SIMON TRAILBLAZER T-60 SERVICE MANUAL 89-260107 – PDF DOWNLOAD
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TABLE OF CONTENTS:
SIMON TRAILBLAZER T-60 SERVICE MANUAL 89-260107 – PDF DOWNLOAD
Introduction vi
Machine Specifications viii
Machine Component Locator ix
Undercarriage Component Locator x
Superstructure Component Locator xi
Boom Component Locator xii
Platform Component Locator xiii
Lubrication Chart xiv
Lubrication Diagram xv
Section l: Transportation and Emergency Procedures
Transporting the Unit 1-3
Unloading Procedures 1-4
Emergency System and Procedures 1-5
Emergency Pump 1-5
Unpowered Emergency Movement 1-5
Emergency Lowering 1-6
Section 2: Hydraulic System
Hydraulic Fluid 2-5
Handling Precautions 2-5
Fluid Recommendations 2-5
Hydraulic Fluid Analysis 2-5
System Flushing Procedure 2-6
Hydraulic System Components 2-9
Hydraulic Pump 2-9
Main Hydraulic Pump 2-9
Main Hydraulic Pump Adjustment 2-1 O
Emergency Pump 2-11
Emergency Pump Adjustment 2-11
Drive/ Steer/ Selector Manifold Assembly 2-11
Directional Control Valves 2-11
Drive/ Brake Valve Assembly 2-12
Motion Control Valve 2-12
Brake Needle Valve 2-12
Brake Shuttle Valve 2-12
Pressure Reducing Valve 2-13
Double Relief Manifold 2-13
Drive Cushion Solenoid Valve 2-13
High Pressure Filter 2-13
High Pressure Filter Element 2-13
Hydraulic Fluid Reservoir 2-13
Hydraulic Fluid Reservoir Maintenance 2-13
Section 2: Hydraulic System (Continued)
Maxi-Reach System 2-14
Maxi-Reach Tests 2-16
Test Set-Up 2-16
Maxi-Reach Set Up 2-16
Boom Lift System 2-18
Directional Control Valves 2-18
Platform 2-18
Ground 2-18
Shuttle Valve Assembly 2-19
Two Speed Valve 2-19
Accumulator 2-19
Lift Cylinder 2-19
Boom Telescope (Extend) System 2-20
Directional Control Valves 2-21
Platform 2-21
Ground 2-21
Shuttle Valve Assembly 2-21
Shuttle Valve 2-21
Flow Control Pressure Compensated Valve 2-21
Sequence Valves 2-22
Regeneration Valve 2-22
Telescope (Extend) Cylinders 2-22
Superstructure Swing System 2-23
Directional Control Valve 2-23
Platform 2-23
Ground 2-23
Shuttle Valve Assembly 2-24
Flow Control Valve 2-24
Double Counterbalance Valve (Swing) 2-24
Swing Drive Motor/ Reducer Assembly 2-24
Platform Rotate System 2-25
Rotate Control Valve 2-25
Rotary Actuator 2-25
Rotary Actuator Maintenance 2-25
Platform Rotator Manifold 2-26
Platform Leveling System 2-27
Level Control Valve 2-27
Double Pilot Operated Check Valve 2-27
Master Level Cylinder 2-28
Relief Valves 2-28
Slave Level Cylinder 2-28
Steer System 2-29
Drive/ Steer Manifold Assembly 2-29
Steer Cylinder 2-29
Steer System Maintenance 2-29
Hydraulic Swivel (Optional) 2-29
Section 3: Drive System
Drive System Components 3-3
Front Wheel Motor 3-3
Hydraulic Drive Motor 3-3
Rear Axle Assembly 3-4
Hydraulic Manifold Valve Assembly 3-4
Motion Control Valve Assembly 3-4
Motion Control Valve 3-4
Brake Needle Valve 3-4
Shuttle Valve 3-5
Pressure Reducing Valve 3-5
Double Relief Valve 3-5
Solenoid Valve 3-5
Drive Enable Valve 3-5
Platform Drive Control Handle 3-5
Drive/ Steer/ Selector Assembly 3-6
Directional Control Valves 3-6
Section 4: Electrical System
Electrical System 4-3
Battery 4-3
Battery Maintenance (In Storage) 4-3
Battery Maintenance (In Use) 4-3
Battery Troubleshooting 4-4
Battery Replacement 4-4
Platform Control Box 4-5
Emergency Stop Button 4-5
Ignition Switch 4-5
Tagg le Switch 4-5
Push Button 4-5
Light Emitting Diode 4-5
Ground Control Box 4-6
Circuit Breaker 4-6
Toggle Switch 4-6
Push Button 4-6
Key Switch 4-6
Volt Meter 4-6
Hour Meter 4-6
Engine Oil Pressure Gauge 4-7
Pendant Control 4-7
Tagg le Switch 4-7
Foot Peda I Switch 4-7
Movement Alarm 4-7
Tilt Alarm 4-8
Tilt Alarm Test 4-8
Ti It Alarm Sensor Adjustment 4-8
Tilt Alarm Horn 4-9
Horn 4-9
Relays 4-9
Limit Switches 4-9
Section 5: Mechanical Components
Mechanical Components 5-3
Tires 5-3
Changing Tires 5-3
Wheels and Lug Nuts 5-3
Wheel Motor Assembly 5-4
Steer Cylinder 5-5
Steer Cylinder Pins 5-5
Base End Cylinder Pin Replacement 5-5
Steer Cylinder Seal Replacement 5-5
Tie Rod Assembly 5-6
Tie Rod Assembly Replacement 5-6
Rear Axle Drive Motor 5-7
Rear Axle Drive Motor Replacement 5-7
Rear Axle Assembly 5-8
Rear Axle Assembly Replacement 5-8
Rear Axle Brake Adjustment 5-9
Axle Disconnect Cylinder 5-9
Superstructure 5-l O
Platform 5- 11
Hoses and Cables 5-11
Miscellaneous Equipment 5-11
Boom 5-12
Boom Pivot Pin and Bushing Replacement 5-12
Wear Pads 5-13
Base Boom Wear Pads Replacement 5-13
Mid Boom Top Front Wear Pad Replacement 5-14
Mid Boom Rear Wear Pads Replacement 5-14
Tip Boom Top Front Wear Pad Replacement 5-15
Moving Anchor Wear Pad Replacement 5-15
Boom Lift Cylinder 5-16
Lift Cylinder Base End Pin Replacement 5-16
Lift Cylinder Rod End Pin Replacement 5-17
Lift Cylinder Seal Replacement (On Machine) 5-18
Bench Replacement Of Lift Cylinder Seals 5-19
Counterbalance Valve Inspection 5-20
Boom Telescope Cylinder 5-21
Telescope Boom Cylinder Pins Replacement 5-21
Telescope Cylinder Removal 5-22
Telescope Cylinder Separation 5-23
Telescope Cylinder Seal Replacement 5-23
Telescope Cylinder Installation 5-24
Counterbalance Valve Inspection 5-25
Platform Level Cylinders 5-26
Platform Level Cylinder Pin Replacement 5-26
Level Cylinder Seal Replacement 5-27
Bleeding the Platform Leveling Circuit 5-28
Maxi-Reach System 5-28
Boom Telescope Diverter Valve Replacement 5-28
Boom Lift Diverter Valve Replacement 5-29
Arm Pin and Needle Bearing Replacement 5-29
Section 6: Maintenance Schedule
Maintenance Schedule 6-3
General Maintenance Tips 6-3
First Three Months of Operation 6-3
Routine Servicing 6-3
Daily Operational Checklist 6-6
Monthly Operational Checklist 6-9
Semi-Annual Operational Checklist 6-11
Section 7: Troubleshooting
General Troubleshooting Tips 7-3
Troubleshooting Chart 7-4
Index
Appendix
Hydraulic Schematics A-3
Electrical Schematics A-7
S.S 05/24