to tow.

To return to normal operation, turn brake actuation lever (1) to "OPEN" position. Turn brake actuation lever (2) to "CLOSED" position. Open emergency pump control valve. Turn motor cross port valve lever to "CLOSED".

FORK LIFTING of the Work Platform:

• Lift the Simon SKYHAWK Work Platform from the sides only. Position forks in the forklift pockets. Ensure that lift truck used has adequate capacity to lift the machine (see "Machine Specifications" for weight).

Do not use tie down lugs to lift the Work Platform.

TRUCK TRANSPORT of the Work Platform:

• Securely attach the machine to the transporting vehicle using the tie down lugs provided. Lugs are located at the center front and center rear of the undercarriage. Ensure that chains or straps have adequate load capacity, and DO NOT OVER-TIGHTEN.

Do not use tie down lugs to lift the Work Platform.

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

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EMERGENCY SYSTEM AND PROCEDURES

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

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

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

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

EMERGENCY LOWERING

Locate the emergency hand pump on the top of the hydraulic reservoir. Close the emergency hand pump control valve by turning the "T" handle clockwise until fully seated. Open the desired boom control (each boom can be lowered individually). Pump the hand pump handle up and down as required to allow the boom sections to lower. Drive and steer functions are not available when using the emergency hand pump.

Machine lowering will be slow when using the emergency hand pump.

Once the boom section has been fully lowered, open the emergency hand pump control valve to relieve pressure in the circuit, and close the boom control valve. If necessary, close the emergency hand pump control valve, then open the remaining boom control. Pump the hand pump handle up and down as required to allow the boom section to lower. Once the platform has been fully lowered, close the boom control valve. Open the emergency hand pump control valve (pump control valve must be open and both boom controls must be closed for normal operation).

• Report the incident to your supervisor immediately.

EMERGENCY DRIVE

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

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EMERGENCY PROCEDURES

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

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

CORRECTIVE ACTION:

1. Have an experienced operator use the emergency lowering procedure to safely lower the platform.
2. Report the incident to your supervisor immediately.

SITUATION: Platform elevated, with operator incapacitated at 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, and operator will not be endangered by platform movement, lower the platform using the emergency lowering procedure.
5. Render first aid to the operator.

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SITUATION: Platform in contact with live power lines, 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 by platform movement.
4. AFTER POWER IS CUT, use the emergency lowering procedure to bring platform with operator to a safe location to render first aid.

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

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MAINTENANCE

GENERAL MAINTENANCE TIPS

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

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

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

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DAILY OPERATIONAL CHECKLIST
All checks must be completed before operation of the Simon SKYHAWK.
DATE INSPECTED BY

	GENERAL INFORMATION
Keep inspection records up-to-date. Record and report all discrepancies to your supervisor. A dirty machine cannot be properly inspected. Keep your SImon SKYHAWK clean!!
THIS CHECKLIST I GER THE LIFE OF TIVE MAINTENAN	MUST BE USED DAILY. FAILURE TO DO SO COULD ENDAN- THE OPERATOR. ALWAYS REMEMBER, A LITTLE PREVEN- CE CAN SAVE MUCH MORE THAN IT COSTS.
INITIAL DE	SCRIPTION
1.	Perform a visual inspection of all machine components, i.e. missing parts, torn or loose hoses, hydraulic oil leaks, torn or disconnected wires, dam- aged tires etc. Replace components as necessary. The module covers on both sides can be removed to inspect components inside.
2.	Check battery charge level and connections.
3. Check hydraulic fluid level with platform fully lowered.
4.	Check tires for damage.
5.	Check hoses for worn areas.
6.	Check platform rails and safety chains for damage.
7.	Check pivot pins for security.
	Check that all warning and instructional labels are legible and secure.
9.	Check that hydraulic pressure is as stated on the data plate.
10.	Check controls for proper operation.
11.	With platform raised, check for the smooth operation of low speed drive.
12.	Check operation of emergency hand pump.
ADDITIONAL MAINTENANCE REQUIREMENTS FOR SEVERE USAGE APPLICATIONS
13.	Check hydraulic system for leakage after every eight hours of operation.

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AWK SERIES	OPERATORS MAI
	WEEKLY OPERATIONAL CHECKLIST
DATE	INSPECTED BY
MODEL NU
	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 SKYHAWK clean!!

THIS CH GER THE TIVE MA	CKLIST MUST BE USED WEEKLY. FAILURE TO DO SO COULD ENDAN- LIFE OF THE OPERATOR. ALWAYS REMEMBER, A LITTLE PREVEN- NTENANCE CAN SAVE MUCH MORE THAN IT COSTS.
INITIAL	DESCRIPTION
	1. Perform all checks listed on Daily Operational Checklist.
	Check battery electrolyte level and specific gravity (fully charged specific gravity should be 1.265).
	3. Check wheel lug nuts for proper torque (75 ft. lbs.).
ADDITIO	AL MAINTENANCE REQUIREMENTS FOR SEVERE USAGE APPLICATIONS
INITIAL	DESCRIPTION
	4. Inspect condition of hydraulic fluid. Oil should have a clear amber color.
	5. Lubricate all grease fittings.
	6. Lubricate all steering linkages and pivot points.

Page 29

MONTHLY OPERATIONAL CHECK	LIST

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.
- Keep your Simon SKYHAWK clean!!

THIS CHECKLIST MUST BE USED MONTHLY. FAILURE TO DO SO COULD EN-DANGER THE LIFE OF THE OPERATOR. ALWAYS REMEMBER, A LITTLE PRE-VENTIVE MAINTENANCE CAN SAVE MUCH MORE THAN IT COSTS.

INITIAL

DESCRIPTION

1. Perform all checks listed on Daily and Weekly Operational Checklists.
2. Lubricate all grease fittings.
3. Inspect condition of hydraulic fluid in the reservoir. Oil should have a clear amber color.
4. Lubricate all steering linkages and pivot points.
5. Inspect the entire machine for signs of damage, broken welds, improper or makeshift repairs..
6. Check the electric motor brushes.
7. Check all decals for legibility.
8. Clean and lubricate all valve spool linkages.
9. Check pin joints and retaining bolts for security.
10. Check hydraulic system pressure.
11. Check left and right spindles for free turning with no end play.
12. Visually inspect power wheel mounting bolts. Bolts should be flush to retainer, with no gap between retainer and hub flange.

ADDITIONAL MAINTENANCE REQUIREMENTS FOR SEVERE USAGE APPLICATION

13. Change hydraulic filter element.

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SEMI - ANNUAL OPERATIONAL CHECKLIST
DATE	INSPECTED BY

	GENERAL INFORMATION
Keep inspection records up-to-date. Record and report all discrepancies to your supervisor. A dirty machine cannot be properly inspected. Keep your Simon SKYHAWK clean!!
THIS CHECK DO SO COUL MEMBER, A THAN IT COS	LIST MUST BE USED AT 6 MONTH INTERVALS. FAILURE TO D ENDANGER THE LIFE OF THE OPERATOR. ALWAYS RE- LITTLE PREVENTIVE MAINTENANCE CAN SAVE MUCH MORE STS.
INITIAL C	DESCRIPTION
	Perform all checks listed on Daily, Weekly and Monthly Operational Check- lists.
	2. Have hydraulic fluid sample analyzed at a test laboratory. Follow the recommendations of test results.
	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 tightness of upper frame and linkage pins.
	4. Check overall platform stability.
	5. Ensure that all switches operate freely in all positions.
	6. Check the electrical mounting and hardware connections for security.
	7. Replace return filter element.
	8. Repack front wheel bearings.

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TROUBLESHOOTING

WARNING !!!

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

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

WHAT TO CHECK IF UNIT WILL NOT OPERATE:

Key switch turned on?
Batteries fully charged?
Battery cables connected?
Wires pulled out or loose?
Hydraulic fluid level low?
Obvious fluid leak or damaged component?

Page 32

Page 33

LUBRICATION CHART

NO. ON	ITEM	SPECIFICATION	FREQUENCY OF
DIAGRAM		AND QUANTITY	LUBRICATION
1	HYDRAULIC RESERVOIR	MOBIL DTE-15 TO FULL MARK W / PLATFORM RETRACTED	CHECK DAILY, ANALYZE EVERY 6 MONTHS, CHANGE YEARLY.
2	HYDRAULIC RETURN FILTER	FILTER ELEMENT	CHANGE EVERY 6 MONTHS
3	PIVOT	LITHIUM N.L.G.I. #2 EP	MONTHLY OR
	PINS	PURGE OLD GREASE	EVERY 100 HRS.*
4	STEERING	LITHIUM N.L.G.I. #2 EP	MONTHLY OR
	SPINDLES	PURGE OLD GREASE	EVERY 100 HRS.*
5	STEERING HUB	LITHIUM N.L.G.I. #2 EP CLEAN AND REPACK	EVERY 6 MONTHS.
6	STEERING	LITHIUM N.L.G.I. #2 EP	MONTHLY OR
	LINKAGE	PURGE OLD GREASE	EVERY 100 HRS.*

* WHICHEVER OCCURS FIRST.

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Twelve Month Limited Warranty

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

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

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

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

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

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

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

(2) the unit is allefed of repaired in social a way as to allect its performance of reliability, of (3) the unit is mounted on a chassis or carrier which does not meet the Company's published minimum requirements.

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

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

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

SIMON AERIALS INC. Milwaukee, WI