powerstep access system for komatsu d475adozer

Powerstep Access System for Komatsu D475A Dozer

Hydraulic Ladder + Full Walkways

PSA-D475A-F/L-FULL 9-10-15

Model No. PSA-D475-FL-FULL

Serial No.: D475-001-FL-FULL- ~

Date Manufactured:

HYDRAULIC LADDER + WALKWAYSKomatsu D475A

Pg2PSA-D475A-F/L-FULL 9-10-15

CONTENTS

Page 3 Section 1 Installation and Mounting instructions

Installation Drawings

15 Section 2 Electrical System Wiring Diagrams

21 Section 3 Recommended Maintenance Procedure

22 Section 4 Operating Procedure

Section 5 Drawings and Repair Parts lists

23 5 Assembly Complete

24 5-1 RH Side Platform Assembly

Parts List

26 5-2 Ladder & Handrail Assembly

27 5-3 LH Side Platform Assembly

Parts List

29 5-4 Back Platform Assembly

Parts List

31 5-5 Drive Unit Assembly

Parts List

33 5-6 PROP Assembly

Parts List

34 5-7 Hydraulic Cylinder

Parts List

Hydraulics Diagram

36 5-8 Power Pack

Parts List

39 5-9 Electrical Controls

Parts List

HYDRAULIC LADDER + WALKWAYKomatsu D475A

Section 1. Installation and Mounting Instructions

See Installation Drawings 23601, 23 625, 23626 & 30264


PROCEDURE

See 23625 - Bolting Pads:

1. Weld components 23 607 01, 02 & 03 to the machine as shown in this drawing.

See 23626 - Platform:

1. Fit the Isolator Housings and Rear Isolator Brackets (fitted together as assemblies)

to the bolting pads on the back of the machine per View X and Detail W.

2. Fit the Rear Spreader Beam across the two assemblies in 'i' above per View X and

Detail W.

3. Fit Isolators to the bolting pad per View Y and Detail U.

4. Fit the Side Platform with all its' auxilary components so as to be supported by the

Rear Spreader Beam at the back and the Isolators at the front, per Views Y & Z

and Details U, V & W.

See 30264 - PROP:

1. Fit Clamp Beams and Clamps to the heavy roof plate of the ROPS, per Details Y &

Z.

2. Hold/clamp the Carrier Bars, already assembled with the PROP and Isolators to the

Clamp Beams so the PROP is central with the stowed ladder, per Detail Y. Tack

weld the Carrier Bars to the Clamp Beams.

3. Adjust the outer end of the PROP so it engages the ladder between the two top

treads (top in stowed position) by fitting/moving Isolator Spacers. Adjust the position

of the PROP so the ladder bears against it firmly when fully raised, by changing

which boltholes are used for the isolator pins.

4. Fully weld the Carrier Bars to the Clamp Beams, per Detail T.

NOTE

Follow all on-site/Mine lifting and safety procedures when installing

Power Step Landings to Dozer.


Section 1. Installation Instruction Drawings Bolting Pads 23 625


DE

TA

ILX

DE

TA

ILY

DE

TA

ILZ

DE

TA

ILW



Section 1. Installation Instruction Drawings Platform 23 626

VIE

W Y

VIE

W U

VIE

W V

VIE

W W

VIE

W X

VIE

W Z



Section 1. Installation Instruction Drawings Assembly 23 601



Section 1. Installation Instruction Drawings PROP P30 264

VIE

W Y

VIE

W V

VIE

W U

VIE

W Z VIE

W T

VIE

W X

VIE

W W


HYDRAULIC LADDER + WALKWAYKomatsu D475ASection 1. Installation Instruction DrawingsPg 1

Dwg PSA-K475-GB-Unit (5 Sheets)

US

E S

AF

E W

OR

KIN

G A

ND

LIF

TIN

G M

ET

HO

DS

AT

AL

LT

IME

S



US

E S

AF

E W

OR

KIN

G A

ND

LIF

TIN

G M

ET

HO

DS

AT

AL

LT

IME

S


Section 1. Installation Instruction Drawings - 23 615, 23 621, 23 623

Drive Arrangement


DR

IVE

AR

RA

NG

EM

EN

T


Section 1. Installation and Mounting Instructions (cont.)

Maintenance Notes


NOTE

Follow all on-site/Mine lifting and safety procedures when installing

Power Step Landings to Dozer.

WARNINGRaising the POWER STEP Landing by external means can create a vacuum in the

hydraulic cylinder and create the opportunity to allow air into the hydraulic system,

defeating the inherent safety features of the POWER STEP.

This must be avoided, to maintain safe operation of the POWER STEP.

In instances where the use of external means to raise the landing must be used,

please follow the following instructions:

Loosen hard plumbed hydraulic lines on cylinder side of lock valve on cylinder.

Raise landing by available means.

Note: Make necessary arrangements to collect displaced oil, and be aware that air enters

the piston side of the cylinder as landing is raised.

Lock in raised position.

Re-tighten hydraulic fittings.

SECURE THE LANDING IN THE RAISED POSITION, MECHANICALLY, CHAIN &

TAGOUT THE POWER STEP

To recommission the POWER STEP:

Loosen hydraulic fittings on cylinder side of lock valve.

Note: Collect displaced oil.

Lower landing to lowest position, using alternate safety approved means, fully retracting

cylinder. Ensure all personnel are clear of step radius.

Operate electrical control switch to purge air from the hydraulic line systems, lock valve

and cylinder.

Tighten the hydraulic fittings either side of lock valve to restriction fitting.

Cycle step unloaded several times to purge all air from hydraulic system.

The Power Step will not operate correctly if there is any air in the hydraulic circuit (due to

the incorrect operation of the lock valve).


Section 2. Electrical System - Wiring Diagram Pg 1


WIR

ING

HA

RN

ES

S



Section 2. Electrical System - Wiring Diagram Pg 2 Non Auto-Raise



Section 2. Electrical System - Wiring Diagram Pg 3 Auto-Raise

Pressure Switch Operated



Section 2. Electrical System - Wiring Diagram Pg 4 Auto-Raise

Toggle Switch Operated




WIRING HARNESS 1

Daily

Visually check ladder and structure for damage, loose components,

handrails, etc.

Check for hydraulic oil leaks from hydraulic cylinders, plumbing and hoses.

Notify the appropriate supervisor for any observed damage or malfunction.

500 Hours

Grease the nipples on the rotation shaft and sector gears.

Check main mounting bolts for torque.

Check hydraulic oil level in power pack and top up as necessary. (Ladder in raised

position).

Top up using same hydraulic oil as used in hydraulics of machine.

Thoroughly check all electrical wiring for damage, replace as necessary.

Repeat daily check as above

5000 Hours

Change hydraulic oil in tank of hydraulic power pack (5.0 litres)

It is recommended that the same hydraulic oil be used in the power pack as the

hydraulics of the machine.

Grease 4 grease nipples on rotation shaft and sector gears, all of these are

accessible with the ladder lowered, and accessed from under the ladder.

Check and inspect all main bolts on ladder system.

Retorque if required.

Repeat daily check as above


Section 3. Recommended Maintenance Procedure


NOTE.THE RELIEF PRESSURE OF THE POWERPACK IS TO BE SET TO 2800PSI.

IF THE POWERPACK IS REPLACED,THIS RELIEF PRESSURE WILL NEED TO BE

RESET USING INLINE GAUGES.

FAILURE TO DO SO MAY RESULT IN ACCIDENT OR INJURY.


Section 4. Operating Procedure


To Lower Ladder (from the machine)

Position machine in a level, safe area, away from the work face, whenever possible.

Apply park brake and lower engine speed to idle.

Check that the area below the Ladder Access System is clear of people and

obstacles, and lower ladder by operating the two position electrical switch adjacent

to the ladder, to the down position by pressing the switch down.

Hold the switch in the down position until ladder is fully lowered.

If the Dozer is parked on uneven ground, the bottom of the ladder may touch the

ground before the ladder is in the fully lowered position.

Should this occur, descend the ladder with caution.

To Raise Ladder

Ascend the ladder onto the landing of the Dozer.

Ensure the area around the ladder is clear of people and standing to the side, clear

of the area the handrails and ladder raises into, operate the electrical switch to the

raise position (up).

Hold the switch in the up position until the ladder is in the fully raised position.

The ladder is now raised and stored.

OPERATING NOTES

NOTE: FLOW CONTROL VALVE ADJUSTMENT:

The valve should be positioned to restrict the flow and speed of the Power Step when

lowering. Adjust the knob on top of the valve by turning left or right (clockwise) when the

step is being lowered, until it is lowering at a safe and reasonable speed.

When it is adjusted, lock the adjusting knob by tightening the grub screw located on the

side of the knob.

NOTE: MAGNETIC 'GO' SWITCH ADJUSTMENT:

The switch target trigger area is located on the opposite side and end from the cable entry

point on the switch. Once it is mounted to the switch bracket, adjust the switch in or out

from the stair steel trigger point, to be within 3mm - 10mm from touching each other when

the stair is in the desired rest position.

[DO NOT EXCEED 10mm DISTANCE BETWEEN THE SWITCH AND STRIKER PLATE].

Test by raising and lowering the Power Step a couple of times and adjust again if

necessary.


Section 5. Assembly Complete PSA-D475A-FL



Section 5-1. RH Side Platform Assembly (PS-23613-A) [Includes Items 1, 2, 3A,B,C, 7, 8, 9, 10 (Qty. 3 only),11, 12, 13A,B, 18, 19, 20, 21, 22, 24,

28]



Section 5-1. RH Side Platform Assembly (PS-23613-A) See Drawing Page 24


Item Part No. Part Name Qty

1

2

3

3A

3B

3C

4

5

6

7

8

9

10

11

12

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

PS-23613

PS-23612

PS-K475LND-HR-B06

PS-KD475-23 614

PS-HRI-A04

PS-HRI-A06

PS-23604

PS-23603

PS-23602

PS-21941-02

PS-23616

PS-21941-06

PS-21930A

PS-21925

PS-21933B

PS-M20X60ZP

CPS-M16X40ZP

CPS-M16X25ZP

CPS-M12X35ZP

CPS-M12X65ZP

CPS-M12X75ZP

CPS-M12X35ZP

CPS-M12X25ZP

CPS-M8X35ZP

CPS-M20NZP

CPS-M12NZP

CPS-M8NN

CPS-M20WH

CPS-M16WH

CPS-M12WH

CPS-M8WH

SIDE PLATFORM

FLOOR PANEL

HANDRAIL REPLACEMENT FABRICATION

HANDRAILS- SIDE PLATFORM (Front only)

HANDRAIL POST-CLAMP ASSY

HANDRAIL POST - DOUBLE CLAMP ASSY.

REAR SPREADER BEAM

REAR ISOLATOR BRACKETS

ISOLATOR HOUSINGS

ANTI VIBRATION MOUNTING

PIVOT PIN BRACKET

RUBBER BUSH (Anti Vibration Mtg.)

ISOLATOR ASSEMBLY

MIDDLE BEARING MOUNTING

ISOLATOR BUSH PIN

BOLT-M20 x 60

BOLT-M16 x 40

BOLT-SOCKET HEAD-M16 x 25

BOLT-M12 x 120

BOLT-M12 x 65

BOLT-M12 x 75

BOLT-M12 x 35

BOLT-M12 x 25

BOLT-M8 x 35

NUT-M20

NUT-M12

NUT-NYLOC-M8

WASHER-HARDENED-M20

WASHER-HARDENED-M16

WASHER-HARDENED-M12

WASHER-HARDENED-M8

1

1

1

1

7

2

1

2

2

2

1

2

3

1

1

4

8

4

6

2

4

36

18

8

4

46

8

4

12

90

16


Section 5-2. Ladder & Handrail Assembly



1

2

3

4

5

5A

6

7

8

9

PS-22002

PS-23617

PS-21958

PS-21926-01

PS-21926-02

PS-21926-03

CPS-M12X45

CPS-M12X30

CPS-M12NZP

CPS-M12WH

LADDER & HANDRAIL FABRICATION

ROTATION SHAFT

PINION ASSY

LADDER SHAFT PIVOT BUSH-MIDDLE

LADDER SHAFT PIVOT BUSH (non drive end)

LADDER SHAFT PIVOT BUSH (drive end)

BOLT-M12 x 45

BOLT-M12 x 30

NUT-M12

WASHER-M12

1

1

1

1

1

1

8

8

16

32

FOLDING STAIRWAYKomatsu D475

Section 5-3. LH Side Platform Assembly (PS-K475LND- A03)See Parts List Page 28



Section 5-3. LH Side Platform Assembly (PS-K475LND-A03)See Drawing Page 27



1

2

3

4

5

6

7

8

9

10

11

12

13

PS-K475LND-B05

PS-K475LND-HR-B01

PS-K475LND-B02

PS-HRI-A04

PS-22789

CPS-M16X45

CPS-M16X40

CPS-M16X35

CPS-M12X35

CPS-M16NZP

CPS-M12NN

CPS-M16WH

CPS-M12WH

LANDING FABRICATION - LHS

HANDRAIL - LHS

MOUNTING BRACKET

POST CLAMP

RUBBER CONNECTOR-HANDRAILS

BOLT-M16 x 45

BOLT-M16 x 40

BOLT-M16 x 35

BOLT-M12 x 35

LOCKNUT-M16

NUT-NYLOC-M12

WASHER-M16

WASHER-M12

1

1

4

4

1

16

4

16

20

20

20

56

40


Section 5-4. Back Platform Assembly (PS-K475LND-A04)See Parts List Page 30




1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

PS-K475LND-B06

PS-K475LND-HR-B02

PS-K475LND-HR-B03

PS-K475LND-B03

PS-K475LND-B04

PS-K475LND-B01

PS-K475LND-HR-B04

PS-K475LND-HR-B05

PS-HRI-A04

PS-22789

CPS-M16X45

CPS-M16X30

CPS-M12X35

CPS-M16NN

CPS-M12NN

CPS-M16WH

CPS-M12WH

WALKWAY FRAME FABRICATION - BACK

HANDRAIL - BACK - OUTER

HANDRAIL - BACK - INNER

WALKWAY BRACKET - LHS

WALKWAY BRACKET - CENTER

WALKWAY BRACKET- RHS

STIFFENER-LH

STIFFENER-RH

POST CLAMP

HANDRAIL RUBBER CONNECTION ASSY.

BOLT-M16 x 45

BOLT-M16 x 30

BOLT-M12 x 35

NUT-NYLOC-M16

NUT-NYLOC-M12

WASHER-M16

WASHER-M12

1

1

1

1

1

1

1

1

10

2

12

4

56

12

56

28

12


Section 5-4. Back Platform Assembly (PS-K475LND-A04)See Drawing Page 29


Section 5-5. Drive Unit Assembly



Section 5-5. Drive Unit AssemblySee Drawing Page 31



1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

33

34

35

PS-63014

PS-23615

PS-23620

PS-23618

PS-21954A

PS-23619-02

PS-21106A

PS-61006-2

PS-21959-06

PS-21959-07

PS-21959-09

PS-21959-06

PS-21959-05

PS-21940-03

PS-23619-01

PS-M24X150ZP

CPS-M20X50ZP

CPS-M12X80ZP

CPS-M12X65ZP

CPS-M12X25ZP

CPS-M10X15ZP

CPS-M8X25

CPS-M5X15ZP

PS-M24NN

CPS-M20NZP

CPS-M12NZP

CPS-M12NN

CPS-M8NZP

CPS-M5NN

PS-M24WH

CPS-M20WH

CPS-M12WH

CPS-M10WH

CPS-M8WH

CPS-M5WH

HYDRAULIC CYLINDER

DRIVE MOUNTING FRAME

SECTOR GEAR

DRIVE GUARD

ACTUATOR CYL. MOUNTING ASSEMBLY

PROXIMITY SWITCH MOUNT BAR

PROXIMITY SWITCH MOUNT PLATE

GREASE NIPPLE M6 STR.

HUB SPACER RING

PIN SPACER RING

SECTOR GEAR BUSH

SECTOR GEAR HUB

CLAMP RING

KEEPER PLATE

SWITCH STRIKER

BOLT-M24 x 120

BOLT-M20 x 50

BOLT-M12 x 80

BOLT-M12 x 65

BOLT-M12 x 25

BOLT-M10 x 15

BOLT-M8 x 25

BOLT-M5 x 15

NUT-NYLOC-M24

NUT-M20

NUT-M12

NUT-NYLOC-M12

NUT-M8

NUT-NYLOC-M5

WASHER-HARDENED-M24

WASHER-HARDENED-M20

WASHER-HARDENED-M12

WASHER-HARDENED-M10

WASHER-HARDENED-M8

WASHER-HARDENED-M5

1

1

1

1

1

1

1

4

1

4

2

1

1

1

1

2

4

5

3

9

4

6

6

2

4

17

3

6

6

2

4

34

4

6

6


Section 5-6. PROP Assembly (PS-21945-A) Includes Items 1 to 13



1

2

3

4

5

6

7

8

9

10

11

12

13

PS-21945

PS-23622-01

PS-23622-02

PS-23622-03

PS-40003

PS-21930A

CPS-M12X120

CPS-M12X90ZP

CPS-M12X60ZP

CPS-M12X40ZP

CPS-M12NZP

CPS-M12NN

CPSM12WH

PROP

CARRIER BAR

CLAMP BEAM

ISOLATOR SPACER

BUFFER

ISOLATOR ASSEMBLY

BOLT-M12 x 120

BOLT-M12 x 90

BOLT-M12 x 60

BOLT-M12 x 40

NUT-M12

NUT-NYLOC-M12

WASHER-HARDENED-M12

1

2

3

6

4

4

4

6

4

8

14

6

22

Clamp Mounting 23622

HYDRAULIC LADDER + WALKWAYKomatsu D475

Section 5-7. Hydraulic Cylinder PS-63014-AH

Incl. Items 1A,1B,2,3,4,5,6,7,8,10,11,12.



1A

1B

1S

2

3

4

5

6

7

8

9

10

11

12

13

PS-63014A

PS-63014-P

PS-63011K

PS-63201

PS-61158-0.30

PS-61154

PS-61157

PS-61163

PS-61160

PS-61147

PS-60051-2.8

PS-61151

PS-61145

PS-61153

PS-60050-2.8

HYDRAULIC CYLINDER (INC. REDUCERS)

PIN - CYLINDER- (WITH RETAINER)

SEAL KIT (NOT SHOWN)

VALVE - PILOT OPERATED LOCKING

FITTING - RESTRICTION 90 DEG

FITTING - ELBOW- O RING 1/4BSPPx9/16”JIC

FITTING - O RING 1/4BSPPx 9/16”JIC

REDUCER JIC x BSPP

TUBE

FERRULES/NUTS 2 x each

HOSE- HYDR. (9/6”JIC SWIVEL FITTING 2.8M)

FITTING-ELBOW 7/16”JIC

FITTING-SWIVEL 9/16”JIC

FITTING-O RING 1/4”BSP x 7/16”JIC

HYDR. HOSE 7/16” SWIVEL FITTINGS

1

2

1

1

2

1

1

2

2

1

1

1

1

1

1

HYDRAULIC LADDER + WALKWAYKomatsu D475

Section 5-7. Hydraulics DiagramSee also Drawing page 34


0.030” 0.030”

Double Acting Hydraulic System with

directional Control Valve and Cylinder

Lock Valve


Section 5-8. Power Pack PS-80103A-SLDSee Parts List Pg 38


8

4

13

27

26 6 5 25

6

2 7

10

29

11

16

14

12

3 3024 3A

Hoses shown

dotted

View B View A

7A

9 9A 8A


Section 5-8. Power Pack PS-80103A-SLD

See Parts List Pg 38


NOTE.THE RELIEF PRESSURE OF THE POWERPACK IS TO BE SET TO 1500PSI.

IF THE POWERPACK IS REPLACED,THIS RELIEF PRESSURE WILL NEED TO BE

RESET USING INLINE GAUGES.

FAILURE TO DO SO MAY RESULT IN ACCIDENT OR INJURY

15

20

21

23

9

View B

9A

View A

32

33

24

14

19

11

16

28

10

18

31

17

12

BEACON

WORKLIGHT 3PIN


Section 5-8. Power Pack PS-80103A-SLDSee Photos Page 36,37



1

2

3

3A

4

5

6

7

7A

8

8A

9

9A

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

33

PS-80103A-SLD

PS-21107-METAL

PS-80103A

PS-80103-CLAMP

PS-82415

PS-84214

PS-82492

PS-61160-M/F-BOX-7/16”F

PS-61160-M/F-BOX-9/16”F

PS-61152

PS-61150

PS-61177

PS-61176

PS-84213

PS-84212

PS-84303

PS-1712080

PS-73012

PS-82493

PS-HD10-5-16P

PS-41010

PS-41011

PS-41012

PS-41013

PS-41014

PS-41023

PS-41024

PS-41041

PS-41019

PS-41017

PS-41018

PS-41016

PS-73010

PS-73009

PS-HD10-3-16P

PS-HD10-5-16P

PS-41032

POWER PACK ASSEMBLY

MOTOR ENCLOSURE- SEALED ST/ST

POWER PACK

CLAMP ELECTRIC MOTOR

AUDIBLE ALARM

BRIDGE RECTIFIER

SOLENOID 24V START MOTOR

HYDRAULIC TUBE 7/16”

HYDRAULIC TUBE 7/16”

HYDRAULIC FITTING 7/16”




135A CIRCUIT BREAKER

5A CIRCUIT BREAKER

ISOLATION SWITCH- (INCLUDING BRACKET)

SEALED WIRING BOX

TOGGLE SWITCH KIT

BATTERY FEED STUDS

5 PIN SOCKET

DECAL-Battery Isolation

DECAL-Battery Supply C/B-135A

DECAL-Controller Supply C/B-5A

DECAL-Battery Supply-PosItive

DECAL-Battery Supply-Negative

DECAL-Up/Down

DECAL HYDRAULIC-HOSES

DECAL OIL TANK

DECAL BRIDGE RECTIFIER

DECAL SOLENOID

DECAL ALARM

DECAL RAISE/LOWER SWITCH

RUBBER BOOT RED

RUBBER BOOT BLACK

3 PIN SOCKET (PARK BREAK)

5 PIN SOCKET (AUTO-RAISE)

DECAL AUTO-RAISE SOCKET

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

2

1

1

1

1

1

1

1

1

1

1

1

1

1

4

2

1

1

1


Section 5-9. Electrical Controls


Control Pendant SwitchMounted on Handrail

7 8

2

3

1

Cab Harness & Equipment

Refer Wiring Harness Drawings

Proximity Switch AssemblyMounted on Fixed Landing

45 6


Section 5-9. Electrical ControlsSee Photos Page 39


WARNING

LOW OR FAULTY BATTERIES WILL VOID

WARRANTY ON THE POWER PACK AND ALL

ELECTRICAL SWITCHES AND COMPONENTS


1

2

3

4

5

6

7

8

PS-73013

PS-73013-B

PS-77005

PS-77009AR

PS-77004

PS-75430

PS-77002

PS-77003

CONTROL PENDANT SWITCH

CONTROL PENDANT BRACKET

HAND RAIL SWITCH HARNESS

AUTO RAISE HARNESS

CABIN TO SWITCH HARNESS

PROXIMITY SWITCH

CABIN BOX LED LIGHT INDICATOR

WIRING HARNESS IN CABIN

1

1

1

1

1

2

1

1

Optional only

1 X Optional

powerstep access system for komatsu d475adozer

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