fullaccess system ground levelto ......2016/12/14 · to suit komatsu pc8000 excavator section 1....

PSA PC8000- RFS 14-12-16

FOLDING RETRACTABLE STAIRWAYManual for Komatsu PC8000 ExcavatorFULL ACCESS SYSTEM GROUND LEVEL TO OPERATORS CAB

(FRS, FIXED STAIR & WALKWAYS)

Model No.:PSA-PC8000-RFS

Serial No.: PC8000-001-FULL to ~

Date Manufactured: Jan 2013

CONTENTS

Page 3 Section 1 Installation and Mounting DrawingsStair Mountings

Tee Beam

Fixed Upper Stair

Mid Position Strut

Mounting Assembly

Bolting Plates

Mounting Frame and Isolator Boxes

Folding Stairs

Handrails

Top walkway & Access

Fixed Upper Stair

Handrails - Lower Stair

32 Section 2 Operating Procedure

33 Section 3 Recommended Maintenance Procedure

Section 4 Drawings and Repair Parts lists

34 4 Assembly Complete

36 4 Top Fixed stair Assembly

Parts List

38 4-1 Mounting Assembly

Parts List

40 4-2 Landing Assembly

Parts List

41 4-3 Stair Upper Assembly

Parts List

43 4-4 Stair Lower Assembly

Parts List

45 4-5 Pivot Assembly

Parts List

47 4-6 Hydraulic Cylinder Assembly

Parts List

Valve Diagram

50 4-7 Power Pack Assembly

Parts List

53 4-8 Electrical Controls

Wiring Diagrams

Optional Electrical Equipment

Pg2PSA PC8000- RFS 14-12-16

FOLDING RETRACTABLE STAIRWAY

To suit Komatsu PC8000 Excavator

Pg3PSA PC8000- RFS 14-12-16



Section 1. Installation Top Bolting Pads PS-24 771

PROCEDURE - See Drawing Page 4

After the RFS landing is fitted:

1. Fit the Cleats to the Cleat Template per View W and View Y

2. Measure up the corner of the electrical room from the height of the landing of the

Power Step RFS stair per Views W and Z, position the Cleat Template and tack

weld it in place.

3. Weld the Cleats to the corner of the electrical room per View V.

4. Mark the heights of the Bolting Pads per Views U and Zz.

5. Assemble the Bolting Pad Template and Bolting Pads to The Cleats at the corner

of the electrical room, per Views S, U and Zz.

6. Weld the Pads to the wall per View T.

NOTE

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

PSFS to Excavator.

Pg4PSA PC8000- RFS 14-12-16



Section 1. Installation Top Bolting Pads PS-24 771

Pg5PSA PC8000- RFS 14-12-16



Section 1. Installation Tee Beam PS-24 772

Procedure.

1. Bolt the Tee Beam and its' accessories to the Bolting Pads per View Z.

2. Fit the Top Strut to the Beam per View Y. Weld the Bolting Pad to the electrical

room wall, also per View Y. Use safer welding, lifting and general working

procedures at all times.

Welding: Cat SP to AS1554 Cat SP unless noted otherwise.

6 cfw uno.

VIEW Y

VIEW Z

Pg6PSA PC8000- RFS 14-12-16



Section 1. Installation Fixed Upper Stair PS-24 773 Sht. 1

PROCEDURE.

With the stair assembled per Drg 24 177A,the lower stair mountings installed per Drg 24186

and the top mountings assembled per Drg 24 772:

Fit the stair assembly to the excavator per View Z, with the bottom end fitted to the lower

mountings per View Y and the top end fitted to the top mountings per Views W & X.

(See Drawings Page 7)

This work is to be undertaken in conjunction with the instructions given on Drg 24 774.

Change the order of the various tasks to suit prevailing conditions, eg the

availability of crane/s.

NOTE


PSFS to Excavator.

NOTE

For Mounting Mid Position Strut

see Drawing PS-24775 - Pg 11

Pg7PSA PC8000- RFS 14-12-16




VIEW W

VIEW X

VIEW Y

Pg8PSA PC8000- RFS 14-12-16



Section 1. Installation Fixed Upper Stair PS-24 774

NOTE


PSFS to Excavator.

PROCEDURE.

1. With the fixed stair mounted to the excavator per Drg 24 773,check that the landing

at the top of the stair is located beside the lower level of the OEM cagin landing,

per Details V and W. If it is not, adjust the position of the whole fixed stairs by

moving it relative to the bottom mountings, per Detail X.

2. IF, when the position of the fixed stair is finally resolved per '1' above, the 100 x 10

flatbar slider attached under the channel frame of the landing does not continue

over the rubber cushions of the mountings, extend the slider per View S and weld

an additional Stiffener between inside the channels using the material provided.

3. Adjust the lateral position of the fixed stair so it is 25 - 40mm away from the lower

level cabin landing, per Detail W. Adjust the lateral position by loosening

clamping bolts and sliding the top and bottom mountings sideways on the SHS

beams.

4. Cut off the frame channels of the top stair landing where they extend past the top

mountings and relocate the Top End Panel so it is approximately aligned with the

centre line of the Tee Beam,per View W.

5. Re-install the OEM emergency escape ladder. Inspect the space around the

ladder - if, per View U, it is found that the outer clamp plate on the horizontal run

of the Tee Beam might snare the clothing of a person using the ladder, weld the

brackets to the beam per Detail T and permanently remove the outer clamp plates.

NOTE

Unless directed otherwise, welding must comply with AS1554 Cat SP.

Pg9PSA PC8000- RFS 14-12-16




NOTE


PSFS to Excavator.

W

V

VIEW Z

VIEW Y

VIEW SDETAIL X

Pg10PSA PC8000- RFS 14-12-16



Section 1. Installation Fixed Upper Stair PS-24774 Sht. 2

Pg11PSA PC8000- RFS 14-12-16



Section 1. Installation Mid Position Strut PS-24775

PROCEDURE.

Fit the Mid Position Strut between the stair frame and the wall of the excavator house.

Locate the strut near the back wall of the fuel tank. Holes are provided in the stair frame

to bolt the isolator mounting to. If these cannot be used, for instance because the

strut would be obstructed by the fuel tank, drill holes to suit. Such holes should be

distanced at least 50mm from existing holes in the stair channel flange.

One end yoke is not fully welded to the strut pipe.

Cut length of the strut to suit and weld the end yoke fully.

Check the other end.

Pg12PSA PC8000- RFS 14-12-16



Section 1. Installation Mounting Assembly PS-24376

Pg13PSA PC8000- RFS 14-12-16



Section 1. Installation (1) Bolting Plates P30 377 & P30 378

INSTRUCTIONS

See drawing P30 378 (Page15)

1. Per View 1 and Detail Z, fit the three inside Mounting Isolator Box Sides

underneath the Closer Plate, with the Side Pad Supports fitted and rubber elements

in place. Use appropriate thread locking compound on bolts and nuts attaching the

Side Pad Supports.

2. Using the Installation Carrier, sling the Stair Mounting Frame into place under the

machine walkway, with rubber elements sitting in place on top, per View 2 and

Detail Y.

3. Also per View 2, fit the two Inner Isolator Shells to their bolting pads but without any

rubber inside.

PROCEDURE.

See drawing P30 377 (Page14)

1. Drill holes for Installation Bolts (shown View 1-1, location View2) in the top plate of

the outer beam (Beam 1) of the side walkway of the excavator - ~18 or ~19 holes.

2 Look at the part of the walkway beam structure shown by the arrow Y in Views 1-1

and 1-2.

- If the lower edge of the inner vertical plate of Beam 1 terminates at the level of

the bottom of the adjacent Beams 2 & 3 as shown in Detail Y-1, allowing the 10mm

fillet weld called for, proceed to '3'.

- If the lower edge of the inner vertical plate of Beam 1 terminates above the level

of the bottom of the adjacent Beams 2 & 3 as shown in the left side of Detail Y-2,

preventing the weld called for in Detail Y-1, fit the Repair Plate to the lower edge of

the vertical plate, full length between Beams 2 & 3.

3. Grind/cut the necessary weld preparations, and fit the Closer Plate under Beam 1

(shown in View 1-1, location View 2, weld prep details View 1-2). Temporarily

support the Closer Plate with the Installation Bolts and other means if required.

Weld the Closer Plate to the machine and remove the Installation Bolts.

4. Fit and weld the Closer Reinforcing Gussets and Closer Gusset Flange to the

Closer Plate and beam, (Views 1-1, 2 and Detail Z).

5. Fit and weld the Inner Isolator Bases under Beams of the walkway (Views 1-1, 1-2

and 2).

NOTE


PSFS to Excavator.

Pg14PSA PC8000- RFS 14-12-16



Section 1. Installation (1) Bolting Plates P30 377

VIE

W 1

-2

DE

TA

ILZ

DE

TA

ILY

-2

VIE

W 2

DE

TA

ILY

-1

VIE

W 1

-1

Pg15PSA PC8000- RFS 14-12-16



Section 1. Installation (2) Mounting Frame P30 378

VIE

W Z

VIE

W 1

VIE

W 2

VIE

W Y

Pg16PSA PC8000- RFS 14-12-16



Section 1. Installation (2A) Isolator Boxes P30 384

See Drawing P30-384 (Page 11)

1. Per Drawing P30 376 and View 1 (Pg7),assemble the Outer Isolator components

on the Mounting Frame. Adjust the clearance or compression of the isolator

elements - the vertical isolator pads should be slightly compressed when initially

installed so assemble with spacer pads in the bottom of the isolator to achieve the

appropriate compression. Horizontally (in/out and forward/backward), initial

assembly can vary from 2mm compression to 2mm clearance. Position the

spacers in consistent positions in all three assemblies.

2. Per Views 2-1 & 2-2, tie the partly assembled isolator boxed in place on the

mounting beam. Use 6mm steel wire cable and a turnbuckle to tighten each box to

the beam. Note that the views do not show turnbuckles but they are required. The

required locations on the beam of the mounting frame is shown in View 3.

3. Per View 4, tie the Top Isolator End Stops and their isolator pads together with tape

- insulation tape, masking tape or duct tape etc.

4. Bolt the three taped-together assemblies to the underside of the box beam closer

plate, per View 5. The tape need not be removed.

NOTE


PSFS to Excavator.

NOTES.

1. USE SAFE WORKING PRACTICES.

2. Apply an appropriate thread-lock compound to all bolts & nuts.

3. Bolt selections are listed on Drg P30 376.

4. One 'Mounting Isolator End Stop P30 352' with a clearance hole cut in it is to be

fitted in the rearmost Outer Islator Mounting, see View 3.

Pg17PSA PC8000- RFS 14-12-16



Section 1. Installation (2A) Isolator Boxes P30-384

VIE

W 3

VIE

W 2

-2V

IEW

2-1

VIE

W 5

VIE

W 4

VIE

W 1

Pg18PSA PC8000- RFS 14-12-16



Section 1. Installation (3) Isolators P30 379

PROCEDURE

See Drawing P30 379

1. Per View 1, fit the Top Pad Stops to the closer plate above the beam of the

mounting frame, at each isolator box. If it is necessary to lower the mounting beam

to make space for hands and/or tools, keep the arms of the mounting beam

engaged in the inner isolator shells and lower the beam.

PLACE BLOCKS OF WOOD OR SIMILAR SPACERS BETWEEN THE MOUNTING BEAM

AND THE CLOSER PLATE OR THE WALKWAY STRUCTURE SO AS TO ELIMINATE

THE DANGER OF CRUSHING A HAND IF THE BEAM MOVES. See View 2.

2. Per Views 1 & 3, fit the the Mounting Isolator Floor Plates to the inner Isolator Box

Sides. Put the Mounting Isolator Elements between the Mounting Frame beam and

the Floor Plates, with 5mm Packing Sheets between the isolator elements per

View 4.

3. Per View 3, fit the Mounting Isolator Bottom Pad Stops to the Floor plates.

4. Per View 3, fit the outer Isolator Box Side with the Side Pad Support fitted and

isolator elements in place. Use thread locking compound on the bolts and nuts

attaching the Side Pad Suports.

5. Per View 3, fit the Mounting Isolator End Stops and Elements.

6. Remove the Inner Isolator Shells and fit the isolator elements, per View 5.

NOTE


PSFS to Excavator.

NOTES.

1. USE SAFE WORKING PRACTICES AT ALL TIMES.

2. The isolators must be correctly adjusted as regards clearance or compression on

the isolator pads. Insert/remove spacers in order to achieve the required results.

- the top and bottom isolators must hold the beam of the mounting frame firm

(vertically). Add/remove any spacers from UNDER the beam,- horizontally, a range

from a small clearance over the isolator pads (up to 2mm) through to a small

compression (up to 2mm) is acceptable.

Where required these spacers can be fitted only on one side of the isolator

assembly, that is, not shared in thickness front and back. Ensure that the spacers

are positioned in such a way that they cannot work free past the relevant

keeper/s.

3. Mounting Isolator End Stop P30 352 00S' with a clearance hole cut in it is to be

fitted in the rearmost Outer Isolator Mounting, see View 6.

Pg19PSA PC8000- RFS 14-12-16



Section 1. Installation (3) Isolators P30 379

VIEW 2

VIEW 3

VIEW 4

VIEW 5

VIEW 1

Pg20PSA PC8000- RFS 14-12-16



Section 1. Installation (3A Mounting Frame P30-385

NOTES.

1. USE SAFE WORKING PRACTICES.

2. One 'Mounting Isolator End Stop P30 352' with a clearance hole cut in it is to be

fitted in the rearmost Outer Islator Mounting, see View 3.

NOTE


PSFS to Excavator.

PROCEDURE

See Drawing P30 385 (Page 21)

1. Per View 1, fit the Mounting Frame, fitted with Isolator Boxes, under the Closer

Beam and bolt in place.

2. Per View 2, fit and bolt the Inner Mounting Isolators to their bolting pads.

3. Remove the beams and bolts holding the isolator boxes to the mounting beam.

Pg21PSA PC8000- RFS 14-12-16



Section 1. Installation (3A) Mounting Frames P30-385

Pg22PSA PC8000- RFS 14-12-16



Section 1. Installation 4 Mounting Braces P30 380

Pg23PSA PC8000- RFS 14-12-16



Section 1. Installation Folding Stair P30 381

PROCEDURE.

1. Fit the stair set to the flanges of the mounting frame. Note, per View 2, that the top bolts in the

flanges must be inserted throught the hollow beam of the mounting frame.

2. Fit the stair's Power Unit in an appropriate place such as under the stair/ladder that leads from the

lower walkway up to the cabin and motor house roof. Pipe up the hydraulics etc. (Not shown.)

VIEW 1

VIEW 2

Pg24PSA PC8000- RFS 14-12-16



Section 1. Installation

Mounting Braces + Handrails & Small Components - PS-24787

PROCEDURE - See Page 25

VARY THE ORDER OF THESE TASKS TO SUIT.

1. Fit the Inner Handrail 24 792 02 to the original toeboard of the excavator walkway,

either by drilling and bolting the toeboard or by welding on

Bolting Pads 24 792 04

2. Fit Outer Handrail Loop 24 792 01 by welding it to the dropper of the Inner

Handrail and by fitting and welding Mounting Bends 24 792 03 to the base of the

new handrail posts and the Outer Handrail Loop. Note that the attachment to the

outer handrail loop should not attach to the top rail, therby blocking free and safe

movement of hands along the rail. View 2 shows an approx height above the

walkway floor - actual installed height should match the outer handrail of the stair

landing.

3. P30 371 Mezzanine Stair Tread to the cleats on the closer plate. Weld the Floor

Extension P30 373 to the side of the border beam of the excavator walkway with its'

surface level with the floor of the walkway. Bolt the Toeboard P30 372 to the inside

edge of the RFS landing.

4. Fit the Fender Bar parts as shown in Detail Z. The purpose of the fender is to guide

the stair into the stowed position without catching on any fixed components if it is

distorted by an accident.

5. Cut the OEM walkway toeboard to dims on View 2. Remodel the OEM handrails to

suit, if necessary using straight pipe and bends supplied with the kit.

NOTE


PSFS to Excavator.

Pg25PSA PC8000- RFS 14-12-16




Handrails and Small Components PS-24 787

See Procedure Pg. 24

VIE

W 2

VIEW 1

VIEW 2

Pg26PSA PC8000- RFS 14-12-16




Lower Stair Mountings & Handrails PS- 24788

PROCEDURE.

After fitting the RFS stair set to the excavator per

View Y and Detail Z:

- fit the Lower Mounting Beam and the

components shown in Views X-1 & X-2

- fit the RFS Landing Extension and Outer

Handrail per Views X-1 & X-2.V

IEW

Y

VIE

W

X-1

VIE

W

X-2

DE

TA

ILZ

Pg27PSA PC8000- RFS 14-12-16



Section 1. Installation Top Walkway & Access PS-24 193

PROCEDURE.

See Drawing page 28

Refering to Views Y and Z-1 and Z-2:

1. Close off the opening in the handrails and toeboard that where the original ladder

emerged on to the walkway behind the cabin.

2. Cut away the original handrails beside the new stair to make an accessway to the

cabin walkway 600 - 700 mm wide.. Trim the sides of the opening to suit.

3. Make supports to suit and raise the floor of the walkway near the cabin door. Raise

the height of the toeboard bordering the raised floor using the material provided.

Cut the toeboard away, down to floor level, in the accessway to the fixed stair.

NOTE


PSFS to Excavator.

Pg28PSA PC8000- RFS 14-12-16



Section 1. Installation Top Walkway & Access PS-24 193

Welding: all Cat SP to AS1554 unless directed otherwise.

5mm continuous fillet weld unless noted otherwise.

VIEW Z-1

VIEW Z-2

VIEW Y

Pg29PSA PC8000- RFS 14-12-16



Section 1. Installation Fixed Upper Stair PS-24 190B

Fit Handrail Opening Loop, Mezzanine Stair Handrail and RFS Landing Back Toeboard

as shown and noted.

Use safe lifting and working procedures at all times.

Welding: Cat SP to AS1554 unless specifically directed

otherwise, 5 cfw uno.

Pg30PSA PC8000- RFS 14-12-16



Section 1. Installation Lower Stile Handrails PS-24786

PROCEDURE

1. Fit Lower Stile Handrails per View Y.

2. Drill holes to suit for top post base.

3. Use Nut Strip per Detail Z to fit nuts for top post base in inaccessible space.

Pg31PSA PC8000- RFS 14-12-16



Section 1. Installation General Arrangement P30 320

Pg32PSA PC8000- RFS 14-12-16

To Lower Stairway (from the machine)

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

Position the excavator body square to the tracks, lower bucket, apply park brake and

lower engine speed to idle.

Descend stairway behind cabin to lower walkway.

Check that the area below and behind the Folding Retractable Stairway (FRS) is clear of

people and obstacles, and lower stairway by operating the two position electrical switch

adjacent to the stairway, to the down position by pressing the switch down.

Hold the switch in the down position until stairway is fully extended and lowered.

If the excavator is parked on uneven ground, the bottom of the stairway may touch the

ground before the FRS is in the fully extended and lowered position.

Should this occur, descend the stairway with caution.

Bottom of stairway is designed to rest on the ground in the fully lowered and extended

position, but can be used in the fully lowered position without resting on the ground.

To Raise Stairway

Ascend the stairway onto the lower walkway of the excavator.

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

the area the handrails and stairway raises into, operate the electrical switch to the raise

position (up).

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

The stairway is now raised and stored.

Note:

The stairway is interlocked with the swing interlock of the excavator, and the machine will

not swing with the stairway out of the fully raised position.

Operation of the FRS mechanically extends the lower stair section as the stairway is

lowered by means of the link rods to the upper platform of the FRS.

There is no method of individual control of the upper and lower sections.



Section 2 Operating Procedure

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.

Pg33PSA PC8000- RFS 14-12-16

Daily

Visually check stairway 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 all grease nipples. Lower or raise stairway for accessibility.

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

lowered position).

Check main mounting bolts for torque.

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 (10.0 litres).

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

hydraulics of the machine.

Grease all grease nipples. Lower or raise stairway for accessibility.

Retorque all main mounting bolts

Repeat daily check as above.



Section 3 Recommended Maintenance Procedure

Pg34

FOLDING RETRACTABLE STAIRWAYTo suit Komatsu PC8000 Excavator

Section 4 Assembly Complete

See

PSA PC8000- RFS 14-12-16

ITEM PART NO. PART NAME QTY

1 PS-24177A TOP FIXED STAIR ASSEMBLY 1

2 PS- 30 376A MOUNTING ASSEMBLY 1

3 PS-30 318A LANDING ASSEMBLY 1

4 PS-30 333A STAIR - UPPER - ASSEMBLY 1

6 PS- 30 301A STAIR - LOWER - ASSEMBLY 1

7 PS-63009-ASSY HYDRAULIC CYLINDER 1

8 PS-80104A-RFS HYDRAULIC - POWER UNIT - ASSEMBLY 1

Pg35PSA PC8000- RFS 14-12-16



Section 4. Assembly Complete



Section 4-1 Top Fixed Stair Assembly PS-24177A

See Parts List Page 37

Pg36PSA PC8000- RFS 14-12-16

Pg37PSA PC8000- RFS 14-12-16



Section 4-1 Top Fixed Stair Assembly PS-24177A

See Drawing Page 36

Item Part No. Part Name Qty

1

1A

2

3

4

5

6

7

8

9

10

11

11A

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

PS-24172

PS-24168

PS-P30321

PS-24755

PS-24161

PS-24175

PS-24173

PS-24758

PS-24761

PS-24154-99

PS-24763

PS-24160-03

PS-24160-00

PS-24766

PS-24181

PS-21930

PS-24183

PS-24185

PS-24765-02

CPS-M20X140ZP

CPS-M12X150ZP

CPS-M12X120ZP

CPS-M12X40ZP

CPS-M12X35ZP

CPS-M12X25ZP

CPS-M12NZP

CPS-M20WH

CPS-M12WH

FIXED STAIR FRAME

TOP LANDING FLOOR PANEL

STAIR TREAD

TEE BEAM

LOWER MOUNTING BEAM

HANDRAILS - INNER

HANDRAILS - OUTER

MOUNTING CUSHION ASSEMBLY

MOUNTING CUSHION SHELF (Incl clamp Pl.)

TEE BRACKET

TOP STRUT

CLAMP PLATE

LOWER MOUNTING BEAM BRACKET

MID POSITION STRUT

LIFTING LUG

BUSH ISOLATOR

ISOLATOR HALF

ISOLATOR PIN

ISOLATOR BOLTING PAD

BOLT-M20 x 140

BOLT-M12 x 150

BOLT-M12 x 120

BOLT-M12 x 40

BOLT-M12 x 35

BOLT-M12 x 25

NUT-M12

WASHER-HARDENED-M20

WASHER-HARDENED-M12

1

1

16

1

1

1

1

1set

1

2

1

2

2

1

4

6

2

2

1

6

16

2

12

94

36

148

6

260

Pg38



Section 4-1 Mounting Assembly PS- 30 376A


PSA PC8000- RFS 14-12-16



Section 4-1 Mounting Assembly PS- 30 376A

(Includes all Items below excluding 14,15,&16)

See Drawing Page 38

PSA PC8000- RFS 14-12-16

Pg39


1

2

2A

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

PS-30365

PS-30369

PS-30375

PS-30366-01

PS-30366-02

PS-30358

PS-30359

PS-30352

PS-30353

PS-30354

PS-30355

PS-30356

PS-30357

PS-30367

PS-30371

PS-30372

PS-30373

PS-M24X100ZP

PS-M24X90ZP

CPS-M16X60ZP

CPS-M16X50ZP

CPS-M16X25ZP

CPS-M12X35ZP

CPS-M12X25ZP

PS-M24NZP

CPS-M16NZP

CPS-M12NZP

CPS-M24WH

CPS-M16WH

CPS-M12WH

MAIN MOUNTING BEAM

BOX BEAM CLOSER

FENDER BAR

MOUNTING ARM BRACE-ARM END TIE

MOUNTING ARM BRACE-DIAGONAL

INNER ISOLATOR SHELL

INNER ISOLATOR BASE

MOUNTING ISOLATOR END STOP

MOUNTING ISOLATOR-BOX SIDE

MOUNTING ISOLATOR-TOP PAD STOP

MOUNTING ISOLATOR-BOTTOM PAD STOP

MOUNTING ISOLATOR-FLOOR PLATE

MOUNTING ISOLATOR-SIDE PAD SUPPORT

MOUNTING ISOLATOR ELEMENT

MEZZANINE STAIR TREAD

TOEBOARD

FLOOR EXTENSION

BOLT-M24 x 100

BOLT-M24 x 90

BOLT-M16 x 60

BOLT-M16 x 50

BOLT-M16 x 25

BOLT-M12 x 35

BOLT-M12 x 25

NUT-M24

NUT-M16

NUT-M12

WASHER - HARDENED- M24



1

1

1

1

1

2

2

12

6

6

6

3

6

1set

2

1

1

4

4

24

4

64

15

28

8

28

15

16

116

58

Pg40



Section 4-2 Landing Assembly PS- 30 318A

PSA PC8000- RFS 14-12-16


1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

PS-30318

PS-24159

PS-24162

PS-24784

PS-30382

PS-30312

PS-63009-B

PS-P30382-04

PS-M24X100ZP

PS-M24X90ZP

CPS-M12X35ZP

CPS-M12X25ZP

CPS-M12X20ZP

PS-M24NZ

CPS-M12NZ

CPS-M24WH

CPS-M12WH

LANDING FABRICATION

LANDING EXTENSION

LANDING TOEBOARD

HANDRAIL-LANDING

HANDRAIL-REPLACEMENT

LANDING-GRID

BUSHES-CLEVIS

BOLTING PAD

BOLT-M24 x 100

BOLT-M24 x 90

BOLT-M12 x 35

BOLT-M12 x 25

BOLT-M12 x 20

NUT-M24

NUT-M12

WASHER-HARDENED-M24

WASHER-HARDENED-M12

1

1

1

1

1

1

2

3

4

4

4

14

12

8

28

16

56

Pg41



Section 4-3 Stair - Upper Assembly PS-30 333A


PSA PC8000- RFS 14-12-16



Section 4-3 Stair Upper Assembly PS-30 333A

Parts List

See Drawing Page 41

PSA PC8000- RFS 14-12-16

Pg42


1

1A

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

PS-30333

PS-30323

PS-30321

PS-30307

PS-30308

PS-30315

PS-40001

PS-30334

PS-30313

PS-32266-SAN

PS-38998-C

CPS-M10X80PR

PS-91107

PS-30335

CPS-M12X40ZP

CPS-M12X35ZP

CPS-M12NZP

CPS-M12WH

STRINGER ASSEMBLY

TOP TREAD

TREAD STEP

BUSHING UPPER & CRANK PIVOT

BUSHING-CENTER-PIVOT

BUFFER-BRACKET

RUBBER STOP

BUFFER-FRAME-LOWER-STAIR

PIVOT-SHAFT-TOP

NON-SLIP NOSING

FRS-SPRING SET

ROLL-PIN-M10 x 80

WASHER-MACHINED

BUSHES-CLEVIS

BOLT-M12 x 40

BOLT-M12 x 35

NUT-M12

WASHER-HARDENED-M12

1

1

7

4

2

2

4

1

1

7

1

2

2

2

14

28

46

96

Set of 2

Pg43



Section 4-4 Stair Lower Assembly PS-30 301A


PSA PC8000- RFS 14-12-16

Pg44



Section 4-4 Stair Lower Assembly PS-30 301A

Parts List

See Drawing Page 43

PSA PC8000- RFS 14-12-16


1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

PS-30301L

PS-30301R

PS-30302L

PS-30302R

PS-30300L

PS-30300R

PS-30322

PS-30321

PS-24778

PS-32266-SAN

PS-36021

CPS-M12X45ZP

CPS-M12X35ZP

CPS-M12X30ZP

CPS-M12NZP

CPS-M12WH

STAIR STRINGER-LH

STAIR STRINGER-RH

STAIR-EXTENSION-LH

STAIR-EXTENSION-RH

STAIR-STILE-CAP-LH

STAIR-STILE-CAP-RH

TREAD-STEP-NARROW

TREAD-STEP-STD

HANDRAIL-LOWER SECTION

NON-SLIP NOSING

TORQUE TUBE LINKAGE

BOLT-M12 x 45

BOLT-M12 x 35

BOLT-M12 x 30

NUT-M12

WASHER-HARDENED-M12

1

1

1

1

1

1

1

7

1set

8

1

4

28

38

70

140

Pg45



Section 4-5 Pivot Assembly


PSA PC8000- RFS 14-12-16



Section 4-5 Pivot Assembly

Parts List

See Drawing Page 45

PSA PC8000- RFS 14-12-16 Pg46


1

1A

2

2A

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

PS-30306

PS-30306-04

PS-30303

PS-30303-01

PS-30304

PS-30305

PS-30327

PS-29004

PS-29003

CPS-M10X80PR

PS-M24X120ZP

PS-M20X100ZP

PS-M20X60ZP

CPS-3/4”X4 1/2”UNF

PS-29004-N

PS-29003-N

PS-M24NN

PS-M20NN

CPS-3/4” N/L UNF

CPS-M24WH

CPS-M20WH

CPS-W3/4”X5”

CRANK ASSY- PRIMARY

SHAFT - PRIMARY

CRANK ASSY - SECONDARY

SHAFT - SECONDARY

CRANK-REACTION-ARM

MECHANISM LINK

ROD-LINKAGE-(2041mm)

ROD END-LH

ROD END-RH

ROLL PIN

BOLT- M24 x 120 10.9

BOLT- M20 x 100 10.9

BOLT- M20 x 60 10.9

BOLT- 3/4”-x 4 1/2” Gr 8

NUT- LOCKING-LH

NUT- LOCKING-RH

NUT- M24-NYLOC

NUT- M20-NYLOC

NUT- NYLOC-3/4”

WASHER-HARDENED-M24

WASHER-HARDENED-M20

BOLT-3/4” x 5” Gr8 UNF

2

1

2

1

2

2

2

2

2

4

4

4

4

2

2

2

4

8

4

8

24

2

Pg47



Section 4-6 Hydraulic Cylinder Assembly PS-63009-ASSY


PSA PC8000- RFS 14-12-16

Pg48PSA PC8000- RFS 14-12-16


1

2

3

4

5

-

PS-63009-A

PS-63009-C

PS-63009-TP

PS-63009-P

CPS-M8x56ZP

PS-63103-N

HYD CYLINDER 2 1/2”

CYLINDER-BUSH-CLEVIS

PIN-CYLINDER-TOP

PIN-CYL-BOTTOM+WASHER

SPLIT PIN - M8 - CLEVIS PIN-TOP

SEAL KIT

2

8

2

2

6

1 NOT SHOWN


7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

PS61160-KIT

PS-61159

PS-61157

PS-61154

PS-61149

PS-61148

PS-63201

PS-61158-5MM

PS-61160

PS-61147

PS-63202

PS-63202-B

PS-63202-C

PS-61163

PS-61006-1

PS-61166

HARD PLUMBING KIT

FITTING-ELBOW- 9/16”JIC x 1/4”BSPP

FITTING-O RING 1/4BSPP x 9/16”JIC

FITTING-ELBOW-O RING 1/4BSPP x 9/16”JIC

FITTING-TEE-9/16”JIC-M/M

FITTING-TEE-9/16”JIC / 1/4” BSPP

VALVE-PILOT OPERATED-LOCKING

FITTING- 5mm RESTRICTION 90 DEG.

TUBES - 4off 110mm, 1 off 517mm

FERRULES

FLOW CONTROL VALVE

FITTING-JIC NIPPLE

FITTING-JIC SWIVEL

FITTING-REDUCER-3/4”UNO-1/4”BSPP

FITTING-GREASE NIPPLE-90

FITTING-TEE 9/16”

.

3

2

1

1

1

1

4

.

10

1

1

1

4

2

2

CYLINDERS

PLUMBING

Incl. all items listed below



Section 4-6 Hydraulic Cylinder Assembly PS-63009-ASSY

Parts List

See Drawing Page 47

Pg49PSA PC8000- RFS 14-12-16



Section 4-6 Hydraulic Cylinders (Valve Diagram)

Pg50



Section 4-7 Power Pack Assembly PS-80104P (Not including Cradle)

Single Valve Power Pack PS-80104P-FRS (Including Cradle)

PSA PC8000- RFS 14-12-16

10

8

7

6

3

4

9

11

14

18

12

17

16

15

13

2

5

1

21

Pg51



Section 4-7 Power Pack Assembly PS-80104P (Not including Cradle)

Single Valve Power Pack PS-80104P-FRS (Including Cradle)

PSA PC8000- RFS 14-12-16

19 20

1

13


1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

PS-514.9.154

PS-509.5.140

PS-115.6.126

PS-147.900.724

PS-147.481.311A

PS-114.4.951

PS-106.936.308

PS-131.2.19

PS-122.11.1258

PS-149.115.123

PS-538.6.200

PS-118.64

PS-147.790.308

PS-122.11.1276

PS-149.990.991

PS-541.3.126

PS-541.6.89

PS-122.11.357

PS-21613

PS-149.120.820

PS-506.4.254

PLASTIC TANK

TANK FILLER CAP

TANK PLUG

PUMP & HOUSING ASSEMBLY

24V MOTOR

DRIVE COUPLING

EMERGENCY HAND PUMP

CLOSED CENTRE (A1 VALVE)

MANUAL OVERRIDE BUTTON

BASE PANEL (MANIFOLD)

REAR BRACKET

PUMP FILTER

SINGLE VALVE COVER

COVER SWITCH

COVER LIGHT

PUMP PICK UP TUBE

RELIEF TUBE

BUZZER

MOUNTING CRADLE

MASTER SWITCH

O RING SEAL 5.34 x 101

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

Pg52PSA PC8000- RFS 14-12-16



Section 4-7 Power Pack Assembly

Single Valve Power Pack - Electrical

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.

BLUE BROWN

ORANGE WHITE

Pg53PSA PC8000- RFS 14-12-16

Proximity Switch AssemblyMounted on Fixed Landing

Control Pendant SwitchMounted on Handrail

3

4 25

1



Section 4-8 Electrical Controls


1

2

3

4

5

PS-73013

PS-73013-B

PS-77005

PS-77009-AR

PS-75430

CONTROL PENDANT SWITCH

CONTROL PENDANT BRACKET

HAND RAIL SWITCH HARNESS

SWITCH HARNESS

PROXIMITY SWITCH

1

1

1

1

2

WARNING

LOW OR FAULTY BATTERIES WILL VOID

WARRANTY ON THE POWER PACK AND ALL

ELECTRICAL SWITCHES AND COMPONENTS

PS-77009-AR

HARNESS

Pg54PSA PC8000- RFS 14-12-16



Section 4-8 Electrical Controls Wiring Diagram 1

Pg55PSA PC8000- RFS 14-12-16




Pg56PSA PC8000- RFS 14-12-16




Pg57PSA PC8000- RFS 14-12-16

1

5

3 42

O P T I O N A L E X T R A O N L Y



Section 4-8 Electrical Controls

1. AERIAL BULKHEAD

2. POWER ON LED

3. LADDER UP LED

4 LADDER DOWN LED

5. POWER/LOGIC PLUG

SUGGESTED WIRING FOR HYDRAULIC POWERSTEP STAIRWAY SYSTEM

Remote Control Unit PS-2394Raise/lower Transmitter

PS-2393

Pg58PSA PC8000- RFS 14-12-16



Emergency Lanyard Kit

PS-HITEX-L/YARD KIT

O P T I O N A L E X T R A O N L Y

Pg59PSA PC8000- RFS 14-12-16



Powerstep Emergency Circuit ( Ladder Down)

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