ELECTRIC EAGLE 32/21 N 41/24N OPERATOR'S MANUAL This Operator's Manual MUST BE READ prior to operating your SIMON ELECTRIC EAGLE 32/21 N or 41/24 N. Selected materlal trom: Hydraulle Work Platform Technical Manual, Boxer Mk. 3 Serles by: ‘Simon Aerials Ltd., Fison Way, Thetford, Norfolk, P24 1HT, England Reprinted In U.S.A. US.) Part No. 89-412792 + Issue 3 dated Sept, 1991 +simon Wild Access Simon Aerials Inc. 10600 West Brown Deer Road Milwaukee, Wisconsin 53224 USA. Phone (414) 355-0802 Fax (414) 365-0832 This Operator's Manual has been reprinted using selected material from the Hydraulic Work Platform Technical Manual originally published by Simon Aerials Ltd., Fison Way, Thetford, Norfolk, IP24 1HT, England Reprinted in U.S.A. (U.S.) Part No. 89-412792 All pages of the above manual, including those not found in this manual, have been reprinted in the Electric Eagle 32/21N and 41/24N Technical Manual, Part No. 89-412790.TABLE OF CONTENTS Boxer - General View Diagram. Introduction . SECTION 1 Boxer MK3 (E) Specifications: Closed Dimensions and Weights (Chart 1) Operating Dimensions (Chart 2) . Design Specifications (Chart 3) ‘Mechanical Components . ‘Hydraulic Components Electric Components . ‘Hydraulic Oil and Equivalent Oil Information . Boxer MK3 (E) Working Envelopes: General Information . Boxer 120. Boxer 140. Boxer MK3 Narrow Aisle Dimension Boxer 120N. Boxer 140 N. SECTION 2 Safe Working Practice: Use of the Machine Information Sources . Hazards Warnings . SECTION 3 Operating Procedures: Pre-Use Checks . .. Ground Control Checks Cage Control Checks ‘Machine Use (On the Highway) . Drive Controls . Service Brakes (Drive Mode) . Emergency Braking . . Access Controls .TABLE OF CONTENTS (Continued) SECTION 3 Operating Procedures (Continued): ‘Access Controls (Cage Assembly) . Access Operation (Cage Assembly) . Cage Rotation on Cage Leveling Ground Controls . Ground Access Control Operation . Complex Control Operation After Use. Battery Charging Battery Indicator Special Precautions: Cold Weather... Overhead Electrical Cables . ‘Safe Working Load (SWL) . Wind Conditions . . Transportation . Towing... Overhead Crane Operations Driving on Slopes . Bedding-In New Brake: Testing the Tilt Alarm Circuit Differential Lock Operation SECTION 4 Emergency Procedures: Procedure ...... Cage Operator Incapacity Cage Control Failure .. Immobility Due To Loss of Drive... To Disengage the Brakes . To Re-engage the Brakes . Overhead Crane Operation . Hydraulic Pump Failure Emergency Rotation . Emergency Lowering From the Cage Assembly (Optional Fit).TABLE OF CONTENTS (Continued) SECTION 9 Maintenance Schedules: General Information . Hydraulic Oils . . Health Waring (Hydraulic Oils) Recommended Equivalent Hydraulic Oils . Pivot Pins and Bearings ...... Servicing Check List (Basic Machines Only) Daily Routine Servicing : Weekly Routine Servicing Monthly Routine Servicing... Six-Monthly Routine Servicing Yearly Routine Servicing . Four- Yearly Routine Servicing Lubrication Chart... Lubrication Diagram . Master Brake Cylinder Location Diagram . Slew Bearing Lubrication . Appendix Applicable Standards and Regulations . ANSI SIA A92.5 - 1993 (Partial) 5. Responsibilities of Dealers 6. Responsibilities of Owners 7. Responsibilities of Users ..... 8. Responsibilities of Operators 9. Responsibilities of Lessors 10. Responsibilities of Lessees Warranty Transfer of Ownership Card Catalog Comment CardBOXER - GENERAL VIEW1 10. INTRODUCTION ‘The elecuic powered Boxer Mk3 (E) Access Platform is developed from the Boxer 2 and 3-Suage self-propeliod models and is manufactured in the U.K. by SIMON AERIALS LTD, of ‘Thetford, Norfolk. ‘The Boxer is available in five models, each with a diferent working height ability, and identified fs the Boxer 120, 130, 140, 150 and 170. Narrow aisle versions are also available, and these ‘models are identified by the leter 'N, which follows the height identification, The Boxer Access Ptatform can be powered by batiery (E), Diese (D), or gas (G). ‘The work platforms have sideways folding boom configurations that allow easy access through standard industial doorways and can operas in narrow aisles and confined spaces with no knuckle ‘or tailswing to restrict manoeuvrability. The unique up-and-over feaure enables Boxer platforms to reach work positions that are fequenly out of range of larger and more expensive machines. ‘All Boxer work platforms are engineered to high standards using the best quality materials and are tesied and stable 10 twice working Toad in all positions, ‘The operator can control the machine from ground or cage positions and the machine can be ‘riven accurately and safely from the cage, even when the booms are fully elevaed. Double-seting cylinder lock-valves prevent descent of booms in the event of hydraulic hose failure and all emergency lowering valves are situated at ground Jevel. Manual rotation is available in the ‘event of an emergency with power loss. ‘The Boxer chassis is of welded steel and the booms are manufactured from square/rectangular hollow stce! sections for optimum strength, lightness and durability. Hoses are abrasion resistant ‘and are protected within the booms (Borer 120, 130, 140 and 150), or by special covers (Boxer 170). ‘The clectic powered Boxer (E) is powered by eight 6 volt Heavy Duty bateries. An advanced ‘bauery charger is incorporated in the electrical cireuit, and baueries can be charged from either a 240 volis A.C. $0 Hz, or 110 volts A.C. 50 Hz supply. Optional tauery packs are available, ‘The transmission system allows outstanding range and performance. The powerful motor and high ‘ground clearance allow the Boxer to climb 1 in 4 slopes, ‘This manual refers to the Boxer 120, 130, 140, 150 and 170 Mk3 Electric models. ‘THE MANUFACTURER RESERVES THE RIGHT TO CHANGE THE SPECIFICATIONS. ‘AND DESIGN WITHOUT PRIOR NOTICE.SECTION 1: SPECIFICATIONSSECTION 1 R_Mk, TION Boxer 120] BOXER 130] BoxER 140] poxER 150] BOXER 170 Length (m) 450 450 474 4m 564 Width (m) (tandard) | 1.80 1.80 1.80 1.80 1.85 Width (m) (narrow) | 1.50 150 150 150 Height (m) 200 2.00 200 200 220 Unladen Weight ig) | 4510 4540 5260 3290 00 OPERATING DIMENSIONS (CHART 2. BoxER 120 | BOXER 130] BOXER 140] BOXER 150] BOXER 170 Max. Cage Floor woo | 100 ne 1370 1470 Height (m) Max. Working uso | 1280 1450 15:50 1650 Height () Max. Working 700 690 19 740 90 Outreach (m) Cage Size(m) (xB) } 1201060 | 120060 | 1200060 | 120x060 | 120x060 390 3.90 390 390 400 Climbabitty (degrees) | 14 4 2 2 13 [omaaym | » | = | a |» | 2 ‘Max. Speed (kav) s 5 5 5 5 (Booms Stowed) Max. Speed (mph) 3 3 3 3 3 Gooms Stowed) Max. Speed 075 075 075 075 075 (Gooms Elevated) Max. Speed (mph) as os os os os @ooms Elevated) Ground Clearance (m) 0.14 ou 014 014 020 Page 11BOXER Mk3 (E) SPECIFICATION, Continued... DESIGN SPECIFICATION (CHART 3): BoxeR 120 | noxer 130 [poxER 140 | BOXER 150 | BOXER 170 SWL Ow) * ns ns 2s 2s ns SW (is) * 6 496 496 496 496 Max. Horizontal 0 “ * “ 0 Platform Pall (ke) Max. Horizontal ry 8 8 s 8 Platform Pal (bs) Max. Wind Speed 10 10 10 0 10 (ise Max. Wind Speed B 2 3 2 2B (mph) Max. Wind Speed 3% 36 36 x6 6 Gefen) Max. Slope for 5 5 5 3 5 Safe Operation (degrees) * Full Range Time 70 70 90 0 100 Up (sc) Full Range Time 0 0 o o 70 Down (secs) ‘Swing LefvRight 0 60 Co o cy (xs) * NOTE: THE INFORMATION DETAILED IN CHARTS 1 TO 3 IS FOR THE STANDARD BOXER MODEL. REFER TO COUNTRY SPECIFICATION CHARTS 4 TO 6 FOR VARIATIONS OF SWL, MAX. SLOPE FOR SAFE OPERATION, BALLAST, DYNAMIC ‘TESTING AND STABILITY AND STRUCTURE.NOTE: Pages 1.3 and 1.4 will not be found in this manual. Al pages not found in this manual are contained in the Electric Eagle 32/21N and 41/24N Technical Manual, Part No. 89-412790‘MECHANICAL COMPONENTS: Tyre Type: ‘Tyre Sise: ‘Axle (120, 130, 140, 150): ‘Axle (170 ONLY): Gearbox (Standard mode!): ‘Wheels (ems): Brakes (120, 130, 140, 150: Brakes (170 ONLY): High Traction Decp Lug (Solid Rubber), 26 em wide, 73 em dia. 250-15 445: 1 ratio 14.058 : 1 ratio 20:1 ratio 381 ‘Scovice ~ Spring applied, hydraulically released * Packing Spring applied, hydraulically released * * Released when the footswitch is depressed and joystick is moved in a forward or reverse direction. il immersed discs integral inside axle housing, HYDRAULIC COMPONENTS: Lift Cylinders: te Filuation: ELECTRIC COMPONENTS: Pump Motor. Pump Pressure: Drive Motor Hand Controller: Baueries (120, 130, 140, 150): Baueries (170 ONLY): Bauery Charger Type: HYDRAULIC OL: Type: Copacity (Reservoir): Double-acting, with overcentre valves ‘Thermoplastic Pressure 48 voll, 3.7Kw, 1200 rpm. Flow rate 10 lirestnin 150 bar (2176 psi) 48 volt, series. wound reversible. Solid ste controlled Joystick ype ‘Stamdad - Eight 6 volt HD, 170 amphi rate Qovion L- Twenty-four 2 volt HD, 210 amp/ar rate ovion 2- Twenty-four 2 volt HD, 252 amp rate Quion 1- Twenty-four 2 volt HD, 258 amp rate Onion 2- Twenty-four 2 volt HD, 300 amp rate FM-Traction, Dual Input Auto 240/110 vols switching for 30 amp 48 volt bauery charging BP ENERGOL HLP 2 26 tinesBOXER MK3 SPECIFICATION, Continued. ‘EQUIVALENT HYDRAULIC OILS: BRAND TYPE BP ENERGOL, HLP 22 SHELL TELLUS 2 FINA ‘GIRKAN 2 ‘TOTAL ‘AZOLLA 2 CASTROL HYSPIN AWS 2 Esso. NUTO HP 22 GULF HYDRASIL 22 AW ‘CHEVRON EP HYDRAULIC OM. 22 Page 1.6BOXER MK3 (ELECTRIC SERIES) WORKING ENVELOPES& BOXER MK3 (E) WORKING ENVELOPES IDENTIFICATION OF MODEL: ‘The various Boxer machines arc ideaiied by their working height ability, ie, Boxer 120 (12 mete working height), or Boxer 140 (14 metre working heigh), The electric powered. Boxer machine is available in five models - Boxer 120, 130, 140, 150 and 170. DIFFERENCE (STANDARD MACHINES: ‘The only structural difference between the Boxer 120 and 130, and the Boxer 140 and 150, is that the Boxer 130 and 150 machines have an extended cage Support post fited to increase the working height by one meu, ‘The Boxer 170 differs from all the other Boxer E's by having enlarged poss, a different axle assembly, a different diferenial lock system, a different braking system, a lager electric dive ‘motor and a different slew ring assembly. The cage has a Differential Lock (Diff, Lock) ‘engagement conuol added 19 the standard contol layout ‘STRUCTURAL DIFFERENCE (NARROW AISLE BOXERS: ‘The working envelope configuration is the same as for the standard machines but the overall ‘machine width is reduced from 1.8 meues to 1.5 meies. Due to the reduction in plinth area, some components differ in positioning from the standard machine. A G.KN, (narrow width) axle ‘and a Brovini gearbox are fiued in place of the G.KN. (standard) drive axle and Brevini gearbox! brake assembly. All measurements are shown in mets. DIMENSIONS DIAGRAM (NARROW AISLE MACHINES): ‘The height measurement noted in the specification (page 1.1) is a nominal two metres, but the Narrow Aisle Boxer 1508 height measurement differs from the Boxer 120 and 140 machines, due to a larger cage support post, With this particular model, the cage assembly can be zoomed out 10 allow easy clearance of doorways and for cage entry. See Narrow Aisle Dimensional diagrams for further details. Page 1.9SIMON BOXER LONOTE: Pages 1.13 and 1.14 will not be found in this manual. All pages not found in this manual are contained in the Electric Eagle 32/21N and 41/24N Technical Manual, Part No. 89-412790SIMON BOXER WONOTE: Pages 1.17 - 1.20 will not be found in this manual. All pages not found in this manual are contained in the Electric Eagle 32/21N and 41/24N Technical Manual, Part No. 89-412790BOXER MK.3 (ELECTRIC SERIES) NARROW AISLE DIMENSIONS Page 1.212010 GAOSS WEIGHT:5200K3 capao circ: 5 SSR WORN i2ecen? Graven cairn? wowing RG Wax TYRE LoaD: TRAVELLING: 1400%9 WORKING: 315069 BOXER MK.3 120 N (NARROW AISLE MACIINE)(6035 16708 eano comer: RUBLE: 2a? YORDG 30a" FALE a? TRVELIG RIG :1de/a? x TE LO TWELDE: ne eg BOXER MK.3 140 N (NARROW AISLE MACHINE) 1.25SECTION 2: SAFE WORKING PRACTICESECTION 2 SAFE WORKING PRACTICE ‘USE_OF THE MACHINE: (a) AT ALL TIMES, IT IS THE RESPONSIBILITY OF THE OPERATOR TO USE THE MACHINE IN A SAFE AND PROPER MANNER. (®) ONLY TRAINED OPERATORS SHOULD BE ALLOWED TO CONTROL THE ‘MACHINE. (© _ UNDER NO CIRCUMSTANCE SHOULD THIS MACHINE BE USED IN SUCH A MANNER AS TO CONTRAVENE ANY INTERNATIONAL, NATIONAL OR LOCAL HEALTH AND SAFETY AT WORK REGULATIONS, OR FACTORIES ACTS AND SUBORDINATE REGULATIONS. INEORMATION SOURCES: ‘THE FOLLOWING INFORMATION SHOULD BE READ AND UNDERSTOOD: (a) “Mobile Elevating Work Plaforns", Draft European Standard, Document No8/74145,, by British Standards Insitute, 1988, (b) "Specification for Mobile Elevating Work Platforms", Document B.S. 7171, by British Standard Institute, 1989. (©) "Safesy in Work with Powered Operated Mobile Work Platforms”. Health and Safety Guidance Note HS(G) 19,, by HMS.O. (@) “Avoidance of Danger from Overhead Electric Lines’. Health and Safety Guidance Note GS6., by HMSO. (© “LP.AF. Guide io MEWPs (Mobile Elevating Work Platforms)", by the Intemational Powered ‘Access Federation, 1987. HAZARDS: ONLY TRAINED MEDICALLY FIT OPERATORS SHOULD OPERATE THE MACHINE. IF UNTRAINED PERSONS ARE PRESENT IN THE PLATFORM FOR INSPECTION DUTIES ‘THEY SHOULD NOT BE PERMITTED TO CONTROL THE MACHINE. ‘The following instructions are minimum requirements to be adapted for safe working practice with the Boxer Mk.3 machine: (2) The safe working load of 225 kgs (496 Its) must not be exceeded (two persons only), unless specified otherwise in Char 4 (Section 1 - Specification). (b) The machine must not be clevated on ground that is more than 5.0 degrees out of level. The ground ‘must be well compacted and capable of taking the weight transfered to the wheels in all stages of| ‘operation. In general, a road quality surface is required, (©The machine must not be usod in wind spoods in excess of 10 meus per second, or 36 kar (23 ‘mph), and the maximum platform horizontal pull of 40 kg (88.2 Ibs) must not be exceeded. Page 2.1% © o @ Oy @ o w 0 (m) @) Page 2.2 Safety belis and helmets should be wor at all mes, and the platform door/bar must be in position when the operators) are in the cage. Care must be exercised when working in an area where there are live electric cables. The local ‘electricity authorities should be contacied for advice. ‘Where there are obstructions such as pillars, addtional care should be taken to avoid collision ‘beaween the obstruction and the work platform, and to prevent the operators) from being trapped. ‘The machine should not be used as a crane or host, nor should the platform be used as a jack or Prop. ‘When working in areas with other moving machines, special care should be taken to prevent collisions with objects that may enter the working envelope, ‘When working in public or peopled area, special care should be taken to prevent members of the public from approaching the work platform. The working area should be cordoned off and people prevented from walking or working undemeath, where objects or the structure may descend onto ‘hem. Consideration should be given to the use of a waming hooter to signify motion of the ‘machine where circumstances may prevent persons close to the machine being aware of its ‘movement, ‘Adequate visibility should be available when the work platform is being used. The work area and the adjacent operating envelope may require ilumination to prevent collision between the work platform and an obstruction. Additionally, it should be remembered that in darkness the shape or extent of the work platform may not be apparent 10 others, and consideration should be given 10 the location and extent of warning light, ec. (Care must be exercised when working undemeath the platform for maintenance of olher purposes. ‘The platform should be chocked up into position and the hydraulic cylinders must not be relied ‘upon to hold position while pars of the body are in a positon where they may become tapped by the superstructure, . ‘Use of the platform should be avoided in areas where rescue of the operator in an emergency ‘would be difficult. ‘The operator should not interfere with, or make adjustments to the hydraulic circuit in an ‘tempt to increase the machine speeds outside the range given in the specification, ‘The machine should not be used if itis not fully serviceable, This includes passing the pre-use checks.i WARNING SPECIAL PRECAUTIONS: BEFORE OPERATING THE MACHINE, READ THE SPECIAL PRECAUTIONS IN SECTION 3. WARNING SAFETY EQUIPMENT: WEAR HELMET AND SAFETY HARNESS AT ALL TIMES WHEN CARRYING OUT OPERATIONS FROM THE PLATFORM. WARNING ELECTRIC SHOCK: THE WORKING PLATFORM IS NOT INSULATED AND EXTREME CARE MUST BE TAKEN WHEN WORKING IN THE VICINITY OF OVERHEAD ELECTRIC CABLES. CONSULT THE LOCAL ELECTRICAL AUTHORITIES FOR ADVICE. WARNING ‘SAFE WORKING LOAD: ‘THE PLATFORM IS DESIGNED TO HOLD TWO PERSONS ONLY, AND THE SAFE WORKING LOAD OF 225 KGS MUST NOT BE EXCEEDED, UNLESS SPECIFIED OTHERWISE IN CHART 4 (SECTION 1 - SPECIFICATION). WARNING EMERGENCY PROCEDURES: DURING ALL EMERGENCY PROCEDURES, PERSONNEL MUST TAKE SPECIAL CARE TO AVOID BEING TRAPPED BY ANY SUDDEN DESCENT OF ‘THE SUPERSTRUCTURE. WARNING WIND SPEED: DO NOT OPERATE THE MACHINE IN WIND SPEEDS IN EXCESS OF 36 KM/HR (3 MPH). WARNING ‘SAKE WORKING PRACTICE: UNDER NO CIRCUMSTANCE SHOULD THIS MACHINE BE USED IN SUCH A MANNER AS TO CONTREVENE ANY INTERNATIONAL, NATIONAL OR LOCAL HEALTH AND SAFETY AT WORK REGULATIONS, OR FACTORIES ACTS AND SUBORDINATE REGULATIONS. Page 23secichentonon nd whens ting ene Soto ‘A wor cnid ot sh win he ter bounded gon rs Dan DANGER J ewe xan hat orig od be manta DANGER I rma dg stove Sn fot deting ts worn at be Sfepharest stn tend vet Seldom Sonat Page 25SECTION 3: OPERATING PROCEDURESSECTION 3 OPERATING PROCEDURES, WARNING READ THE SPECIAL PRECAUTIONS (PARAGRAPHS 19 TO 28) BEFORE ATTEMPTING TO OPERATE THE MACHINE, 1, PREAUSE CHECKS: Before the Boxer is usd atthe start ofa day, or after an extended period without use, the following checks must be cared out to ensure thatthe machine is safe and in good condition for use: (@) Check batery elecooyte level and connections. (©) Check all lbels are readable and secure. (© Cheek hydraulic oll level. (@) Check that the bauery charger is disconnected from the A.C. mains electric supply (©) Check tyres for damage, (©) Chock wheel bolts for security. (@) Check Tit Alarm (see SPECIAL PRECAUTIONS, paragraph 28 for detail), 2, GROUND CONTROL CHECKS: With the cage assembly empty: (@) Test all operations (if, rotate, et.) ©) Check for Uneven or jetey operation. i) Hydraulic oil aks. Gi) Pivot pin security - Ensure that all securing bolts are in place on each pin locking point. WARNING DO NOT OPERATE THE MACHINE IF THESE CHECKS REVEAL A DEFECT. Page 3.1WARNING ENSURE THAT THE FOLLOWING CHECKS ARE CARRIED OUT ON A LEVEL SURFACE. (8) Cary out the checks described in paragraph 2, (b) Check drive and normalemergency braking. (© Check slow drive speed with the upper boom slightly elevated, (@) Check fast drive speed with the booms fully down, WARNING DO NOT OPERATE THIS MACHINE IF THESE CHECKS REVEAL A DEFECT. 4. MACHINE USE (ON THE HIGHWAY): ‘The machine IS NOT equipped for highway use and should only be driven on the public highway in compliance with relevant statutory regulations, 5. DRIVE CONTROLS: ‘The drive controls are located in the cage assembly and consist of a joystick controller and a footswitch. The footswitch must be activated during all drive, ift and descent operations, (@) Forward and Reverse Operation: (Select “Cage” at the ground controls, Select "Drive" atthe cage controls, Depress the footswitch. The footswitch MUST be fully depressed during all diving functions. ‘The footswitch must be depressed and the joystick control moved to give a forward or reverse motion. 6. SERVICE BRAKES (DRIVE MODE): ‘The Service Brakes are spring applied when the joystick is in the centre (neutral) position and remain applied during "Lilting” operations, Deceleration is achieved by moving the Joystick controller in the opposite direction to the direction of travel. It is recommended that this procedure is caried out with no pause atthe “neutral” position, as this will allow smoother braking. 7. EMERGENCY BRAKING: Emergency braking is achieved by depressing the "Emergency Stop" push-bution contro, by releasing the foctswitch, or by reuming the joystick contol to neutral Page 3.210, ‘ACCESS CONTROLS: ‘The controls in the work cage are those nomnally used in operation. The ground controls are located on the turet and are intended for use in tests and emergencies only. Care should be ‘exercised to avoid unauthorised interference from the ground station when the work cage is elevated. ACCESS CONTROLS (CAGE ASSEMBLY): ‘The access controls consist of a function selecior switch, function levers, rotation Jever, "Emergency Stop" push-bution control and a “Dead Man's" fociswitch. ACCESS OPERATION (CAGE ASSEMBLY): Before Entering the Cage Assembly: (2) Ensure that all pre-use checks are carried out (©) Switch on electrical power at the key.switch position, (© Release both "Emergency Stop" push-button controls (into the “out” postion). (@) Check that the blue "Power On" light is illuminated. If tis not, check that both “Emergency Stop" push-button controls are fully released (in the “out” position). (©) Switch the station selector switch to "Cage". ‘After Entering the Cage Assembly: (Select “Lift” mode, (@) Depress the footswitch. (h) Select the required function, Page 33‘Available Control Functions: = Lower Boom: Up Down = Middle Boom: Up Down Boxer 140/150 only) = Upper Boom: Up Down = Zoom: Exiend ——-Retract = Rotate: Left Right = Cage Level: Front Back NOTE: — The footswitch must be activated at all times during Cage Access functions. 11, CAGE ROTATION: Rotation i achieve by operating a lever positioned below the cage rotation worm box. The lever releaes the cage lock and allows the cage to be rested by tung the handle on the rotation box. 12, CAGE LEVELLING: ‘Cage levelling (forwards and backwards) is achieved by operating a lever on the main valve assembly block, 13, GROUND CONTROLS: “Te ground contls are loca on the tet and consist of a key activated “Power OnvOIT™ ‘switch, "Power On" light, "Pump Or/OfT" switch, "Emergency Stop” push-button control, “Lift 1", “Lift 2, "Lit 3" Borer 1407150 ony), "Zoom* and "Rota" levers. Thre is no cage levelling facility. Page 3.414, GROUND ACCESS CONTROL OPERATION: ‘The ground controls have identical functions to the cage controls and are for testing and ‘emergency procedures. There are no cage levelling, footswitch or bauery indicator facilites. ‘Switch the selector switch to the "Ground” position for all ground functions. 18. COMPLEX CONTROL OPERATION: ‘Some complex control operation is available by using more than one function lever. Response, however, will depend on the amount of pressure in the various components. 16. AETER USE: ‘When the machine is no longer required, switch the ignition switch wo “OfT” and depress the sgyound or cage “Emergency Stop" push-bution contol. 17. BATTERY CHARGING: Batiery charging is by a magnetically controlled FM-Traction charger, This charger will automaticaly switch to the required input voltage and will operate on 110 volts or 240 volts A.C. 50 Hz. (see Section 6 for further details) (@) Connect charger plug to an appropriate Mains supply. (b) Select the charge rte by inserting an insulated screwdriver into the small hole to the left of the LED display. The charge rate can be set to cither a 13 hour charge or a 6.5 hour charge. WARNING DO NOT OPERATE THE CHARGE RATE SWITCH DURING CHARGING OPERATION. (©) Switch "On" the charger. The "Or/OMT switch is located on the charger front panel NOTE: The yellow LED illuminates during the charging process. The green LED ittuminates when charging is complete. (@) When charging is complete, switch the charger to “Of” (© Switch Mains power “OfT” and disconnect the charger from the Mains supply point. 18, BATTERY INDICATOR: IMPORTANT: If the batteries have been disconnected, the battery indicator will read “Full” when the batteries are re-connected, Before disconnecting the batteries, note the state of discharge. The controller will settle to the correct level after a period of operation. The battery state indicator is located in the cage and is permanently displayed during machine ‘operations. When the charge state falls to 75%, the red LED will ash as an indication thatthe charge rate has deteriorated 10 a low level, If deterioration is allowed to continue, i., the battery stale falls @ futher 5%, the battery condition will be such that no lift or descent capability will be available, It is recommended that the machine is taken out of service as soon as the red waning LED flashes, and the batteries fully charged before any further machine operation takes place. Page 3.519, SPECIAL PRECAUTIONS - COLD WEATHER: In very cold, “below zero" weather conditions, the hydraulic oil should be allowed to warm before full operation of the machine is caried out. Precautions must also be taken to ensure that the hydraulic oil is kept free from water contamination, by regular oil maintenance. Emulsified water can freeze out ofthe oil as ice crystals, completely blocking the suction strainer and causing hhydraulic pump damage. (@) Ensure that all contol valves operate smoothly and return freely to the neutral postion without sticking. (b) Ensure that rotation drive teeth are not blocked by ice. (©) Ensure that steering linkages are free from ice and whe stering operates smoothly. (@) Ensure the cage floor is free from ce to allow a firm foothold without danger of slipping. WARNING BRAKING IN ICY CONDITIONS: CARE MUST BE TAKEN TO AVOID SUDDEN BRAKING WHEN THE GROUND SURFACE IS ICY. IT IS RECOMMENDED THAT ALL DRIVING OPERATIONS ARE CARRIED OUT SLOWLY AND A SAFE MARGIN IS ALLOWED FOR MANOEUVRING AROUND OBJECTS. ‘The working cage IS NOT INSULATED and extreme care must be taken when working in the vicinity of overhead electrical cables. Allowance must be made for movement of cablesmachine, ‘due 10 wind condition and the operator should read, "AVOIDANCE OF DANGER FROM OVERHEAD ELECTRIC LINES", Health and Safety Guidance Note GSé6, by HMS.O. The local electricity authorities should be contacted for advice. WARNING ‘THE WORKING CAGE IS NOT INSULATED AND EXTREME CARE MUST BE TAKEN WHEN WORKING IN THE VICINITY OF OVERHEAD ELECTRICAL CABLES. CONSULT ‘THE LOCAL ELECTRICAL AUTHORITIES FOR ADVICE. REMEMBER - IF IN DOUBT - ASK ‘The maximum safe working load of the Boxer machine is 225 kegs (496 Ibs) (two persons), unless otherwise stated in Chart 4 (Section 1 - Specification). When carrying out operations from ‘the cage, the weight of tools and equipment must be taken into consideration and the safe working Joad MUST NOT BE EXCEED! 22, SPECIAL PRECAUTIONS - WIND CONDITIONS: “The machine should no be operated in wind spends in excess of 10 metressccond (36 kr - 23 mph, During normal machine operations, consideration shoud be given to nearby obec, especially when working inthe close viciiy’'ofbuidfings and electrical cables, when sudden gusts of wind could cause the machine to sway and possibly tap the operat’ anmshhands beween the cage railing and the object. I is recommended that a reasonable safety distance is kept between lose objects and the cage assembly during all machine operations. Page 3.623. SPECIAL PRECAUTIONS - TRANSPORTATION: ‘Care must be taken when preparing the machine for storage or uansporttion. The booms must be fully down and the zoom boom fully retracted. WARNING ENSURE ALL BOOMS ARE FULLY DOWN WITH THE TOP BOOM LOCATED WITHIN ‘THE BOOM REST WITH THE ZOOM BOOM FULLY RETRACTED, Ia drive fault is associated with the clecic dive motor or gearbox, the machine must be towed ‘backwards (with the scering assembly to the reat). Towing speeds MUST NOT exceed 8 krvhr (GS mph, or the drive motor will be damaged, Before towing is aiempied, the brakes must be disengaged and the steering lock pin removed. It is also recommeneded thatthe stering cylinder is safely secured to prevent accidental contact wih the ground during the towing operation (sce ‘Section 4, for Emergency Procedures). WARNING BEFORE ATTEMPTING TO TOW THE MACHINE, ENSURE THE STEERING LOCK PIN 18 REMOVED, THE BRAKES DISENGAGED AND THE STEERING CYLINDER SAFELY SECURED. DO NOT TOW THE MACHINE AT SPEEDS EXCEEDING 8 KM/HR (5 MPH). IF THIS WARNING IS IGNORED, THE DRIVE MOTOR WILL BE DAMAGED. ‘SPECIAL PRECAUTIONS - OVERHEAD CRANE OPERATIONS: ‘The Boxer machine has four lifting points situated at te four comers of the chassis. The Boxer 120 and 130 (2-Stage models) weigh 4510 kgs and 4540 kgs respectively. The Boxer 140 and 150 G-Stage models) weigh 5260 kgs and 5290 igs respectively. During lifting operations, take all instvctions from the crane operatce, 26, SPECIAL PRECAUTIONS - DRIVING ON SLOPES: ‘There is a danger that the machine may “run away" when deiving down an incline. The operator should ensure that speed is kept within the limits of 5 kv (3 mph) with booms stowed, and 0.75 Jane (05 mph) with booms elevated, 2, When fiting replacement brake shoes, or re-adjusing the brakes, special atention must be taken to allow sufficient bedding-in of the brake shoes before fully operating the machine. See Section 7 for special instructions for brake adjustment. CAUTION BEFORE ALLOWING THE MACHINE TO BE USED FOR OPERATIONS, TEST DRIVE. ‘THE MACHINE AND OPERATE THE BRAKING SYSTEM FOR AT LEAST TEN TIMES ‘TO ENSURE THAT THE BRAKES ARE BEDDED-IN. Page 3.7‘The tilt alarm testis an essential safety west and must be carrod out during pre-use chocks (soe paragraph 1). Although the tilt alarm sensor circuit is selfchecking and will sound for une ‘seconds when the machine is switched on (lo indicate tha the circuit is serviceable), itis Jimporant w also carry out a manual test of the sensor by pressing down the sensor unit (located in the electrical module) to simulate a tking movement. When this action is carried out, and ‘provided that the amount of tt is fully applied, the tit waming alarm will sound, I at any time during machine use a wire becomes disconnected in the tilt alarm circuit, the ‘waming alarm will sound continoously, until the fault is rectified. If this should occur while the ‘machine isin te elevated posiion, 200m in immediately and being the cage down to the stowed positon, DO NOT USE THE MACHINE UNTIL THE FAULT IS FULLY RECTIFIED. WARNING IF THE TILT ALARM IS ACTIVATED DURING MACHINE OPERATIONS, ZOOM IN AND LOWER THE PLATFORM INTO THE STOWED POSITION. ENSURE THAT ‘THE FAULT IS FULLY INVESTIGATED AND RECTIFIED BEFORE THE MACHINE IS ALLOWED TO CONTINUE WITH OPERATIONS. 2». Page 3.8 ‘The diff. lock sysiem fied to the Model 170 is not an automatic type as fied to the Boxer models 120 to 150, The system employed on the model 170 gives 100% engagement on selection and is hydraulically operated with a spring release. It is not designed for, or intended for continuous use but is fied to give increased traction when driving on rough or undulating ground, or when in slippery conditions.SECTION 4: EMERGENCY PROCEDURESSECTION 4 EMERGENCY PROCEDURES WARNING DURING ALL EMERGENCY LOWERING PROCEDURES, TAKE CARE NOT TO BE. ‘TRAPPED BY THE DESCENDING SUPERSTRUCTURE. 1, PROCEDURE: Before any emergency procedure is carried out: (a) If possible, take instructions from the cage operator. (b) Switch ground contol station selector 1o “Ground” and atiempt to operate the ground controls. 2. CAGE OPERATOR INCAPACITY: ‘The cage should be lowered using the ground controls (soe Section 3). 3. CAGE CONTROL FAILURE: ‘The cage should be lowered using the ground contols (sx Section 3). 4. IMMOBILITY DUE TO LOSS OF DRIVE: If the machine becomes immobile due wo batery failure, gearbox or drive motor failure, the following options are available: (@) Battery Failure: ‘This condition will be displayed on the Battery State Indicator (cage conuol pane!) If possible, replace weak or faulty batteries with fully charged batteries. (©) Drive Motor/Gearbox Failure: Towing Operations: Ifa drive fault is associated with the electic drive motor or gearbox, the machine must be towed from the work site. The towing bracket is an optional fit (sce page 4.2 for diagram). Page 4.1‘THE LOCK PIN MUST BE REMOVED AND THE BRAKES DISENG. OPERATIONS CAN BEGIN (REFER TO PARAGRAPH 4(t) AND 5 FOR DETAILS). JAGED BEFORE TOWING ‘STEERING LOCK PIN LOCATION Page 4.2If no towing bracket is fiued, the machine must be towed backwards (with the steering assembly to the reat). The tet must be tumed 180 degrees to allow the cage to be kept clear during the towing operation (see instructions for manual rotation). Care must be taken during the towing operation, as the cage assembly could make contact with the ‘pound if the surface is uneven. ‘Towing speeds MUST NOT exceed 8 Jawhr (5 mph), or the dive motor will be damaged, Before towing is auempted, the brakes MUST be disengaged, the stering lock pin removed, and the steer cylinder safely secured to prevent accidental contact with the ground during the towing operation. WARNING BEFORE ATTEMPTING TO TOW THE MACHINE, ENSURE THE STEERING LOCK PIN 1s REMOVED, THE BRAKES DISENGAGED, AND THE STEERING CYLINDER SAFELY SECURED. S. TQ DISENGAGE BRAKES: (@) Fully close the knurled knob on the valve block (located atthe left-hand end of the module). (b) Move the black hand pump lever (located on top of the hydraulic oil tank) to the right (©) Operate the hand pump (located on top of the hydraulic oil tank) until pressure has built up safficienly w disengage the brakes, BRAKE DISENGAGEMENT CONTROL, Page 43WARNING DO NOT ATTEMPT TO TOW THE MACHINE WITH THE STEERING LOCK PIN IN POSITION OR WITH THE BRAKES APPLIED. ALWAYS SECURE THE STEER CYLINDER BEFORE TOWING TO PREVENT GROUND CONTACT AND POSSIBLE DAMAGE. IF NO TOWING BRACKET IS FITTED, THE MACHINE MUST BE TOWED BACKWARDS WITH THE STEERING ASSEMBLY TO THE REAR. THE TURRET MUST BE MANUALLY ‘TURNED 180 DEGREES, SO THAT THE CAGE IS KEPT CLEAR DURING THE TOWING OPERATION. DO NOT EXCEED 8 KM/IR (5 MPH) WHEN TOWING. IF THIS WARNING IS IGNORED, ‘THE DRIVE MOTOR WILL BE DAMAGED. 6 TO RE-ENGAGE BRAKES: ‘When the operations in Paragraph 5 are completed, fully open the knurled knob on the valve block (located atthe left-hand end of the module), and move the black hand pump lever (ocated on top of the hydraulic ol tank) to the lft 7. OVERHEAD CRANE OPERATION: If towing is impossible, duc to tersin or the close proximity of buildings, it is recommended that the machine is removed from the ste with the use of an overhead crane, ‘The Boxer has four liting points situated at the four comers ofthe chassis. The Boxer 120 and 130 (@-Siage models) weigh 4510 kgs and 4540 kgs respectively. The Boxer 140 and 150 (-Stage models) weigh 5260 kgs and 5290 kgs repoctively. During iting operations, take all instructions from the crane operator. 8. HYDRAULIC PUMP FAILURE: ‘All funetions can be achieved by moving the black handpump lever to the left and operating the ‘handpump (located on top of the hydraulic oil tank, in the le-hand module), then depressing the relevant ground control function lever and operating the handpump. NOTE: Zoom and Lift funetions are difficult and will require some effort. Lowering All Booms: ‘The booms can be lowered by moving the black handpump lever 1o the lef, then depressing the relevant ground control function lever and operating the Randpump, 9. EMERGENCY ROTATION: Rotation can be carried out hydraulically, using the handpump and function lever (UK. and ‘Swedish machines), or by manually tuming the square shaft on the worm gearbox (located under ‘the rotating tured) with a 17mm (S/8") socket. An extension bar will be required to reach the shaft Page 4.410. EMERGENCY LOWERING FROM THE CAGE ASSEMBLY (OPTIONAL: Cenain Boxer models have Emergency Lowering facilis incorporated in the cage assembly. The lowering contol is situated to the right of the main machine controls and consist ofa selection lever, pump assembly, and handpump (handle stored atthe bottom right-hand side of the cage). ‘ToLower Cage: (@) Fit handpump handle to Emergency Lowering pump. (b) Depress selection lever to the "down" position. (© Operate the handpump handle to lower the boom. Page 45SECTION 9: MAINTENANCE SCHEDULES NOTE: Sections 5 through 8 will not be found in this manual. All pages not found in this manual are contained in the Electric Eagle 32/21N and 41/24N Technical Manual, Part No. 89-412790SECTION 9 TENA\ HED! 1, GENERAL INFORMATION: ‘The Boxer Mk3 series has been specially designed to reduce maintenance to a minimum. It is essential thatthe specified servicing inswucions are followed 10 ensure safety and reliability ‘The hydraulic pump, motor, cylinders and pressure valves are self-Jubricating internally. The ‘tumtable slewing ring is grease-packed and the corosion-resistant pivot pins and bearings are Dre-lubricated and require attention only at six monthly intervals. NOTE: During the guaranice period, minor oil leaks may occur until the various hydraulic ‘components and pipe fiuings are "beddedin”. It is particularly important that inspection of all hydraulic components, hoses and pipe fiings for oil leaks, etc, should form part of the weekly service for the firs three months operational use, and conective action taken, a¢ required, HYDRAULIC OWS: Hydraulic oils not shown on the Recommended Lubricants Chart (page 92) may be used, providing that the manufacturer is reputable and the oil complies with the following requirements:- (a) Highly refined mineral oil incorporating anti-oxidant, antirust, ant-foam, and ant-wear additives. (b) The oil must have good demulsibilty, so that water is not circulated in the system. (©The optimum viscosity range at operating temperature is 1640 centistokes. (@) The viscosity index should preferably be 100, and not less than 90. (©The viscosity range wil wally be: TEMPERATE oc 3008 TEMPERATE 4c 300s TROPICAL oc 7008 ‘TROPICAL 40°C 50S ‘TROPICAL 100°C &s (Mineral hydraulic oils produced by different companies will usually mix with each other satisfactorily. However, the oll producers should be consulted in case of doubt. (@) For sub-zero temperatures, the use of Sholl Tellus TIS or equivalent hydraulic uid with viscosity index of 151E and pour point MINUS 50°C is recommended. (b) For topical emperature, the use of BP Energol HLP 100 or equivalent is recommended. Page 9.1Mineral oils act as solvents on the natural oil in dhe skin and frequent and prolonged skin contact can cause dermatitis or severe itation. Normally, mineral hydraulic ols present no health hazard when uscd intelligendy and it is recommended Witt protective clothing and proper washing facilities should be provided or be accessible. If oil is splashed into the eyes, it must be washed out wboroughly using copious quantities of water, If invitation persists, medical advice should be sought WARNING ‘THE ATTENTION OF ALL PERSONS IN REGULAR CONTACT WITH MINERAL OILS SHOULD BE DRAWN TO THE NEED FOR THOROUGH HYGIENE AND THE CORRECT METHOD FOR HANDLING TO AVOID POTENTIAL HAZARDS TO HEALTH, BP ENERGOL HLP 22 SHELL ‘TELLUS 22 FINA CIRKAN 22 TOTAL ‘AZOLLA 22 CASTROL, HYSPIN AWS 22 4 SSO NUTO HP 22 GULF HYDRASIL 22 AW ‘CHEVRON EP HYDRAULIC OIL 22 WARNING (Models 120, 130, 140 and 150 ONLY) BRAKE FLUID: DO NOT PUT HYDRAULIC OIL IN THE SERVICE BRAKE MASTER BRAKE CYLINDER. USE ONLY SAE J1703 UNIVERSAL GRADE BRAKE AND CLUTCH FLUID (US. SPECIFICATION: FMVSS 116 DOT 3). 5. PIVOT PINS AND BEARINGS: All pivot pins have been Parco Lubrite 2 weated and only requir lubrication chocks at 4-yearly intervals. The Parco Lubrite 2 weatment converts the metallic surface of the pin to a manganese ion phosphate coating, giving high oil absorptive and corrosion resistant qualities. All pivot pin bearings are stel-backed, acetal co-polymer lined and only require lubrication checks at 4-yearly intervals, Page 9.2Recommended lubricant is '‘MOLYKOTE LONGTERM 2 PLUS' extreme pressure grease or equivalent, NOTE: In topical climates, pins and bearings may require more frequent lubrication. ‘There are no grease nipples for pin or bearing lubrication. The pins ‘must be removed and lubricated by hand, Page 93SERVICING CHECK LIST {BASIC MACHINE ONLY) DAILY: ‘Check hydraulic oil level ‘Check tyre condition. (Check cage door lock. WEEKLY: ‘Check hydraulic system for leakage. ‘Check control valves for self-ccnte. ‘Check steering system for oil leakage and wear ‘Check bauery electrolyte levels. ‘Check pivot pin security. MONTHLY: ‘Check hydraulic oil for contamination, Check drive gearbox ol (Check master brake cylinder oil level (models 120, 130, 140 and 150 ONLY). (Check chassis mounting bolts. Check rotation gearbox oil level. ‘Check pivot pin secury, Lubricate slew ring tooth. Lubricate ll small pivots Uioughout the machine. MONTHLY: Check cage levelling. Check cage pivots. (Check boom cylinders. (Check axle assembly. Change pressure ine filter, Test all machine systems, ‘XEARLY: ‘Examine/change oil in rotation gearbox. Examine/change hydraulic oil for contamination. ‘Examine inside of hydraulic oil tank for contamination, Examine/change oil in wansmission brake (models 120, 130, 140 and 150 ONLY). Examine machine structure for damage, corrosion, et. Examine cage mounting security. FOUR YEARLY: Detsiled inspection of all exible hoses. Deuziled inspection of all pivot pins and bearings. NOTE: THIS CHECK LIST 1S ONLY TO BE USED AS A REMINDER OF THE DETAILED INSTRUCTIONS GIVEN IN THIS MANUAL. ALL DETAILED SERVICING INSTRUCTIONS MUST BE IMPLEMENTED. Page 9.4DAILY ROUTINE SERVICING IYDRAULIC OIL LEVEL: Before checking the ol level, ensure Wit the machine booms are slowed in the traveling position and the machine is standing on level ground. The oil level must be 2.54 ems (1 inch) below Whe top Of the oil level gauge. Refer to the lubrication chart (page 9.17) for the corect grade of oil if the reservoir requires "topping-up". ‘TYRE CONDITION: (Check that machine tyres are in good condition. CAGE DOOR Lock: Check the security of tie cage door Page 953. contro os ‘Cage contro! valves must be checked for correct operation. Check that control valve handles ‘automatically return 10 the cenure (neutral) position. HYDRAULIC: (@) _ Pressurise the hydraulic circuit and inspect the system for any signs of cil leakage, paricularly at flexible hoses, connections and hydraulic components, (b) Examine all pivot pins on booms, cylinders and levelling system to ensure that they are Positively secured in position, ‘STEERING: (Check the steering cylinder for oil leakage and the steer linkage for wear. BATTERIES: ‘Chock the bauery elecuolyic levels. Replenish with dislled water, if nocessary, PIVOT PINS: (Check all pivot pins for security, Page 9.7LY Ri SERVICING HXDRAULIC O1L: Allow the machine to stand ovemight, or for atleast 8 hours, without operating the pump. ‘This will allow water and any olker impurities to separate out of te oil and seule 10 the botiom of the tank. Disconnect the %," pine from we pump side of the ball vale and block off wo prevent cil leakage from the system. ‘Open the ball valve atthe botiom of the tank just enough to allow a gradual trickle of oil and drain ‘uid from the tank into a wansparent container, unl clean oil lows. Under normal operating Conditions, a maximum of 0.25 lixes (', pint) is usually sufficient to remove all impurities, If the ol! does not flow clear but has a cloudy appearance, itis usually an indication that water is Present. If this condition occurs, a complete oil change will be necessary. ‘CHASSIS BOLTS: (Check all chassis bolts for signs of looseness. Re-ighten if necessary. SLEW RING GEAR TEETU: Remove any dirt or grit from between the gear leeth and re-lubricate (refer to Lubrication Char, page 9.17 for dois). NOTE: If solvents or a high-pressure washer a used for cleaning, re-grease the slew ring beatings. Check the gearbox oil level. Top-up with EP 90, ‘The filler plug is located atthe top of the gearbox and the dain plug is located atthe botom of the ‘earbox housing. The oil level should reach the filler plug hole (withthe machine on level sg70und). Low oil level is usually due to seal failure on the wormshaft. LUBRICATION: Lubricate all small pivots (but NOT the main pin pivots) throughout the machine with any good ‘quality medium grade oil. Special attention should be given to the cage contol lever pivols. FIVOT PIN SECURITY: ‘Examine all pivot pins on booms, cylinders and levelling system and ensure that they are all Positively secured in position, DRIVE GEARBOX: ‘Check oil level. Top-up with EP 90 grade oil ‘MASTER BRAKE CYLINDER (models 120, 130. 140 and 189 ONLY: ‘Check oil level. Top-up with SAE J1703 UNIVERSAL Brake and Clutch Fu. Page 9.9TT (a) Examine bout levelling cylinders, particularly at the pivot points, for wear or damage. Ensure that the end fitings are secur, (b) Check cylinders and hose fiuings for leakage. CAGE PIVOTS: ‘The main pivots on the booms, cylinders and levelling system are fied with comosion-resistant pins and pre-lubrcated bearings. Check the bearings with the pivet pins removed. ‘The bearings are stctl-backed, acetal co-polymer Lined. If whe beatings should show any defect, they should be reptaced with the comect type. Consult Simon Aerials Lid. BOOM CYLINDERS: (a) Hydraulically west the cylinders at fully earacied and extended positions and check that there is no movement berween rod and bearing housing, or between cap and tube. (®) Check all cylinders for oil leakage. XLE_ASSEMBLY: (Check oil level, Top-up with EP 99 oil, PRESSURE LINE FILTER: Change the Pressure Line Filter element (S.A. No. 11357). ‘MACHINE TEST: ‘Test the following systems: (@) Drive assembly, luding drive shaft, axle, couplings. drive motor and. gearbox. (b) Slew ring and rotation gearbox, (©) Cage rotation worm drive, (@) All machine functions. Page 9.111 3. YEARLY ROUTINE SERVICING ROTATION GEARBOX: (@) Remove the drain plug and drain the oil from the rotation gearbox housing. The oil wll flow more easly and hold any impurities in suspension if the tumiable is rotated for @ short petiod to warn the oil before draining. (b) Replace the drain plug, refill the gearbox with EP 90 (or equivalen) oil Refit filler plug, ‘SLEW RING BEARINGS: Grease the slew ring by routing the tumiable, as necessary. HYDRAULIC OM: Providing the hydraulic oil has been regularly maintained, it should only require to be changed at approximately two-yearly intervals, but this is dependent on maintenance, amount of use, application, temperature, atmospheric conditions and other factors. If the oil has a cloudy appearance, this indicates that water is presen. If the oil has changed from clear amber 10 dark brown, accompanied by a siong “bum” smell this indicates over-heating of lhe oil. The cause should be investigated and rectified. The presence of either condition requires a ‘complete oil change. HYDRAULIC OIL TANK: ‘Carefully check the condition of the cil inside the tank to ensure that it flows easily and is of clear, amber colour in appearance, In cases of gross contamination, it will be necessary to completely drain and re-fill the entire hydraulic system. ‘ToResfil the Tank Only: (@) Ensure thatthe oil temperature is sufficienly high wo allow the ol to flow freely. (b) Place a suitable container under the drain tp or atach a suitable hose 1 lead from the drain tap to the waste oil container (© Open the drain tap and drain off all the oil from the tank, (@) Remove the tank top plate for intemal inspection and cleaning. (©) Renew or clean the suction hose and close the dain tap, (0) Replace the cover plate, renew the gasket if necessary, and re-fil the tank to the correct level, ‘Materials: Approximately 19 lives of BP Energol HLP 22 hydraulic ol TRANSMISSION BRAKE. (models 120, 130, 140 and 15) ONLY: (Check the condition of the oil and top-up with BP Energol HLP 22 hydraulic oil Page 9.13Page 9.14 STRUCTURAL EXAMINATION: A thorough examination of the complete machine should be caricd out for any signs of damage, corrosion, misalignment, material fractures, tc. Particular auention must be given to the condition of all welded joints CAGE MOUNTING: (@) Check that all mounting bolts are secure. (b) Check cage frame members are in good condition.IR R VI NOTE: The following recommendations are based on the advice of supplier: and the requiements of various rainal safety egulaions. They should be applied with discretion, depending on such facirs a8 the amount of use and type of work, environmental conditions, local safety regulations, cc, Inspect all flexible hoses over their entre length, Renew any hose showing looseness or corrosion 4 the end Guings, cracking, blistering or excessive woar of te our prosctve covering, ‘PIVOT PINS AND BEARINGS: (@) Remove the pivot pins for examination. (©) Check the pivot pin bearings with the pivot pins removed. Renew the bearings, as necessary. ‘The pivot pins are Parco Lubrive 2 weated and the pivot pin bearings are stel-backed, ‘acetal co-polymer lined. The correct type of pin and bearing should be fited. Consult Simon Aerials Lid, Page 9.15LUBRICATION (SEE DIAGRAM, PAGE 9.19) PART GREASE/OIL | _ FREQUENCY NOTE, Rotation Gearbox EP 90 Check Monthly : ‘Change Yearly ‘Axle Assembly EP90 6 Monthly : Change Yearly Drive Gearbox EP 90 Check Monthly : Change Yearly LitvPump Motor Vaseline 6 Monthly Smear electrical (grease) connections Hydraulic 0 BP LLP 22 ‘Check Weekly Fil to 2.54 ems from Change Yearly filer hole neck Lint Cylinders Molykote 2 Weekly . Grease) PinsBearings Molykote 2 4 Yearly More frequent in Gerease) tropical climates Wheel Bearings 1s2 Yearly : (grease) Brake Mechanism Molykote 2 Yearly Smear all moving (grease) parts #4 Zoom Boom Molykote 2 Monthly Inner part Grease) wo 40 Monthly Outer part Master Brake SAE J1703 ‘Check Monthly + ands Transmission Brake | BP HLP 22 Check Yearly oa Stew Ring : : o * See diagram, page 9.19 ** See Slew Bearing details, page 9.24 "** Models 120, 130, 140 and 150 ONLY Page 9.17XTNO OSI PUP Opt “OE “GEL SOU « VEOVIT NOLLVOTAATT ‘ONTIVAE “THSHAN («1H Toowana ae) + BIVAE NOISSINSNVAL (cour avs) g « WNMAO Divas wiswW (06 a) xomAUVaD JARI 06 axv SLLSNTILTHS: SALVATIO OwaZ-ans Oot dH 1OOuaNa dd: SALVWITD ToKdOuL dTHIOOWANG dd: SALVO ALVAAWL oan , XORIVAD NOLVLON (€6 a0Vd 6 "108s 339) SONIVaG CNY SNId Page 9.19GIN HON aNV aYVUE. “SYGAIND €0LIf AVS HUM dN-dOL + ee SS Pp SSLEW BI RI IN. GREASE CHARACTERISTICS: The greases used for the Slew Bearing are of two different types, cach having a particular function: () For The Bearing: + Operating temperature: 30%C to 150°C + ASTM penevation at 25°C (ASTM D217) rnon-worked 269 worked (10,000 eyeles) 284 + Drop point, as per ASTM D566 187 + Viscosity at SOC (for base oil) uno + Timken OK test load in Ibs (min, requiremens) .. 30 () Bor The Gears: + Extreme pressure lubricant + BTRA viscosity at 50°C (minimum) 100 + Engler viscosity at SOC. = 165 ROLLIX-DEFONTAINE RECOMMENDATION: ‘According to the operating conditions, we recommend: + MOBIL DORCIA 30 when subject to shock loading. + ESSO SURRET FLUID 30F for normal operation, ‘The teth must be thoroughly cleaned, particularly within the gaps between the teeth, before lubrication. For this operation we recommend a proprietary solvent. Lubrication frequency : approximately 150 hours. ther brands of grease may be used, provided that they possess the same lubrication characteristics as those quoted. (@) BEARING LUBRICATION: For the bearing lubrication, the grease holes are tapped 10 x 100 (not fine) thread which is a ‘European standard and suitable for this application. + Centralized lubrication, this takes a number 6 or 8 tube (DIN 2391) + Conventional lubrication, spherical head, staight or bent grease nipples are used (Standards AFNOR - NFR 165-21 - DIN 3410) () LUBRICATION FREQUENCY: = Regular Operation: every 100 hours, = Intensive Operation : every 50 hours. NOTE: The Slewing Ring should be rotated after the lubrication operation, then the lubricant should be topped-up. Page 9.23ATIC Page 9.24 GREASE BRAND BEARING GEAR Antar Epexa 2 Pebron engrenage 1401 BP Energrease EP2 GR 154 GS Castrol Spheerol - Elf EIfEP2 Elfnera 4900 x fluid Esso Beacon EP2 ‘Surret fluid 30F Fina Marson EPL2 - Igol Perfect - Labo GS 2061 : Mobil Mobilplex 47 Dorcia 30 Shell Alvania EP2 Cardium EP fluid H Total Multis EP2 - Texaco Multifak EP2 Crater 2 x fluidEAGLE 32/21N & 41/ 24N OPERATOR'S MANUAL = oO Z| ia Qa Qa < APPENDIX son Page A-1 gEAGLE 32/ 21N & 41/ 24N OPERATOR'S MANUAL Table of Contents, Appendix Applicable Standards and Regulations. ANSVSIA A92.5 - 1993 (Partial)... 5. Responsibilities of dealers . 6. Responsibilities of owners ... 7. responsibilities of users 8, Responsibilities of operators 9. Responsibilities of lessors . 10. Responsibilities of Lessees APPENDIX Wy sanetonEAGLE 92/21N & 41/ 24N OPERATOR'S MANUAL Lz APPLICABLE STANDARDS AND REGULATIONS In addition to the operational instructions provided herein, various standards and governmental regulations also apply fo the use and operation of your Simon Aerial Work Platform. APPENDIX ‘Attached hereto are copies of some of the applicable codes, regulations and standards with which you must comply if his 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 aver time. For complete, current copies of U.S.A. standards, you must annually write to: American Notional 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 forthe area in which the equipment will be operated in order to obtain current copies of these regulations Cole) Page A-3EAGLE 32/ 21N & 41/ 24N OPERATOR'S MANUAL o a a 7 a a =< = a = a z =<LL EAGLE 92/ 21N & 41/ 24N OPERATOR'S MANUAL ANSI/SIA A92.5 - 1993 (PARTIAL) 5. RESPONSIBILITIES OF DEALERS 5.1 Basic Principles. Sound principles of sofely, training, inspection, maintenance, application and operation consistent with all data available regarding the parameters of intended use ond expected environment shall be applied in the training of operators, in maintenance, application, safely provisions and operation of the aerial platform with due consideration of the knowledge that the unit will be corrying personnel. ANSI/ SIA A92.5-1993 5.2 Manuals. Deolers shall keep and maintain copy(ies) of he operating and maintenance manual(s) required in section 4.19 of this standard. Operating manuol(s) shall be provided with each rental, lease, or sale delivery. These monual(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 moitenance manuai(s) shall be provided with each sale delivery. 5.3 Predelivery Preparation. Aerial platforms shall be inspected, serviced and adjusted fo manufacturer's requiremants prior to each delivery by sale, lease or rental. 5.4 Maintenance Safety Precautions. Before adjustmnets and repairs are started on an aerial platform, the following precautions shall be taken as applicable: (©) Powerplant stopped and starting means rendered inoperative. (b) All controls in the *off* position and all operating systems secured from inadvertent motion by brokes, blocks, or other means. (© Boom and platform lowered to the full down position, if possible, or otherwise secured by blocking or cribbing fo prevent dropping. @ Hydraulic oll pressure relieved from all hydraulic circuits before loosening or removing hydraulic components. Safely 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 oerial platform parts or components. 5.6 Training. Whenever a deoler 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 sole, lease or rental. aaa Page A-5EAGLE 32/ 21N & 41/ 24N OPERATOR'S MANUAL 5.7 Operation. When a dealer operates an ceria! platform in sales demonstrations or otherwise for his beneficial use, he and his operating personnel shall assume the responsbilities of users os specified in section 7 and responsibilities of operators as ‘specified in section 8 of this standard. 5.8 Assistance to Owners and Users. I 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 recordsfor at least three years: (©) 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 aerialplatform shall be made only with prior writen permission of the manufacturer. 5.11 Manufacturers Safety Bulletins. The dealer shall comply with safety related bulletins Qs 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 addressof the new owner within sixty (60) days. oO a a 8 a Q < = a > a z <=LL EAGLE 92/21N & 41/ 24N OPERATOR'S MANUAL 6. RESPONSIBILITIES OF OWNERS 6.1 Basle Principles. Sound principles of safety, training, inspection, maintenance, pplication and operation consistent with all data available regarding the parameters of intended use and expected environment shall be opplied 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 he 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 ‘on integral part of the aerial platform and are vital to communicate the necessary softy information to users and operators. In addition, parls and maintenance manual(s) sholl be provided with each sale delivery. 6.3 Predelivery Preparation. Aerial platforms shall be inspected, serviced and adjusted to manufacturer's requirements prior fo each delivery by sale, lease or rental 6.4 Maintenance. The owner of an aerial platform shall arrange that the maintenance specified in his standard is properly performed on a timely basis. The owner shall establish @ preventive maintenance program in accordance with the manufacturer's recommenda- ions 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 cerial platform is returned to service. 6.5 Frequent Inspection. The owner of an aerial platform shall couse a frequent inspection to be performed on the aerial platform: (0) That hos been in service for three (3) months or 160 hours, whichever comes first. (0) Before putting into service a machine which has been out of service for a period longer ‘han three (3) months of time. ‘The inspection shall be made by a person qualified as a mechanic on the specifimake and model of the aerial platform. The inspection shall include all items specified by the manufacturer fora frequent inspection and shall include but not be limited fo the following: ©) All functions and their contols for speed(s), smoothness and limits of motion. (0) Lower controls including the provisions of overriding of upper controls. (©) All chain ond coble mechanisms for adjustment and worn or damaged parts. @) All emergency and safety devices. @) Lubrication of all moving parts, inspection of fitter element(s), hydraulic oll, engine ol, ‘ond coolant os specified by the manufacturer. D Visual inspection of structural components and other critical components such as fasteners, pins, shatis, turntable attachment bolts, and locking devices. (@) Placard, warnings and contro! markings. Joao Page A-7EAGLE 32/ 21N & 41/ 24N OPERATOR'S MANUAL 6.5 Frequent Inspection (continued). (h) Additional items specified by the manufacturer. (@ Correction of all mattunctions and problems identified and further inspection it necessary. @ Affer correction or replacement of any component, the unitshallbe inspected and tested in accordance with above paragraph 6.5. 6.6 Annual Inspection. The owner of an cerial platform shall cause an annual inspection to be performed on the oerial platform no later than thirleen (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 on erial 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 inadvertant motion by brakes, blocks or other means. (©) Elevating assembly and plotform lowered fo the full down position, if possible, or otherwise secured by blocking or cribbing to prevent dropping. @ Hydraulic oil pressure relieved from all hydraulic circuits before loosening or removing hydraulic components. ©) Safely props or latches installed where applicable as prescribed by the manufacturer. 6.8 Replacement Parts. When parts or components ore replaced, they shall be identical oF equivalent to original cerial 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 ‘on cerial paitform, 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 {raining on the proper use and operation of the aerial platform shall be provided upon each delivery by sale, lease or rental. 6.11 Operation. When an owner operates an cerial 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 his standard. ANSI/ SIA A92.5-1993 U/ sonexz 6.12 Assistance to Users and Operators. if an owner is unable to answer a user's or operator's questions relating fo 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: (© Name and address of the purchaser of each aerial platform by serial number and date of delivery. (b) Records of the person(s) frained upon each delivery of an cerial platform. © Written records of he 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. (@ Records of the predelivery preparation performed prior fo each delivery. 6.14 Modifications. Modificationor 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 {ss received from the manufacturer or dealer. 6.16 Ownership Records. When a change in ownership of an aerial device occurs, itshall 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. Page A-9 EAGLE 32/ 21N & 41/ 24N OPERATOR'S MANUAL ANSI/ SIA A92.5-1993EAGLE 32/21N & 41/ 24N OPERATOR'S MANUAL 7. RESPONSIBILITIES OF USERS 7.1 Basie Principles. The information inthis standard must be supplemented by good job management, safety control and the opplication of sound principles of safely, 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 od aerial platforms, conformance with ood safety practices in this area is the responsibility ofthe user and his operating personnel including the operator. Decisions on the use and operation of the oerial platform must always be made with due consideration for the fact that the machine will be carrying personnel whose safely 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 stondard. The operating manual(s)shall be stored in the location required in section 4.20 of this standard. These manuals are considered an intergral part of the cerial platform and are vital fo 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 sholl be immediately removed from service until repaired. Repairs shall be made by o 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. 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 fest including but not limited fo the following: (©) Operating and emergency controls. (b) Sofely devices. (c) Personal protective devices, including fall protection. @) Alt, hydraulic and fuel system leaks. (©) Cables and wiring harness. © Loose or missing parts. (Q) Tires and wheels. (h) Placards, warnings, control markings and operating and sofely manual(s). (D Outriggers, stabilizers, extendible axles and other structures. @ Guardrail system. @® liems specified by the manufacturer. 4 sone ANSI/ SIA A92.5-1993 Page A-10EAGLE 32/21N & 41/ 24N OPERATOR'S MANUAL xz 7.3.4 Maintenance Safety Precautions. Before adjustments and repairs are started on an cerial piatform, the following precautions shall be taken as applicable: (@) Powerplant stopped and starting means rendered inoperative. (b)Al controls in the “off position and all operating systems secured from inadvertent motion by brakes, blocks or other means. (© Boom and platform lowered to the full down position, if possible, or otherwise secured by blocking or cribbing to prevent dropping, (@) Hydraulic oil pressure relieved from all hydraulic circuits before loosening or removing hydraulic components. (©) Safety props or latches installed where applicable as prescribed by the manufacturer. (D Precautions specified by the manufacturer. ANSI/ SIA A92.5-1993 7.4 Replacement Parts. When paris or components are replaced, they shall be identical oF 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. 7.6 Operator Training. Whenever a user directs or authorizes an individual fo operate an erial platform, he shall ensure that the individual hos been trained in accordance with the manufacturer's operating and maintenance manual, the user's work instructions and Tequirements listed in section 8 of this standard before operating the aerialplatform. 7.6.1 Model Training. The user shall be responsible for the operator being trained on the model of thecerial platform that he will be operating. Such training shall be in an area free of obstructions, under the direction of o qualified person for a time sufficient to determine thot 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: (@) 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 sofety ules, or been trained by a qualified person on the contents of the manufacturer's ‘operating instruction(s) and users safely rules. (© Understood by reading or by having a qualified person explain all decals, warnings nd instructions displayed on the aerial platform. (@ Determine that ine purpose for which the oerial platform is fo be used is within the scope of the intended applications defined by the manufacturer. al Page A-11EAGLE 32/21N & 41/ 24N OPERATOR'S MANUAL 7.7 Before Operation (continued). @) Been provided with approved fall protection devicesand 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 s but not limited to: (0) Drop-offs or holes. (b) Bumps and floor obstructions. (©) Debris. (@) Overhead obstructions and high voltage conductors. © Hazardous locations. D Inadequate surface and support fo withstand all load forces imposed by the oerial platform in all operating configurations. (g) Wind and weather conditions. (h) Presence of unauthorized persons. (® Other possible unsafe conditions. 7.9 During Operation. The aerial platform shall be used in accordance with this standard. The user shall ensure that before each movement of the aerial platform, if repositioning of J, ‘the platform, that the operator shall ensure: (©) The aerial platform is operated on a surface within the limits specified by the manufocturer. (b) The outrigger, stoblizers, extendible oxles, or other stability enhancing means, are used as required by the manufacturer. (© Guardrails ore installed and access gates or openings are closed per manufacturer's instructions. @) The load and its distribution on the platform and any platform extension ore in ‘accordance with the manufacturer's rated capacity for that specific configuration (@) There is adequate clearance from overhead obstructions. ( The minimum sofe approach distance (M.S.A.D.) fo energized power lines and parts, 4 listed in Table 1 ore maintained. (See Fig. 3, page 23 of complete standard, for examples of safe operating procedures.) (@ The precautions defined in 7.3.3, 7.7, 7.8, 7.9, 7.10 and 7.11 of this standard are followed during operation of the aerial platform. 7.10 Hazardous Locations. Itshall be the responsibility of the user to determine the hazard classification of any particular atmosphere or location according to ANSI/NFPA 505 -1987. 7.10.1 Hazardous Locations. Aerial platforms operated in hazardous locations shall be approved and of the type required by ANS/NFPA 505-1987, ANSI/ SIA A92.5-1993 Page A-12 Lyxz 7.11 Warnings and Instruction, The user shall direct his operating personnel ond ‘supervise their work to ensure operation of the aerial platform in compliance with this standard. 7.11.1 Personnel Footing. Personnel shall maintain a firm footing on the platform floor while working therein. Use of planks, ladders or any other device on the aerial platform for achieving additional height or reach shall be prohibited. 7.11.2 Precaution from Other Moving Equipment. When other moving equipment or vehicles are present, special precautions shall be taken to comply with local ordinances or Safely standards established for the workplace. Warnings such as, but not limited to, flags, roped-off areas, flashing lights and barricades shall be used. 7.11.3. Reporting Problems or Malfunctions. The operator shall immediately report tohis supervisor any problem or matfunctions which become evident during operation. Any problems or motfunctions that affect the safety of operations shall be repoired prior to continued use. 7.11.4 Altering Safety Devices. Altering or disabling of interlocks or other safely devices shall be prohibited, 7.11.5 Entanglement. Care sholl be token fo prevent rope, electric cords and hoses from becoming entangled in the cerial platform. 7.11.6 Capacity Limitation. Rated capacities shall not be exceeded when loads are transferred to the platform at any height. 7.11.7 Work Area. The operator shall ensure that the area surrounding the aerial platform is clear of personnel and equipment before lowering the platform. 7.11.8 Fueling. The engine shall be shut down while fuel tanks ore being filled. Fuelingshall be done in a well-ventilated area free of flame, sparks or other hazards ‘which may cause fire or explosion. 7.11.9 Battery Charging. Batteries shall be charged in a well-ventilated area free of flame, sparks or other hazards which cause fire or explosion. 7.11.10 Improper Platform Stabilization. ‘The aerial platform shall not be positioned ‘against another object to steady the platform. 7.11.11 Misuse as a Crane. The cerial platform shall not be used as a crane. 7.11.12 Operating Area. The aerial platform shall not be operated from a position on trucks, trailers, railway cars, floating vessels, scaffolds or similar equipment untess the pplication is approved in writing by the manufacturer. Page A-13 EAGLE 32/ 21N & 41/ 24N OPERATOR'S MANUAL ANSI/ SIA A92.5-1993EAGLE 92/ 21N & 41/ 24N OPERATOR'S MANUAL 7.11.13 Travel Speed. Under all travel conditions, the operator shall limit travel speed ‘according to conditions of ground surface, congestion, visibility, slope, location of personnel, and other factors causing hazards of collision or injury to personnel. 7.11.14 Elevated Driving Requirements. Before and during driving while the platform is elevated, the operator shall: @) Maintain a clear view of the path of travel. (P) Maintain a safe distance from obstacles, debris, drop-ofts, holes, depressions, ramps and other hazards to ensure safe elevated travel. (C) Maintain a sofe distance from overhead obstacles. 7.11.15 Stunt Driving. Stunt driving ond horseplay shall not be permitted. 7.11.16 Unguthorized Use. Means shall be used to protect against use by ‘unauthorized person(s). 7.12 Operation of the Aerial Platform. if a users also the operator of an aerial platform, he shall have the responsibilities of operators specified in section 8 of this standard as well as responsibilities of users os specified in section 7 of this standard. 7.13 Assistance to Operator. If a user is unable to answer an operator's question(s) felating to rated capacity, intended use, maintainance, condition of the aerial platform, or safety of operation of the aerial platform the user shallobtain the proper information from the dealer, owner or manufacturer and provide that information fo the operator before use of the aerial platform in the application of concern. 7.14 Shutdown of Aerial Platform. The user shall direct his operating personnel fo cease ‘operation of the aerial platform in case of any suspected matfunction(s) or any potentially hazardous condition(s) that may be encountered. Further information concerning sofe operation shall be requested from the owner, dealer or manufacturer before further operation. 7.15 Record Retension. The user shall retain the following records for at least three (3) years: (Q) Records of the operator(s) trained on each model of an cerial platform. (b) Written records of the frequent and annual inspection shall be kept by the user when he performs the inspection(s). The records shall include the date of Inspection, any deficiences found, the corrective action recommended and identification of the person(s) performing the inspection. (©) Writlen records of all repairs accomplished on the aerial platform shall include the date ‘of any such repair, a description of the work accomplished and identification of the person(s) performing the repair. 7.16 Modifications. Modification or alteration of an cerial platform shall be made only with prior written permission of the manufacturer. Ui/ onLL EAGLE 32/ 21N & 41/ 24N OPERATOR'S MANUAL 7.17 Manufacturer's Safety Bulletins. The user shall comply with sofely related bulletins as received from the manufacturer, dealer or owner. Page A-15 ANSI/ SIA A92.5-1993EAGLE 32/21N & 41/ 24N OPERATOR'S MANUAL 8. RESPONSIBILITIES OF OPERATORS 8.1 Basle Principles. The information in this standard must be supplemented by good judgement, sofety contro! and coution in evaluating each situation. Since the operator is. indirect control of the oerial platform, conformance with good safely practices in this area is the responsibilty of the operator. The operator must make decisions on the use ond operation ofthe aerial platform with due consideration for the fact that his own safely as well 4s the safety of other personnel in the platform is dependent on those decisions. 8.2 Manuals. The operatorshall be awore that he operating ond sofely manuals, including the manual which defines the responsibilities of dealers, owners, leSsors, lessees, users ‘and operators are stored on the aerial platform and the location where they are stored. The operator shall be familiar with the manuals stored on the aerial plotform and consult them when questions arise with respect to the oerial platform, 8.3 Pre-start Inspection. Before use each day or at the beginning of each shift, the aerial platform shall be given a visual inspection and functionattest including but not limited to the following: (©) Operating and emergency controls. (b) Safety devices. © Personal protective devices, including fall protection. @ Air, hydraulic and fuel system(s) leaks. © Cables and wiring hamess. © Loose or missing ports. @ Tires and wheels. (h) Placards, warnings, control markings and operating manual(s). ) Outriggers, stablizers, extenible oxles and other structures. @ Guordrail system. (W) lems specified by the manufacturer. 8.4 Problems or Malfunctions. Any problems or matfunctions that affect the sofety of operations shall be repaired prior to the use of the aerial platform. 8.5 Training. Theoperator shall be trained on the same model of cerial paltform or one having operating characteristics consistent with the one fo be used during actual work site operation. Under the direction of a qualified person, the trainee shall operate the aerial platform for a sufficient period of time to demonstrate proficiency and knowledge in the actual operation of the aerial platform, Care shall be token to ensure the orea of such operation has a minimum of obstacles and is conducive to training. Only properly trained and authorized personnel shall be permitted fo operate the aerial platform. ANSI/ SIA A92.5-1993 Page A-16 Z/ oemLi 8.6 Before Operation. Before being authorized to operate the aerial platform, the operator shail have: () Been instructed by o qualified person in the intended purpose and function of each of the controls. (b) Read and understood the manufacturer's operating instruction(s) and users sofety Tules, or been trained by a quolified person on the contents of the manufacturer's operating instruction(s) and users safely rules. (© Understood by reading or by having a qualified person explain all decals, wamings and instructions displayed on the aerial platform. 8.7 Work Place Inspection. Before the cerial platform is used and during use, the operator ‘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. (o) Bumps and floor obstructions. (©) Debris. (@) Overhead obstructions and high voltage conductors. (@) Hazardous locations. (PD Inadequate surface and support to withstand all load forces imposed by the aerial platform in all operating configurations. (g) Wind and weather conditions. (f) Presence of unauthorized persons. @ Other possible unsafe conditions. 8.8 During Operation. The aerial platform shall be used in accordance with this standard. ‘The operator shall ensure the following before each elevation of the platform: (@ Ensure the aerial platform is operated on a surface within the limits specified by the manufacturer. (b) Ensure the outriggers, stabilizers, extendible axles or other stability enhancing means, ‘re used as required by the manufacturer. (© Ensure that guardrails are installed and acoess gates or openings are closed per manufacturer's instructions. (@ Ensure the load and its distribution on the platform adn any platform extension(s) are in accordance with the manufacturer's rated capacity for that configuration. (© Ensure there is adequate clearance from overhead obstructions. (® Ensure thatthe minimum safe approach distances (M.S.A.D.) fo energized power lines ‘and ports are maintained. (See Fig.3, page 23 of complete standard for examples of safe operating procedures.) (g) Ensure all personne! in the platform are wearing fall protection devices and other safety gear as required at all times. 8.9 Hazardous Locations. It shall be the responsibility of the user to determine the hazard Classification of any particular atmosphere or lacation according to ANSVNFPA 505-1987. Page A-17 EAGLE 32/ 21N & 41/ 24N OPERATOR'S MANUAL ANSI/ SIA A92.5-1993EAGLE 32/21N & 41/ 24N OPERATOR'S MANUAL 8.9.1 Hazardous locations. Aerial platforms operated in hazardous locations shall be ‘pproved and of the type required by ANSVNFPA 505-1987. 8.10 Warnings and Instructions. The operator shall ensure the operation of the aerial platform is in compliance with this standard, 8.10.1 Personnel Footing. Personnel shall maintain a firm footing on the platform floor while working therein. Use of planks, ladders or any other device on the aerial platform for achieving additional height or reach shall be prohibited. 8.10.2 Precaution for Other Moving Equipment. When other moving equipment or vehicles are present, special precautions shall be taken to comply with local ordinanoes or sofely standards established for the workplace. Warnings such as, but not limited to, flags, roped-off areas, flashing lights and barricades shall be used. 8.10.3 Reporting Problems ot Malfunctions. The operator shall immediately report to his supervisor ony problems or malfunctions which become evident during operation. Any problems or matfunctions that affect the safety of operation shall be repaired prior to continued use. 8.10.4 Reporting Potentially Hazardous Locations. The operator shall immediately report fo his supervisor any potentially hazardous location(s) (environment) which /, become evident during operation. 8.10.5 Altering Safety Devices. Altering or disabling of interlocks or other safety devices shall be prohibited. 8.10.6 Entanglement. Care shall be taken to prevent rope, electric cords and hoses from becoming entangled in the aerial platform. 8.10.7 Capacity Limitation. Rated capacities shall not be exceeded when loads are transferred to the platform at any height. 8.10.8 Work Area. The operator shall ensure that the area surrounding the aerial platform is clear of personne! and equipment before lowering the platform. 8.10.9 Fueling. The engine shall be shut down while fuel tanks ore being filled. Fuelingshall be done in a well-ventilated area free of flame, sparks or other hazards which may cause fire or explosion 8.10.10 Battery Charging. Botteries shall be charged in a well-ventilated area free of flame, sparks or other hazards which cause fire or explosion. 8.10.11 Improper Platform Stabilization. The aerial platform shall not be positioned ‘against another object to steady the platform. 8.10.12 Misuse as a Crane. The ceria! platform shall not be used as a crane. Ul/ ford ANSI/ SIA A92.5-1993 Page A-18EAGLE 82/21 & 41/ 24N OPERATOR'S MANUAL ILA 8.10.13 Unusual Operating Support Conditions. The aerial platform shall not be operated from a position on trucks, trailers, railway cars, floating vessels, scaffolds or similar equipment unless the application is approved in writing by the manufacturer. 8.10.14 Travel Speed. Under all travel conditions, the operator shall limit travel speed ‘according to conditions of ground surface, congestion, visibility, slope, location of personnel and other factors causing hazards of collision or injury fo personnel. 8.10.15 Elevated Driving Requirements. Before and during driving while the platform is elevated, the operator shall ANSI/ SIA A92.5-1993 (0) Maintain a clear view of the path of travel. (b) Maintain a safe distance from obstacles, debris, drop-offs, holes, depressions, ramps and other hazards fo ensure sofe elevated travel. (©) Maintain a safe distance from overhead obstacles. 8.10.16 Stunt Driving. Stunt driving and horseplay shall not be permitted. 8.10.17 Unauthorized Use. The operator shall implement means provided to protect ‘ogainst use by unauthorized person(s). 8.10.18 Misuse as a Jack, The boom and platform of the aerial platform shall not be used fo jack the wheels off the ground unless the machine is designed for that purpose by the manufacturer. 7 8.10.19 Driving on Slopes. The aerial platform shall not be driven on grades, side slopes or ramps exceeding those for which the aerial platform is rated by the ‘manufacturer. 8.10.20 Snagged Platform. If the platform or elevating assembly become cought, snaggedor otherwise prevented from normal motion by adjacent structure or other ‘obstacles such that control reversal does not freethe platform, all personnel shall be removed from the platform before attemptsare made to free the platform using ground controls. 8.11 Assistance to Operator. If an operator encounters any suspended matfunction of the cerial platform, or any hazard or potentially unsafe condition relating to copacity, intended se of safe operation, he shall cease operation of the cerial platform ond request further information as to safe operation from his management or the owner, dealer, or manufac- turer before further operation of the aerial platform. 8.12 Modifications. Modifications or alteration of an aerial platform shall be made only with prior writlen permission of the manufacturer. a8 Page A-19EAGLE 32/ 21N & 41/ 24N OPERATOR'S MANUAL 9. RESPONSIBILITIES OF LESSORS 9.1 Basic Principles. Sound principles of sofely, training, inspection, maintenance, pplication ond operation consistent with all data available regarding the parameters of intended use and expected environment shall be applied in the performance of responsi- bilities of lessors with due consideration of the knowledge that the unit will be carrying personnel. {9.2 Lessor. A lessor is a person(s) or entity who leases, rents, loans or otherwise provides. ‘an aerial platform to another party for the beneficial use of that party (the user). A lessor May also be a dealer, owner, lessee, user or operator. 9.2.1 Lessor as a Dealer. When a lessor uses the aerial platform as a dealer, he shall have the responsibilities of dealers as specified in section 6 of this standard. 9.2.2 Lessor as an Owner. When a lessor uses the cerial platform as an owner, he ‘shall have the responsibilities of owners as specified in section 6 of this standard. 9.2.3 Lessor as a User. When a lessor uses the derial platform as a user, he shall have the responsibilities of users as specified in section 7 of this standard. 9.2.4 Lessor as an Operator. When a lessor uses the aerial platform as an operator, U, he shall have the responsibilities of operators as specified in section 8 of this standard. ° ry a 6 a a < = a = a z =Ll EAGLE 32/21N & 41/ 24N OPERATOR'S MANUAL 10. RESPONSIBILITIES OF LESSEES 10.1. Basic Principles. Sound principles of safety, training, inspection, maintenance, ‘pplication and operation consistent with all data available regarding the parameters of intended use and expected environment shall be applied in the performance of responsi- bilities of lessees with due consideration of the knowledge that the unit will be carrying personnel. 10.2 Lessee. A Lessee is o Person(s) or entity to whom an aerial platform is provided by lease, rental, loan or other arrangement. A lessee may also be a user or operator. 10.2.1 Lessee as a Dealer. When a lessee uses the aerial platform as a dealer, he ‘shall have the responsibilities of dealers as specified in section 5 of this standard. 10.2.2 Lessee as an Owner. When a lesse uses the erial platform as an owner, he shall have the responsibilities of owners as specitied in section 6 of this standard, 10.2.3 Lessee as a User. When a lessee uses the aerial platform as a user, he shall have the responsibilities of users as specified in section 7 of this standard. 10.2.4 Lessee as an Operator. When a lessee uses the aerial platform as an operator, he shall have the responsibilities of operators as specified in section 8 of this standard. Page A-21 ANSI/ SIA A92.5-1993Ssimon AERIALS Twelve Month Limited Warranty ‘Simon Aerials Inc. (the “Company” warants, tothe original Buyer only, {) thatthe units of equipment manufactured and sold by it conform to the Company’s published ‘pocfcations; {)thatall component parts manufactured by it shallbe free from defects in material or workmanship for ‘Y2months from the dato tho units frst placed in service; and {6) that component parts not manufactured by the Company shall be freo from dofects in material or Workmanship forthe period warranted by the Company's vendor. lt the Buyer dlecovers within the warranty period a fallure to conform to specications ora dfectin material ‘of workmanship, it must prompty submit notice of such conditon to the Company and retum the non- ‘conforming par) tothe factory, freight prepaid, together with a propery completad Simon Aerials Inc. ‘Warranty Claim Form as furnished by the Company. In no event shall such notice be received later than 90, ‘days folowing expiration ofthe applicable warranty poriod. If, ttor inspection by factory Qually Assurance ‘personnel, the retumed part(s) are judged t be notin conformity with specications or defective in material ‘or workmanship, the Company willcorect such conditon by dalivering repaired or new replacement part(s) te the Buyer, fre of charge. This remedy isthe Buyers exclusive romody for breach of warranty. ‘This warranty does not cover damage causod by shipment, misuse of the unit (including operation beyondunit specification limits), talure to propery service and maintain the unitin accordance with the Company’s Manval of Factory Serie Bullatins, altoraton of the unt or natural disasters (cuch as fre, food, wind and lighting) ‘and shall be void if (1) the unitis altored or ropaired contrary othe Company's authorized instructions, (@) the units altored or repaicod in such a way as to affects performance or oily, oF (@) the units mounted on a chassis or earir which does not meet the Company's publshod 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. It field ropar or parts replacement is necessary on warranted components, Simon Aerials wil reimburse

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