Powerstep Access System for Komatsu D475A Dozer

Hydraulic Ladder + Full Walkways

Model No. PSA-D475-FL-FULL

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

PSA-D475A-F/L-FULL 9-10-15
HYDRAULIC LADDER + WALKWAYS
Komatsu D475A

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

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Section 1. Installation and Mounting Instructions

See Installation Drawings 23601, 23 625, 23626 & 30264

NOTE
Follow all on-site/Mine lifting and safety procedures when installing
Power Step Landings to Dozer.

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.

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Section 1. Installation Instruction Drawings Bolting Pads 23 625

DETAIL Z
DETAIL Y
DETAIL X
DETAIL W

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Section 1. Installation Instruction Drawings Platform 23 626

VIEW U
VIEW Y

VIEW W
VIEW V

VIEW Z
VIEW X

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Section 1. Installation Instruction Drawings Assembly 23 601

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Section 1. Installation Instruction Drawings PROP P30 264

VIEW W
VIEW X

VIEW V
VIEW Y

VIEW T
VIEW Z

VIEW U

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Section 1. Installation Instruction Drawings
Pg 1

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

USE SAFE WORKING AND LIFTING METHODS AT ALL TIMES

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Section 1. Installation Instruction Drawings
Pg 2
USE SAFE WORKING AND LIFTING METHODS AT ALL TIMES

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Section 1. Installation Instruction Drawings
Pg 3
USE SAFE WORKING AND LIFTING METHODS AT ALL TIMES

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Section 1. Installation Instruction Drawings
Pg 4
USE SAFE WORKING AND LIFTING METHODS AT ALL TIMES

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Section 1. Installation Instruction Drawings
Pg 5
USE SAFE WORKING AND LIFTING METHODS AT ALL TIMES

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

Drive Arrangement

DRIVE ARRANGEMENT

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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.

WARNING
Raising 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).

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Section 2. Electrical System - Wiring Diagram Pg 1

WIRING HARNESS

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

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

Pressure Switch Operated

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

Toggle Switch Operated

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Section 2. Electrical System - Wiring Diagram Pg 5

WIRING HARNESS 1

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Section 2. Electrical System - Wiring Diagram Pg 6

WIRING HARNESS 1

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Section 3. Recommended Maintenance Procedure

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

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.

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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.

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Section 5. Assembly Complete PSA-D475A-FL

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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]

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

Item Part No. Part Name Qty

1 PS-23613 SIDE PLATFORM 1

2 PS-23612 FLOOR PANEL 1
3 PS-K475LND-HR-B06 HANDRAIL REPLACEMENT FABRICATION 1
3A PS-KD475-23 614 HANDRAILS- SIDE PLATFORM (Front only) 1
3B PS-HRI-A04 HANDRAIL POST-CLAMP ASSY 7
3C PS-HRI-A06 HANDRAIL POST - DOUBLE CLAMP ASSY. 2
4 PS-23604 REAR SPREADER BEAM 1
5 PS-23603 REAR ISOLATOR BRACKETS 2
6 PS-23602 ISOLATOR HOUSINGS 2
7 PS-21941-02 ANTI VIBRATION MOUNTING 2
8 PS-23616 PIVOT PIN BRACKET 1
9 PS-21941-06 RUBBER BUSH (Anti Vibration Mtg.) 2
10 PS-21930A ISOLATOR ASSEMBLY 3
11 PS-21925 MIDDLE BEARING MOUNTING 1
12 PS-21933B ISOLATOR BUSH PIN 1
14 PS-M20X60ZP BOLT-M20 x 60 4
15 CPS-M16X40ZP BOLT-M16 x 40 8
16 CPS-M16X25ZP BOLT-SOCKET HEAD-M16 x 25 4
17 CPS-M12X35ZP BOLT-M12 x 120 6
18 CPS-M12X65ZP BOLT-M12 x 65 2
19 CPS-M12X75ZP BOLT-M12 x 75 4
20 CPS-M12X35ZP BOLT-M12 x 35 36
21 CPS-M12X25ZP BOLT-M12 x 25 18
22 CPS-M8X35ZP BOLT-M8 x 35 8
23 CPS-M20NZP NUT-M20 4
24 CPS-M12NZP NUT-M12 46
25 CPS-M8NN NUT-NYLOC-M8 8
26 CPS-M20WH WASHER-HARDENED-M20 4
27 CPS-M16WH WASHER-HARDENED-M16 12
28 CPS-M12WH WASHER-HARDENED-M12 90
29 CPS-M8WH WASHER-HARDENED-M8 16

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Section 5-2. Ladder & Handrail Assembly

Item Part No. Part Name Qty

1 PS-22002 LADDER & HANDRAIL FABRICATION 1

2 PS-23617 ROTATION SHAFT 1
3 PS-21958 PINION ASSY 1
4 PS-21926-01 LADDER SHAFT PIVOT BUSH-MIDDLE 1
5 PS-21926-02 LADDER SHAFT PIVOT BUSH (non drive end) 1
5A PS-21926-03 LADDER SHAFT PIVOT BUSH (drive end) 1
6 CPS-M12X45 BOLT-M12 x 45 8
7 CPS-M12X30 BOLT-M12 x 30 8
8 CPS-M12NZP NUT-M12 16
9 CPS-M12WH WASHER-M12 32

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Section 5-3. LH Side Platform Assembly (PS-K475LND- A03)

See Parts List Page 28

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Section 5-3. LH Side Platform Assembly (PS-K475LND-A03)

See Drawing Page 27

Item Part No. Part Name Qty

1 PS-K475LND-B05 LANDING FABRICATION - LHS 1

2 PS-K475LND-HR-B01 HANDRAIL - LHS 1
3 PS-K475LND-B02 MOUNTING BRACKET 4
4 PS-HRI-A04 POST CLAMP 4
5 PS-22789 RUBBER CONNECTOR-HANDRAILS 1
6 CPS-M16X45 BOLT-M16 x 45 16
7 CPS-M16X40 BOLT-M16 x 40 4
8 CPS-M16X35 BOLT-M16 x 35 16
9 CPS-M12X35 BOLT-M12 x 35 20
10 CPS-M16NZP LOCKNUT-M16 20
11 CPS-M12NN NUT-NYLOC-M12 20
12 CPS-M16WH WASHER-M16 56
13 CPS-M12WH WASHER-M12 40

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Section 5-4. Back Platform Assembly (PS-K475LND-A04)

See Parts List Page 30

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Section 5-4. Back Platform Assembly (PS-K475LND-A04)

See Drawing Page 29

Item Part No. Part Name Qty

1 PS-K475LND-B06 WALKWAY FRAME FABRICATION - BACK 1

2 PS-K475LND-HR-B02 HANDRAIL - BACK - OUTER 1
3 PS-K475LND-HR-B03 HANDRAIL - BACK - INNER 1
4 PS-K475LND-B03 WALKWAY BRACKET - LHS 1
5 PS-K475LND-B04 WALKWAY BRACKET - CENTER 1
6 PS-K475LND-B01 WALKWAY BRACKET- RHS 1
7 PS-K475LND-HR-B04 STIFFENER-LH 1
8 PS-K475LND-HR-B05 STIFFENER-RH 1
9 PS-HRI-A04 POST CLAMP 10
10 PS-22789 HANDRAIL RUBBER CONNECTION ASSY. 2
11 CPS-M16X45 BOLT-M16 x 45 12
12 CPS-M16X30 BOLT-M16 x 30 4
13 CPS-M12X35 BOLT-M12 x 35 56
14 CPS-M16NN NUT-NYLOC-M16 12
15 CPS-M12NN NUT-NYLOC-M12 56
16 CPS-M16WH WASHER-M16 28
17 CPS-M12WH WASHER-M12 12

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Section 5-5. Drive Unit Assembly

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Section 5-5. Drive Unit Assembly

See Drawing Page 31

Item Part No. Part Name Qty

1 PS-63014 HYDRAULIC CYLINDER 1

2 PS-23615 DRIVE MOUNTING FRAME 1
3 PS-23620 SECTOR GEAR 1
4 PS-23618 DRIVE GUARD 1
5 PS-21954A ACTUATOR CYL. MOUNTING ASSEMBLY 1
6 PS-23619-02 PROXIMITY SWITCH MOUNT BAR 1
7 PS-21106A PROXIMITY SWITCH MOUNT PLATE 1
8 PS-61006-2 GREASE NIPPLE M6 STR. 4
9 PS-21959-06 HUB SPACER RING 1
10 PS-21959-07 PIN SPACER RING 4
11 PS-21959-09 SECTOR GEAR BUSH 2
12 PS-21959-06 SECTOR GEAR HUB 1
13 PS-21959-05 CLAMP RING 1
14 PS-21940-03 KEEPER PLATE 1
15 PS-23619-01 SWITCH STRIKER 1
16 PS-M24X150ZP BOLT-M24 x 120 2
17 CPS-M20X50ZP BOLT-M20 x 50 4
18 CPS-M12X80ZP BOLT-M12 x 80 5
19 CPS-M12X65ZP BOLT-M12 x 65 3
20 CPS-M12X25ZP BOLT-M12 x 25 9
21 CPS-M10X15ZP BOLT-M10 x 15 4
22 CPS-M8X25 BOLT-M8 x 25 6
23 CPS-M5X15ZP BOLT-M5 x 15 6
24 PS-M24NN NUT-NYLOC-M24 2
25 CPS-M20NZP NUT-M20 4
26 CPS-M12NZP NUT-M12 17
27 CPS-M12NN NUT-NYLOC-M12 3
28 CPS-M8NZP NUT-M8 6
29 CPS-M5NN NUT-NYLOC-M5 6
30 PS-M24WH WASHER-HARDENED-M24 2
31 CPS-M20WH WASHER-HARDENED-M20 4
32 CPS-M12WH WASHER-HARDENED-M12 34
33 CPS-M10WH WASHER-HARDENED-M10 4
34 CPS-M8WH WASHER-HARDENED-M8 6
35 CPS-M5WH WASHER-HARDENED-M5 6

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

Clamp Mounting 23622

Item Part No. Part Name Qty

1 PS-21945 PROP 1
2 PS-23622-01 CARRIER BAR 2
3 PS-23622-02 CLAMP BEAM 3
4 PS-23622-03 ISOLATOR SPACER 6
5 PS-40003 BUFFER 4
6 PS-21930A ISOLATOR ASSEMBLY 4
7 CPS-M12X120 BOLT-M12 x 120 4
8 CPS-M12X90ZP BOLT-M12 x 90 6
9 CPS-M12X60ZP BOLT-M12 x 60 4
10 CPS-M12X40ZP BOLT-M12 x 40 8
11 CPS-M12NZP NUT-M12 14
12 CPS-M12NN NUT-NYLOC-M12 6
13 CPSM12WH WASHER-HARDENED-M12 22

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

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

Item Part No. Part Name Qty

1A PS-63014A HYDRAULIC CYLINDER (INC. REDUCERS) 1

1B PS-63014-P PIN - CYLINDER- (WITH RETAINER) 2
1S PS-63011K SEAL KIT (NOT SHOWN) 1
2 PS-63201 VALVE - PILOT OPERATED LOCKING 1
3 PS-61158-0.30 FITTING - RESTRICTION 90 DEG 2
4 PS-61154 FITTING - ELBOW- O RING 1/4BSPPx9/16”JIC 1
5 PS-61157 FITTING - O RING 1/4BSPPx 9/16”JIC 1
6 PS-61163 REDUCER JIC x BSPP 2
7 PS-61160 TUBE 2
8 PS-61147 FERRULES/NUTS 2 x each 1
9 PS-60051-2.8 HOSE- HYDR. (9/6”JIC SWIVEL FITTING 2.8M) 1
10 PS-61151 FITTING-ELBOW 7/16”JIC 1
11 PS-61145 FITTING-SWIVEL 9/16”JIC 1
12 PS-61153 FITTING-O RING 1/4”BSP x 7/16”JIC 1
13 PS-60050-2.8 HYDR. HOSE 7/16” SWIVEL FITTINGS 1

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Section 5-7. Hydraulics Diagram

See also Drawing page 34

Double Acting Hydraulic System with

directional Control Valve and Cylinder
Lock Valve

0.030” 0.030”

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

See Parts List Pg 38

13 29 26 6 5 25

View B View A

10

11

16

9 9A 24 2 8 8A 7 3 3A 30

7A

14 Hoses shown 27
6
dotted

12

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

See Parts List Pg 38

28 18

10

16 31

11
17
19

14 12

32

33

View A 24
15
9

23
21

9A

BEACON
20
WORKLIGHT 3PIN

View B
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

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

See Photos Page 36,37

Item Part No. Part Name Qty

1 PS-80103A-SLD POWER PACK ASSEMBLY 1

2 PS-21107-METAL MOTOR ENCLOSURE- SEALED ST/ST 1
3 PS-80103A POWER PACK 1
3A PS-80103-CLAMP CLAMP ELECTRIC MOTOR 1
4 PS-82415 AUDIBLE ALARM 1
5 PS-84214 BRIDGE RECTIFIER 1
6 PS-82492 SOLENOID 24V START MOTOR 1
7 PS-61160-M/F-BOX-7/16”F HYDRAULIC TUBE 7/16” 1
7A PS-61160-M/F-BOX-9/16”F HYDRAULIC TUBE 7/16” 1
8 PS-61152 HYDRAULIC FITTING 7/16” 1
8A PS-61150 HYDRAULIC FITTING 9/16” 1
9 PS-61177 HYDRAULIC FITTING 9/16” 1
9A PS-61176 HYDRAULIC FITTING 7/16” 1
10 PS-84213 135A CIRCUIT BREAKER 1
11 PS-84212 5A CIRCUIT BREAKER 1
12 PS-84303 ISOLATION SWITCH- (INCLUDING BRACKET) 1
13 PS-1712080 SEALED WIRING BOX 1
14 PS-73012 TOGGLE SWITCH KIT 1
15 PS-82493 BATTERY FEED STUDS 2
16 PS-HD10-5-16P 5 PIN SOCKET 1
17 PS-41010 DECAL-Battery Isolation 1
18 PS-41011 DECAL-Battery Supply C/B-135A 1
19 PS-41012 DECAL-Controller Supply C/B-5A 1
20 PS-41013 DECAL-Battery Supply-PosItive 1
21 PS-41014 DECAL-Battery Supply-Negative 1
22 PS-41023 DECAL-Up/Down 1
23 PS-41024 DECAL HYDRAULIC-HOSES 1
24 PS-41041 DECAL OIL TANK 1
25 PS-41019 DECAL BRIDGE RECTIFIER 1
26 PS-41017 DECAL SOLENOID 1
27 PS-41018 DECAL ALARM 1
28 PS-41016 DECAL RAISE/LOWER SWITCH 1
29 PS-73010 RUBBER BOOT RED 4
30 PS-73009 RUBBER BOOT BLACK 2
31 PS-HD10-3-16P 3 PIN SOCKET (PARK BREAK) 1
32 PS-HD10-5-16P 5 PIN SOCKET (AUTO-RAISE) 1
33 PS-41032 DECAL AUTO-RAISE SOCKET 1

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HYDRAULIC LADDER + WALKWAY
Komatsu D475A

Section 5-9. Electrical Controls

Control Pendant Switch
Mounted on Handrail
Proximity Switch Assembly
Mounted on Fixed Landing 1

5 6 4 2

Cab Harness & Equipment 3

Refer Wiring Harness Drawings

7 8

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HYDRAULIC LADDER + WALKWAY
Komatsu D475A

Section 5-9. Electrical Controls

See Photos Page 39

Item Part No. Part Name Qty

1 PS-73013 CONTROL PENDANT SWITCH 1

2 PS-73013-B CONTROL PENDANT BRACKET 1
3 PS-77005 HAND RAIL SWITCH HARNESS 1
4 PS-77009AR AUTO RAISE HARNESS 1 Optional only
5 PS-77004 CABIN TO SWITCH HARNESS 1
6 PS-75430 PROXIMITY SWITCH 2 1 X Optional
7 PS-77002 CABIN BOX LED LIGHT INDICATOR 1
8 PS-77003 WIRING HARNESS IN CABIN 1

WARNING
LOW OR FAULTY BATTERIES WILL VOID
WARRANTY ON THE POWER PACK AND ALL
ELECTRICAL SWITCHES AND COMPONENTS

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