Manual for Cat D11T Dozer With Extended Square Tank · FOLDING LADDER Manual for Cat D11T Dozer With Extended Square Tank PSA-D11T-F/L-2 28-05-09 Model No.PSA-D11T-F/L-2 Serial No.:LD11T-EXT-FT-001

FOLDING LADDERManual for Cat D11T DozerWith Extended Square Tank

PSA-D11T-F/L-2 28-05-09

Model No.PSA-D11T-F/L-2Serial No.:LD11T-EXT-FT-001Date Manufactured: October 2008

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FOLDING LADDERCaterpillar D11T Dozer(With Extended Square Tank)

PSA-D11T-F/L-2 28-05-09

CONTENTS

Page 3 Section 1 Installation and Mounting instructionsInstallation Drawings

11 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 Ladder AssemblyParts List

18 5-2 Walkway Assembly L.H.S.Parts List

20 5-4 Spreader AssemlyParts List

21 5-5 Drive Unit AssemblyParts List

23 5-6 PROP AssemblyParts List

24 5-7 Hydraulic CylinderParts ListValve diagram

26 5-8 Power Pack Parts List

28 5-9 Electrical ControlsParts List

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FOLDING LADDERCaterpillar D11T Dozer

Installation and Mounting InstructionsSee Drawings 23 190, 23 191 & 23 192 (Page 5,6,7 & 8)

PSA-D11T-F/L-2 28-05-09

NOTEFollow all on-site/Mine lifting and safety procedures when installingPower Step Landings to Dozer.

PROCEDURE

See Drawing 23 190 (Page 5)

1. Remove cover plate at the back of the mudguards then remove horn/s.

2. Fit Bolting Pads/Blocks as shown.

3. Re-locate horn/s to suit.

See Drawing 23 191 (Page 6 & 7)

4. Per View 1, fit 23 158 Rear Spreader Plate to the rear of the machine, bolted to the mounting blocks welded to the mudguards etc. Fit Washer Plates (provided) under bolt beads - Washer Plates not shown.

5. Fit Landing Brackets and Isolators to Spreader Plate per View 1.

6. Fit Isolators to mounting plates welded to sides of mudguards per View 1.Fit Isolator Pin Brackets to Isolators. Note (per View 2) that the 'neck' of the Isolator Pin Bracket is offset - install with the neck near to the machine & therefore the rectangular bolting plate away from the machine.

7. Fit Landing Brackets and Isolators to Spreader Plate per View 1.

8. Per View 3, put the side landing (complete with ladder) on the Isolator Pin Brackets (Item iii.) and bolt on. See also View 4. Also fit Isolator Pin Brackets to the arm on therear end of the side landing main beam and attach to Isolators (on Spreader Plate) using Isolator Bush Pin per View 5.

9. Per View 6, weld in the Spacer between the rear section of the landing handrail andthe OEM/agent's tank-top rear walkway.

10. Per View 7, cut back the profiled side plate and the hinge of the single-tread step between the original mudguard deck and the tank-top walkway. Location of step indicated per View 6.

11. Grease the gears in the drive mechanism.

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Section 1 Installation Instruction Drawings - 23 192

PSA-D11T-F/L-2 28-05-09

PROCEDURE (cont.)

See Drawing 23 192 (Page 8)

1. Lower ladder as far as it will go. Ensure its' lowered travel is limited by the stops at the top of the ladder (see View 2) and not by the drive mechanism. If the drive mechanism is limiting down travel, re-arrange spacers/packers behind the actuator attachment so the ladder stops limit the travel - see View 3.

2. Fit the Prop System Mounting Frame to the ROPS over the cabin per View 1. Use existing bolting blocks at the back + Bolting Pad 23 160 14 at the front. Also weld ROPS Roof Button 23 160 16 to the ROPS roof, 3 off. Spacers 23 160 13 might be required under the rear cleats.

3. Raise the ladder as far as it will go. Per View 1, bolt the PROP Arm 21 945 to the Spacer Frame 23 161 using the middle of five holes available for the isolator bush bolts. Locate the assembled PROP Arm and Spacer Frame so as to engage the ladder centrally and support it in the middle of its' range of free movement (slap). Weld the blocks in place, per View 4.

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Section 1 Installation Instruction Drawings - 23 190

PSA-D11T-F/L-2 28-05-09

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Section 1 Installation Instruction Drawings - 23 191 (Page 1)

PSA-D11T-F/L-2 28-05-09

VIEW 2

VIEW 3

VIEW 1

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Section 1 Installation Instruction Drawings - 23 191 (Page 2)

PSA-D11T-F/L-2 28-05-09

VIEW 4 VIEW 5

VIEW 7

VIEW 8

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FOLDING LADDERCaterpillar D11T DozerSection 1 Installation Instruction Drwgs 23 192

PSA-D11T-F/L-2 28-05-09

VIEW

4

VIEW

3

VIEW

2

VIEW

1

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Section 1 Installation Instruction Drawings - 22 520 Page 1

Drive Arrangement

PSA-D11T-F/L-2 28-05-09

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Section 1 Installation and Mounting Instructions (Cont.)Maintenance Notes

PSA-D11T-F/L-2 28-05-09

NOTEFollow all on-site/Mine lifting and safety procedures when installingPower Step Landings to Dozer.

WARNING

Raising the POWER STEP Ladder by external means can create a vacuum in thehydraulic 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 Ladder must be used, pleasefollow the following instructions:

Loosen hard plumbed hydraulic lines on cylinder side of lock valve on cylinder.Raise Ladder by available means.Note: Make necessary arrangements to collect displaced oil, and be aware that air entersthe piston side of the cylinder as platform is raised.Lock in raised position.Re-tighten hydraulic fittings.SECURE THE LADDER 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 Ladder to lowest position, using alternate safety approved means, fully retractingcylinder. Ensure all personnel are clear of step radius.Operate electrical control switch to purge air from the hydraulic line systems, lock valveand 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 tothe incorrect operation of the lock valve).

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Section 2 Electrical System - Wiring Diagrams Page 1

PSA-D11T-F/L-2 28-05-09

Power Step D11 Machine and Dash Wiring for Ladder Lamps

Power Step D11 Shutdwn Circuit

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Section 2 Electrical System - Wiring Diagram Page 2

Pow

er S

tep

D1 1

Ele

ctric

al C

ircui

t

DailyVisually 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 HoursGrease 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. (Stairway in raisedposition).

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 HoursChange 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 stairway lowered, and accessed from under the stairway.

Check and inspect all main bolts on stairway system.Retorque if required.

Repeat daily check as above

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Section 3 Recommended Maintenance Procedure

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Section 4 Operating Procedure

PSA-D11T-F/L-2 28-05-09

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 truck is parked on uneven ground, the bottom of the stairway may touch the ground before the ladder is in the fully lowered position.Should this occur, descend the ladder with caution.

To Raise LadderAscend the ladder onto the landing of the truck.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.

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Section 5 Assembly Complete

PSA-D11T-F/L-2 28-05-09

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Section 5-1 Ladder Assembly

PSA-D11T-F/L-2 28-05-09

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Section 5-1 Ladder Assembly See Drawing Page 16

PSA-D11T-F/L-2 28-05-09

Item Part No. Part Name Qty

123456789

10

PS-21924PS-23167PS-21958PS-21926-01PS-21926-02PS-21926-03CPS-M12X50ZPCPS-M12X20ZPCPS-M12NZPCPS-M12NZP

LADDER & HANDRAIL FABRICATIONROTATION SHAFTPINION ASSEMBLYLADDER SHAFT PIVOT BUSH-MIDDLELADDER SHAFT PIVOT BUSH-NON DRIVE ENDLADDER SHAFT PIVOT BUSH- DRIVE ENDBOLT-M12 x 50BOLT-M12 x 20NUT-M12WASHER-M12

1111118888

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Section 5-2 Walkway Assembly L.H.S.

PSA-D11T-F/L-2 28-05-09


Section 5-2 Walkway Assembly L.H.S.See Drawing Page 18

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123456789

1011121314151617181920212223242526272829

PS-23165PS-23166PS-23168PS-21932PS-21930PS-21976PS-21941-02PS-21941-06PS-21933PS-21925PS-21926PS-22005-01PS-22005-03/02PS-22789-01PS-22789-02PS-22789-03CPS-M12X75ZPCPS-M12X65ZPCPS-M12X40ZPCPS-12X35ZPCPS-M12X30ZPCPS-M12X25ZPCPS-M8X35ZPCPS-M12NZPCPS-1/2”NNCPS-M8NNCPS-M12WH CPS-1/2”WHCPS-M8WH

WALKWAY-LEFT SIDEFLOORING PANELHANDRAILISOLATOR PIN BRACKETSISOLATOR MOUNTINGSFRONT PIVOT PIN BRACKETANTI VIBRATION BEARINGRUBBER BUSHISOLATOR BUSH PINMIDDLE BEARING MOUNTINGPIVOT BUSHESISOLATED HANDRAIL LINKISOLATOR RUBBER/CLAMPMOUNTING BARCLAMP BARISOLATOR ELEMENTBOLT-M12 x 75BOLT-SOCKET HEAD-M12 x 65BOLT-M12 x 40BOLT-M12 x 35BOLT-M12 x 30BOLT-M12 x 25BOLT-M8 x 35NUT-M12NUT-NYLOC-1/2”UNC NUT-NYLOC-M8WASHER-HARDENED-M12WASHER-HARDENED-1/2”WASHER-HARDENED-M8

111261222112222122

284

16328

3048

8048


Section 5-3 Spreader Assembly

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123456789

101112131415

PS-23158PS-21931 98PS-21931 99PS-23159 05PS-23159 06PS-23159 01PS-23159 03PS-22933PS-21930CPS-M20X60ZPCPS-M12X25ZPCPS-1/2”NNCPS-M20WHCPS-M12WHCPS-1/2”WH

SPREADERISOLATOR PIN BRACKET-OUTERISOLATOR PIN BRACKET-INNERWASHER PLATESWASHER PLATEINNER MOUNTING BLOCKOUTER MOUNTING BLOCKISOLATOR BUSH PINISOLATOR MOUNTINGBOLT-M20 x 60BOLT-M12 x 25NUT-NYLOC-1/2” UNCWASHER-HARDENED-M20WASHER-HARDENED-M12WASHER-HARDENED-1/2”

111412126

10204

10204


Section 5-4 Drive Unit Assembly

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Section 5-4 Drive Unit AssemblySee Drawing Page 21

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123456789

10111213141516171819202122232425262728

PS-63014PS-21974PS-21959PS-21984PS-21954PS-21991PS-61006-2PS-21940-03PS-21959-09PS-21959-08PS-21959-05PS-M24X150ZPCPS-20X65ZPCPS-M12X80ZPCPS-M12X65ZPCPS-M12X25ZPCPS-M10X15ZPCPS-M5X15ZPPS-M24XNNPS-M20NZPCPS-M12NZPCPS-M12NNCPS-M5NNCPS-M24WHCPS-M20WHCPS-M12WHCPS-M10WHCPS-M5WH

HYDRAULIC CYLINDERDRIVE MOUNTING FRAMESECTOR GEARDRIVE GUARDACTUATOR CYL. MOUNTING ASSEMBLYPROXIMITY SWITCH PLATESGREASE NIPPLE M6 STR.PIVOT PIN KEEPER PLATESECTOR GEAR BUSHSECTOR GEAR HUBCLAMP RINGBOLT-M24 x 150BOLT-M20 x 65BOLT-M12 x 80BOLT-M12 x 65BOLT-M12 x 25BOLT-M10 x 15BOLT-M5 x 15NUT-NYLOC-M24NUT-M20NUT-M12NUT-NYLOC-M12NUT-NYLOC-M5WASHER-HARDENED-M24WASHER-HARDENED-M20WASHER-HARDENED-M12WASHER-HARDENED-M10WASHER-HARDENED-M5

11111121211245394624

143624

1746


Section 5-5 PROP Assembly

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123456789

1011121314

PS-23160PS-21945PS-23169PS-23160-16PS-23160-14PS-23160-13PS-21930PS-40003CPS-1/2”UNCCPS-M12X25ZPCPS-M12NZPCPS-1/2”NNCPSM12WHCPS-1/2”WH

PROP MOUNTING FRAMEPROPPROP SPACER FRAMEROOF BUTTONBOLTING PADSPACERISOLATOR MOUNTINGBUFFERISOLATOR PIN 1/2” x 4.5”BOLT-M12 x 25NUT-M12NUT-NYLOC-1/2” UNCWASHER-HARDENED-M12WASHER-HARDENED-1/2”

111322444

23144

278


Section 5-6 Hydraulic Cylinder

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1-23456789

101112131415

PS-63014PS-63011KPS-63201PS-63202PS-63202BPS-63202CPS-61159PS-61154PS-61157PS-61158-0.30PS61163PS-61163PS-60031-FTPS-60051-2.8PS-61156-1MMPS-61145

HYDRAULIC CYLINDER SEAL KIT (NOT SHOWN)VALVE - PILOT OPERATED LOCKINGFLOW CONTROL VALVEFITTING - JIC NIPPLEFITTING- JIC SWIVELFITTING - ELBOW-9/16” JICFITTING - ELBOW- O RING 1/4BSPPx9/16”JICFITTING - O RING 1/4BSPPx 9/16”JIC FITTING - 0.030” RESTRICTION 90 DEGREDUCER JIC x BSPPTUBEFERRULESHOSE- HYDR. (9/6”JIC SWIVEL FITTING 2.8M)FITTING - 1MM RESTRICTION 90 DEGFITTING 9/16 JIC SWIVEL

1111111122222221


Section 5-6 Hydraulic Cylinder (Valve Diagram)See also Drawing page 24

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Double Acting Hydraulic System withdirectional Control Valve and Cylinder

Lock Valve

0.030” 0.030”


Section 5-7 Power Pack

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9 8 414 2627 25 5

18 17 16

6

19

22

21

15

20

18 23 8

2 7 3

10

28

11

13

15

12

2924


Section 5-7 Power PackSee Photo Page 26

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123456789

1011121314151617181920212223242526272829

PS-80103A-SSPS-21107SSPS-80103APS-75024PS-84214PS-82402PS-60050-900MMPS-61152PS-61177PS-84213PS-84212PS-84303PS-84303-BPS-1712080PS-73012CPS-CAB20M20CPS-CAB16M20CPS-CAB12M16PS-41011PS-41012PS-41023PS-41010PS-41024PS-41041PS-41019PS-41017PS-41018PS-73010PS-73009

POWER PACK ASSEMBLY (Incl. Items.2-11)MOTOR ENCLOSURE- SEALED ST/STPOWER PACKAUDIBLE ALARMBRIDGE RECTIFIERSOLENOIDHYDR. HOSES 9/16”JIC STRAIGHT SWIVELHYDRAULIC FITTINGHYDRAULIC FITTING135A CIRCUIT BREAKER5A CIRCUIT BREAKERISOLATION SWITCHISOLATION SWITCH BRACKETSEALED WIRING BOXTOGGLE SWITCH KITWIRE HARNESS GLANDWIRE HARNESS GLANDWIRE HARNESS GLANDDECAL ELECTRICALDECAL ELECTRICALDECAL ELECTRICALDECAL ELECTRICALDECAL HYDRA-HOSESDECAL OIL TANKDECAL SOLENOIDDECAL BRIDGE RECTIFIERDECAL ALARMRUBBER BOOT REDRUBBER BOOT BLACK

11111122211111121311111111131


Section 5-8 Electrical ControlsRefer also Wiring Drawings Page 11 & 12.

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4

8

6

7

3

9

5

12

Proximity Switch AssemblyHand Control Switch Assembly


Section 5-8 Electrical ControlsRefer also Wiring Drawings Page 11 &12.See Photo Page 28.

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1--

2---

34

56789

1011

PS-73013PS-73013BPS-73005

PS-75430PS-75430APS-75430BPS-75402

--

PS-41011PS-84213PS-76001PS-77003PS-63202PS-60051-2.8MPS-21107-SS

HAND CONTROL SWITCH ASSEMBLYBRACKETHARNESS

PROXIMITY SWITCH ASSEMBLYBRACKETBRACKETHARNESS

MANUALSINSTALLATION DRAWINGS

DECAL FOR 135A CIRCUIT BREAKER135A CIRCUIT BREAKERCONTROL BOXCONTROL BOX HARNESSFLOW CONTROL VALVEHYDRAULIC HOSESENCLOSURE-ST. STEEL(for Power Pack)

11111111

1-

1111111

Documents

Manual for Cat D11T Dozer With Extended Square Tank · FOLDING LADDER Manual for Cat D11T Dozer With Extended Square Tank PSA-D11T-F/L-2 28-05-09 Model No.PSA-D11T-F/L-2 Serial No.:LD11T-EXT-FT-001