Manual Komatsu 960E 930E 4 3 12 - powerstep.com.au...Komatsu 960E Truck Section 1. Mounting and Installation See Page 4 PSA-K960E-FS 07-3-12 Pg3 PROCEDURE (Drawings 23635 & 23636)

PSA-K960E-FS 07-3-12

Model No.: PSA-K960E-FS

Serial No.:960E-001 to 960E-009

Date Manufactured: October 2009

FOLDING STAIRWAY

Manual for Komatsu 960E Truck - Hydraulic Power Pack

FOLDING STAIRWAYKomatsu 960E Truck

Pg2PSA-K960E-FS 07-3-12

CONTENTS

Page 3 Section 1 Mounting and Installation

7 Section 2 Electrical Installation

8 Section 3 Operating Procedure

9 Section 4 Recommended Maintenance Procedure

10 Section 5 Assembly Complete-Main Assemblies

11 5-1 Assembly Complete

Parts List

12 5-2 Landing Assembly

Parts List

14 5-3 Stair Assembly

Parts List

16 5-4 Hydraulics -Cylinder Assembly

Cylinder and Components

Valve Diagram

18 5-5 Power Pack Assembly

Parts List

21 5-6 Electrical System

Wiring Diagrams


Section 1. Mounting and Installation

See Page 4

Pg3PSA-K960E-FS 07-3-12

PROCEDURE (Drawings 23635 & 23636)

See Drawing 23635 (Adjustments)

1. Set up the stair set with bolting faces of the landing vertical,like it will be when

installed on the truck.

2. With one of the cylinder pins removed, lower the stair to its' deployed position as

seen in View 2. Adjust the angle of inclination of the stair to 44 - 45Deg. to the

horizontal. Adjust by grinding the stop pads on both stiles or by building the stop

pads up with weld and then grinding. The bearing faces should be smooth and

flat so as not to bite into the flange plate quickly, thereby losingthe adjustment.

(This procedure should be repeated periodically during the service life of the stair

set.) Views 2 & 3.

3. Replace the cylinder pin and fully retract the cylinder. Ensure that the retracted

cylinder allows the stair to decline to the angle set in ii above. If not, adjust the

position of 23 675 Stair Actuator Attachment on the stair stile. View 2.

4. By extending the cylinder, raise the stair to the vertical stowed position. View 1.

5. Adjust the position of the Stair Buffer Bracket 23 653 on the stair stile so that the

buffer is compressed firmly when the stair is in the stowed position. View 1.

6. Adjust the positions of the Handrail Bumpers 23 651 mounted to the stair stiles and

handrail posts so they bear firmly on the handrails when the stair is stowed. These

bumpers are there to prevent vibration and rattling. View 1.

7. Adjust the position of the Go Switch Trigger 23 657 so the Go Switch creates the

appropriate connection when the stair is raised, View 4.

See Drawing 23636 (Bolting Pads)

1. Per Views 1, 2 & 3, attach the Bolting Pads to the bolt-on bumper extension at the

end of the central fixed bumper. Weld only to the extension.

2. Per View 4, fit the assembled stair set to the bolting pads, without the Landing

Deck or Landing Floor Infill fitted.

3. Per Views 5 and 6, fit the Landing Floor Infill and then the Landing Deck.

NOTE

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

PSFS to Truck.


Section 1. Mounting and Installation 23635

Pg4PSA-K960E-FS 07-3-12


Section 1. Mounting and Installation 23636

Pg5PSA-K960E-FS 07-3-12

VIE

W 1

VIE

W 6

VIE

W 3

VIE

W 4

VIE

W 5

VIE

W 2


Section 1. Mounting and Installation (Dimensions) 23678

Pg6PSA-K960E-FS 07-3-12


Section 2. Electrical Installation

Pg7PSA-K960E-FS 07-3-12

Procedure

Remove centre console panel in cabin -

- to do this remove six (6) screws and gear selection knob.

Position stairway indicator panel on centre console, above hour meter.

- drill two mounting screw holes (6mm or 7/32")

- one electrical cable hole (12mm or 15/32")

- do not re-fix console Panel

Remove four (4) screws holding Komatsu fuse panel behind operator's seat. Drill one hole

to insert Caterpillar fuse holder - fit fuse holder, into fuse indicator panel - tighten. Drill

size (12mm or 15/32").

Remove rear access panel from back of cabin and run short conduit through the main

cable gland to inside centre console, ensuring conduit goes underneath control box.

Connect blue wire start from conduit above to blue wire of cabin indicator panel harness.

In rear access, connect black wire, with 10mm eye terminal to machine ground, and blue

wire to outer terminal of newly inserted fuse holder.

Install short blue wire to screw terminal of Komatsu circuit breaker, and other end to fuse

holder.

Run wiring harness from Power Step Folding Stairway magnetic proximity switch around

under radiator, and follow cabling/hose routing up to air line/ electrical outlet on rear Right

Hand Side of cabin.

Drill hole in RH Cabin access panel - route wiring harness in through access panel, and

through to under centre console - connect wires appropriately as colour coded. Hole

saw/drill size (24mm), cable tie harness as appropriate, approximately every 300mm.

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 3. Operating Procedure

Pg8PSA-K960E-FS 07-3-12

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 4. Recommended Maintenance Procedure

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 on regular service.

- Check daily service as above.

Pg9PSA-K960E-FS 07-3-12


Section 5. Assembly Complete - Main Assemblies

See Pg 11

Pg10PSA-K960E-FS 07-3-12

Item Part No. Part Name Qty

1

2

PSA-K960E-FS

PS-23667A

ASSEMBLY COMPLETE

LANDING ASSEMBLY

(INC.HANDRAILS)

REFER TO 5-1 FOR DETAILS

1

1

3 PS-23662A STAIR ASSEMBLY

(INC.HANDRAILS)

REFER TO 5-1 FOR DETAILS

1

4 PS-62999-AH HYDRAULIC CYLINDER

1

5 PS-80103A-SLD POWER PACK 1

FOLDING STAIRWAY

Komatsu 960E TruckHydraulic Operation

Section 5-1 Assembly Complete PSA-K960E-FS

Pg11PSA-K960E-FS 07-3-12


Section 5-2 Landing Assembly PS 23667A

Pg12PSA-K960E-FS 07-3-12

Hydraulic Cylinder

See page 16


Section 5-2 Landing Assembly PS-23667A

Parts ListSee Drawing Pg 12

Pg13PSA-K960E-FS 07-3-12


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

PS-23667

PS-23671

PS-23673

PS-23669

PS-23651-01

PS-23668B

PS-75430

PS-23655-02

PS-23654-01

PS-23654-03

PS-23679

PS-23651-02

PS-61006-2

CPS-M16X40ZP

CPS-M16X40ZP

CPS-M16X30ZP

CPS-M10X35ZP

CPS-M10X30ZP

CPS-M10X16ZP

CPS-M8X16ZP

CPS-M6X50ZP

CPS-M6X20ZP

CPS-M5X50ZP

CPS-M10NN

CPS-M6NN

CPS-M5NZP

CPS-M16WH

CPS-M10WH

CPS-M8WH

CPS-M5WH

LANDING FRAME

LANDING DECK-STEP TREAD

HAND SHIELD

LANDING FLOOR INFILL

HANDRAIL BUMPER

BOLTING PADS-MAIN MOUNTING BLOCKS

GO- SWITCH

BUSH-(Nylon)

STAIR HINGE PIN

WASHER-(Dia 55)

SPECIAL WASHER

HANDRAIL BUMPER LINER

GREASE NIPPLE-M6 Str.

BOLT-M16 X 40 Bolt

BOLT-M16 X 40 Socket head

BOLT-M16 x 30 (For infill)

BOLT-M10 x 35

BOLT-M10 x 30

BOLT-M10 x 16

BOLT-M8 x 16

BOLT- M6 x 50 Socket head

BOLT-M6 x 20 Pan Head

BOLT - (Go Switch)

NUT-NYLOC-M10

NUT-NYLOC-M6

NUT-M5

WASHER - HARDENED - M16



FLAT WASHER- M5

1

1

1

1

2

2

2

2

2

2

8

2

2

6

2

2

6

4

4

4

2

6

4

6

8

4

2

20

4

8

FOLDING STAIRWAY

Komatsu 960E Truck

Section 5-3 Stair Assembly PS-23662A

Pg14PSA-K960E-FS 07-3-12


Section 5-3 Stair Assembly PS23662A

Parts ListSee Drawing Page 14

Pg15PSA-K960E-FS 07-3-12


1

1A

2

2A

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

PS-23662 LH

PS-23662 RH

PS-23465 LH

PS-23465 RH

PS-22266A

PS-23659

PS-23672-99

PS-23672-98

PS-23675

PS23651-01

PS-23651-02

PS-23656 LH/RH

PS-23653 LH/RH

PS-23657

PS-40002

CPS-M12X35ZP

CPS-M12X30ZP

CPS-M10X25ZP

CPS-M6X20ZP

CPS-M12NZP

CPS-M10NZP

CPS-M6NZP

CPS-M12WH

CPS-M10WH

STAIR STILES FABRICATION-LH

STAIR STILES FABRICATION-RH

STAIR EXTENSION-LH

STAIR EXTENSION-RH

STAIR TREADS

STAIR TREAD (Modified)

HANDRAIL-FRONT-INNER

HANDRAIL-REAR-OUTER

STAIR ACTUATOR ATTACHMENT

HANDRAIL BUMPER (Matched Pair)

HANDRAIL BUMPER LINER

HANDRAIL BUMPER MOUNTING(pair)

STAIR BUFFER BRACKET (Matched Pair)

GO SWITCH TRIGGER

RUBBER STOP

BOLT-M12 x 35

BOLT-M12 x 30

BOLT-M10 x 25

BOLT-M6 x 20 Pan Head

NUT-M12

NUT-M10

NUT-M6

WASHER-HARDENED-M12

WASHER-HARDENED-M10

1

1

1

1

6

1

1

1

1

2

2

2

2

2

2

12

54

8

6

66

8

8

132

16

FOLDING STAIRWAY

Komatsu 960E Truck

Section 5-4 Hydraulics -Cylinder Assembly P/No. PS-62999-AH

Pg16PSA-K960E-FS 07-3-12


1

1A

1B

1C

1S

2

3

4

5

6

7

8

9

10

11

12

13

14

PS-62999-A

PS-62999-HPK

PS-62999-A

PS-62999-P

CPS-M4X50ZP

PS-63103

PS-63201

PS-61159

PS-61154

PS-61157

PS-61158-5MM

PS61163

PS-61160

PS-61147

PS-61158-1MM

PS-61145

PS-61143

PS-60051-3.5

PS-PS-61183

HYDRAULIC CYL. (with hard plumbing )

HARD PLUMBING KIT

HYDRAULIC CYLINDER 2 1/2”

PIN - CYLINDER

SPLIT PIN-M4-CLEVIS PIN-BOTTOM & TOP

SEAL KIT (Not shown)

VALVE - PILOT OPERATED LOCKING

FITTING - ELBOW-9/16” JIC

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

FITTING - O RING 1/4BSPPx 9/16”JIC

FITTING - 1 mm RESTRICTION 90 DEG

REDUCER JIC x BSPP

TUBE (Cut to suit) 110mm

FERRULES

FITTING - 1mm RESTRICTION 90 DEG

FITTING- 9/6”JIC SWIVEL

CAP

HOSE- HYDR. ( 9/6”JIC SWIVEL FITTING)

TEE FITTING

1

1

1

2

4

1

1

1

1

2

1

2

1

2

1

1

2

2

2

CYL. END

ROD END

NOTE: HYDRAULIC CYLINDER ASSEMBLY P/No PS- 62998-AH includes Part No.s 1 to 12

Pg17PSA-K960E-FS 07-3-12

FOLDING LADDERKomatsu 960E Truck

Section 5-4. Hydraulic Cylinder (Valve Diagram)See also Drawing page 16

Double Acting Hydraulic System with

directional Control Valve and Cylinder

Lock Valve

0.030”0.030”


Section 5-5 Power Pack PS-80103A-SLDSee Parts List Pg. 20

Pg18PSA-K960E-FS 07-3-12

9 9A 8

4

14

29

28 6 5 27

6

2 7 7A

10

31

11

17

13

15

12

3 3226 3A8A

Hoses shown

dotted

View AView B


Section 5-5 Power Pack PS-80103A-SLD See Parts List Pg. 20

Pg19PSA-K960E-FS 07-3-12

16

23

25

9

View B

9A

View A

34

35

24

15

21

11

17

18

30

10

20

33

19

12

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

22

Pg20PSA-K960E-FS 07-3-12


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

34

35

PS-80103A-SLD

PS-21107-METAL

PS-80103A

PS-80103-CLAMP

PS-82415

PS-84214

PS-82492

PS-60050-900MM 9/16”

PS-60050-900MM 7/16”

PS-61152

PS-61150

PS-61177

PS-61176

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

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

HYDR. HOSES 9/16”JIC STRAIGHT SWIVEL

HYDR. HOSES 7/16”JIC STRAIGHT SWIVEL

HYDRAULIC FITTING 9/16”




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

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

1

2

1

1

1

1

1

1

1

1

1

1

1

1

1

1

6

3

1

1

1


Section 5-5 Power Pack PS-80103A-SLDSee Photos Pg. 18 & 19

Pg21PSA-K960E-FS 07-3-12

Cab Harness & Equipment

Refer Wiring Harness Drawings Pages 23-26

Proximity Switch AssemblyMounted on Fixed Landing

2

4

3

5

1

6 7

FOLDING STAIRWAYKomatsu 960E TruckHydraulic Operation

Section 5-6. Electrical Controls

Pg22PSA-K960E-FS 07-3-12


Section 5-6. Electrical Controls See Photos Pg. 21


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

Pg23PSA-K960E-FS 07-3-12


Section 5-6 - Electrical System Wiring Diagram - Pg 1

KO

M

96

0E

H

ydra

ulic

syste

m

PS

-PC

-16

77

Pg24PSA-K960E-FS 07-3-12


Section 5-6 - Electrical System Wiring Diagram - Pg 2

KO

M 9

60

EH

ydra

ulic

Opera

tion

Pg25PSA-K960E-FS 07-3-12


Section 5-6 - Electrical System Wiring Harness - Pg 3

Pg26PSA-K960E-FS 07-3-12


Section 5-6 - Electrical System Wiring Harness - Pg 4

Documents

Manual Komatsu 960E 930E 4 3 12 - powerstep.com.au...Komatsu 960E Truck Section 1. Mounting and Installation See Page 4 PSA-K960E-FS 07-3-12 Pg3 PROCEDURE (Drawings 23635 & 23636)