to suit komatsu d375adozer - power step · 2019. 8. 8. · folding ladder komatsu d375adozer...

POWER STEP HYDRAULIC FOLDING LADDER

TO SUIT KOMATSU D375A DOZER

PSA-D375A-F/L 21 7 11

Model No.PSA-Kom D375A-F/L

Serial No.:D375-001-FL TO D375-006-FL

Date Manufactured: OCT 2010

FOLDING STAIRWAYKomatsu D375A Dozer

PSA-D375A-F/L 21 7 11 Pg2

CONTENTS

Page 3 Section 1 Installation and Mounting instructions

Installation Drawings

10 Section 2 Electrical System Wiring Diagrams

13 Section 3 Recommended Maintenance procedure

14 Section 4 Operating Procedure

Section 5 Drawings and Repair Parts lists

15 5 Assembly Complete

16 5-1 Landing Assembly

Parts List

18 5-2 Ladder Assembly

Parts List

19 5-3 Drive Unit Assembly

Parts List

21 5-4 PROP Assembly

Parts List

22 5-5 Hydraulic Cylinder

Parts List

24 5-6 Power Pack

Parts List

27 5-7 Electrical Controls

FOLDING LADDERKomatsu D375A Dozer

Section 1. Installation and Mounting Instructions

PSA-D375A-F/L 21 7 11 Pg3

NOTE

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

Power Step Landings to Dozer.

General Arrangement

See Drawing PSA-KD375-Unit

PROCEDURE

See Drawings PSA-K375-INST-01 Rev B3

Landing Mounting See Page 4 and 5

PROP Mounting See Page 6

General Arrangement - See Pg 7

Drive Arrangement - See Pg. 8

FOLDING LADDERKomatsu D375A See Dwg. PSA-K375-INST-01 RevB3

PSA-D375A-F/L 21 7 11 Pg4


PSA-D375A-F/L 21 7 11 Pg5


PSA-D375A-F/L 21 7 11 Pg6

PSA-D375A-F/L 21 7 11 Pg7



Section 1. Installation Instruction Drawings - 23 621

Drive Arrangement

PSA-D375A-F/L 21 7 11 Pg8


Section 1. Installation and Mounting Instructions (cont.)

Maintenance Notes

PSA-D375A-F/L 21 7 11 Pg9

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 Diagrams Page 1

PSA-D375A-F/L 21 7 11 Pg10

WIR

ING

HA

RN

ES

S

CO

MP

LE

TE

CA

B H

AR

NE

SS

P/N

77

00

1

PSA-D375A-F/L 21 7 11 Pg11

FOLDING LADDERKomatsu D375A

Section 2. Electrical System - Wiring Diagram Page 2

PSA-D375A-F/L 21 7 11 Pg12


Section 2. Electrical System - Wiring Diagram Page 3

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

PSA-D375A-F/L 21 7 11 Pg13


Section 4. Operating Procedure

PSA-D375A-F/L 21 7 11 Pg14

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.


Section 5. Assembly Complete

PSA-D375A-F/L 21 7 11 Pg15


Section 5-1. Landing Assembly

PSA-D375A-F/L 21 7 11 Pg16


Section 5-1. Landing Assembly See Drawing Page 16

PSA-D375A-F/L 21 7 11 Pg17

Item Part No. Part Name Qty

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

PS-KD375-B05

PS-KD375-B04

PS-KD375-A04

PS-KD375-B02

PS-KD375-B01

PS-KD375-B07

PS-23602

PS-21941-02

PS-23616

PS-21941-06

PSA-KD375-B15

PS-21930A

PS-21925

PS-KD375-C040

PS-HRI-C08

CPS-M16X65ZP

CPS-M16X45ZP

CPS-M16X40ZP

CPS-M12X110ZP

CPS-M12X75ZP

CPS-M12X65ZP

CPS-M12X60ZP

CPS-M12X40ZP

CPS-M12X35ZP

CPS-M8X35ZP

CPS-M16NZP

CPS-M12NZP

CPS-M12NN

CPS-M8NN

CPS-M16WH

CPS-M12WH

CPS-M8WH

CPS-M12WH

PS-S245

SIDE PLATFORM

FLOOR PANEL

HANDRAILS

REAR SPREADER BEAM

MOUNT REAR BEAM BRACKET

SUBFRAME SUPPORT

ISOLATOR HOUSING

ANTI VIBRATION MOUNTING

PIVOT PIN BRACKET

RUBBER BUSH (Anti Vibration Mtg.)

REAR HANDRAIL BRACE

ISOLATOR ASSEMBLY

MIDDLE BEARING MOUNTING

ISOLATOR BUSH PIN

RUBBER PAD

BOLT-M16 x 65

BOLT-M16 x 45

BOLT-M16 x 40

BOLT-M12 x 110

BOLT-M12 x 75

BOLT-SOCKET HEAD-M12 x 65

BOLT-M12 x 60

BOLT-M12 x 40

BOLT-M12 x 35

BOLT-M8 x 35

NUT-M16

NUT-M12

NUT-NYLOC-M12

NUT-NYLOC-M8

WASHER-HARDENED-M16

WASHER-HARDENED-M12

WASHER-HARDENED-M8

SPRINGWASHER-M12

BUSH-S245

1

1

1

1

2

1

2

2

1

2

1

3

1

1

2

4

8

4

6

2

2

2

24

18

4

4

2

2

2

4

46

2

4

4


Section 5-2. Ladder Assembly

PSA-D375A-F/L 21 7 11 Pg18


1

1A

2

3

3A

4

5

5A

6

7

8

9

PS-22025

PS-30224

PS-30217A

NPN

PS-30235-02

PS-30226-01

PS-30226-02

PS-30226-03

CPS-M12X50

CPS-M12X20

CPS-M12NZP

CPS-M8NZP

LADDER & HANDRAIL FABRICATION

LADDER TREAD

ROTATION SHAFT (INCLUDES PINION)

PINION

KEEPER PLATE

LADDER SHAFT PIVOT BUSH-MIDDLE

LADDER SHAFT PIVOT BUSH (non drive end)

LADDER SHAFT PIVOT BUSH (drive end)

BOLT-M12 x 50

BOLT-M12 x 40

LOCKNUT-M12

SPRINGWASHER-M12

1

8

1

1

1

1

1

1

8

8

16

32


Section 5-3. Drive Unit Assembly

PSA-D375A-F/L 21 7 11 Pg19


Section 5-3. Drive Unit Assembly 23 621See Drawing Page 19

PSA-D375A-F/L 21 7 11 Pg20


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-30215B

PS-30220

PS-30218A

PS-21954A

PS-30619-01

PS-30619-02

PS-61006-2

PS-21959-06

PS-21959-07

PS-21959-09

PS-21959-08

PS-21959-05

PS-21940-03

PS-30219-01

PS-M24X150ZP

CPS-20X65ZP

CPS-M12X80ZP

CPS-M12X65ZP

CPS-M12X25ZP

CPS-M10X15ZP

CPS-M8X25

CPS-M5X15ZP

PS-M24XNN

PS-M20NZP

CPS-M12NZP

CPS-M12NN

CPS-M8NZP

CPS-M5NN

PS-M24WH

CPS-M20WH

CPS-M12WH

CPS-M10WH

CPS-M10WH

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 150

BOLT-M20 x 65

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

4

1

2

1

1

1

1

2

4

5

3

9

4

6

6

2

4

17

3

6

6

2

4

20

4

6

6


Section 5-4. PROP Assembly

PSA-D375A-F/L 21 7 11 Pg21


1

2

3

4

5

6

7

8

9

10

11

13

14

15

16

PSA-KD375-B12

PSA-KD375-B13

PSA-KD375-C023

PSA-KD375-C039

PS-40003

PS-21930A

CPS-M16X45ZP

CPS-M12X120ZP

CPS-M12X95ZP

CPS-M12X30ZP

CPS-M12NZP

CPS-M10NZP

CPSM12WH

CPSM12WH

CPSM12WH

PROP FRAME FABRICATION

PROP MOUNTING FRAME FABRICATION

WELD-ON MOUNTING BLOCK

SPACER PLATE

RUBBER CONE STOPPER

ISOLATOR ASSEMBLY

BOLT-M16 x 45

BOLT-M12 x 120

BOLT-M12 x 95

BOLT-M12 x 30

NUT-M12

NUT-M10

WASHER-HARDENED-M16

WASHER-HARDENED-M12

WASHER-HARDENED-M10

1

2

6

3

4

4

6

4

4

4

4

8

6

21

4

Clamp Mounting


Section 5-5. Hydraulic Cylinder

PSA-D375A-F/L 21 7 11 Pg22

PS-63014-AH HYDRAULIC CYLINDER WITH PLUMBING (INC. ITEMS 1, 2, 6, 7, 8, 9, 10)


1

-

2

3

4

5

6

7

8

9

10

11

11A

12

PS-63014

PS-63011K

PS-63201

PS-63202

PS-61159

PS-61154

PS-61157

PS-61158-0.30

PS61163

PS-61161

PS-60047

PS-60051-2.8 9/16

PS-60051-2.8 7/16

PS-61145

HYDRAULIC CYLINDER ASSEMBLY

SEAL KIT (NOT SHOWN)

VALVE - PILOT OPERATED LOCKING

FLOW CONTROL VALVE

FITTING - ELBOW-9/16” JIC

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

FITTING - O RING 1/4BSPPx 9/16”JIC

FITTING - 0.030” RESTRICTION 90 DEG

REDUCER JIC x BSPP

TUBE

FERRULES

HOSE-HYDR. (9/16”JIC SWIVEL FITTING 2.8M)

HOSE-HYDR. (7/16”JIC ST. SWIVEL 2.8M)

FITTING 9/16 JIC SWIVEL

1

1

1

1

1

1

2

2

2

1

2

1

1

1


Section 5-5. Hydraulic Cylinder (Valve Diagram)See also Drawing page 22

PSA-D375A-F/L 21 7 11 Pg23

0.030” 0.030”

Double Acting Hydraulic System with

directional Control Valve and Cylinder

Lock Valve


Section 5-6. Power Pack PS-80103A-SLDSee Parts List Pg 26

PSA-D375A-F/L 21 7 11 Pg24

9 8

4

14

29

28 6 5 27

6

2 7

10

31

11

17

13

15

12

1

3226 3

Hoses shown

dotted

View B View A

9A

7A


Section 5-6. Power Pack PS-80103A-SLD

See Parts List Pg 26

PSA-D375A-F/L 21 7 11 Pg25

20

24

15

21

11

1017

18

30

19

16 2223

25

9

View A

View B

9A


Section 5-6. Power Pack PS-80103A-SLDSee Photos Page 24,25.

PSA-D375A-F/L 21 7 11 Pg26


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

PS-80103A

PS-21107-METAL

PS-80103-CLAMP

PS-82415

PS-84214

PS-82402

PS-60050-900MM

PS-61152

PS-61177

PS-84213

PS-84212

PS-84303

PS-84303-B

PS-1712080

PS-73012

PS-82493

PS-HD10-5-16P

PS-HD10-5-16S

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

POWER PACK

MOTOR ENCLOSURE- SEALED ST/ST

CLAMP ELECTRIC MOTOR

AUDIBLE ALARM

BRIDGE RECTIFIER

SOLENOID 24V START MOTOR

HYDR. HOSES 9/16”JIC STRAIGHT SWIVEL

HYDRAULIC FITTING

HYDRAULIC FITTING

135A CIRCUIT BREAKER

10A CIRCUIT BREAKER

ISOLATION SWITCH

ISOLATION SWITCH BRACKET

SEALED WIRING BOX

TOGGLE SWITCH KIT

BATTERY FEED STUDS

5 PIN SOCKET

5 PIN PLUG

DECAL-Battery Isolation

DECAL-Battery Supply C/B-135A

DECAL-Controller Supply C/B-10A

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

1

1

1

1

2

1

1

1

2

2

2

1

1

1

1

1

1

2

1

1

1

1

1

1

1

1

1

1

1

1

3

1

NOTE - For Items 19 to 30 (Decals)

Suffix - P Denotes Portugese Translation.

Suffix - S Denotes Spanish Translation.


Section 5-7. Electrical Controls

PSA-D375A-F/L 21 7 11 Pg27

Cab Harness & Equipment

Refer Wiring Harness Drawing

Proximity Switch AssemblyMounted on Fixed Landing

Control Pendant SwitchMounted on Handrail

6

2

7

3

5

4

1


Section 5-7. Electrical ControlsSee Photos Page 27

PSA-D375A-F/L 21 7 11 Pg28


1

2

3

4

5

6

7

8

8A

PS-73013

PS-73013-B

PS-75430

PS-77005

PS-77004

PS-77002

PS-77003

PS-60051-3.5

PS-60050-3.5

CONTROL PENDANT SWITCH

CONTROL PENDANT BRACKET

PROXIMITYSWITCH

HAND RAIL SWITCH HARNESS

PROXIMITY MAGNETIC SWITCH HARNESS

CABIN BOX LED LIGHT INDICATOR

WIRING HARNESS

HYDRAULIC HOSE WITH 9/16” FITTINGS

HYDRAULIC HOSE WITH 9/16” FITTINGS

1

1

1

1

1

1

1

1

1

Not shown

Not shown

WARNING

LOW OR FAULTY BATTERIES WILL VOID

WARRANTY ON THE POWER PACK AND ALL

ELECTRICAL SWITCHES AND COMPONENTS

to suit komatsu d375adozer - power step · 2019. 8. 8. · folding ladder komatsu d375adozer...

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