Manual Komatsu HD785 START - Power Step...2011/08/31 · Valve Diagram Parts List 22 4-6 Power Pack Parts List FOLDING STAIRWAY Komatsu HD785 Water Truck SECTION 1. Mounting and Installation

PSA-KHD785-FS 31-8-11

FOLDING STAIRWAY

Manual for Komatsu HD785 Truck

Model No.: PSA-HD785-FS

Serial No.: HD785-FS-001C to 003C

Date of Manufacture: Aug. 2011

FOLDING STAIRWAYKomatsu HD785 Water Truck

Pg 2PSA-KHD785-FS 31-8-11

CONTENTS

Page 3 Section 1 Mounting and Installation Notes

Installation Drawings

5 Section 2 Operating Procedure

6 Section 3 Recommended Maintenance Procedure

7 Section 4 Assembly Complete-Main Assemblies

8 4 Assembly Complete

Parts List

9 4-1 Landing Frame Assembly

Parts List

10 4-2 Stair Landing Assembly

Parts List

12 4-3 Stair Assembly

Parts List

14 4-4 Electrical System

Controls

Parts List

Wiring Diagrams

20 4-5 Hydraulics -Cylinder Assembly

Valve Diagram

Parts List

22 4-6 Power Pack

Parts List


SECTION 1. Mounting and Installation - Drawings - PSA-KHD785-AO1


NOTE

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

PSFS to Truck.


SECTION 1. Mounting and Installation Drawings PSA-KHD785-UNIT



SECTION 2. Operating Procedure


To Lower Stairway (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 Stair Access System is clear of people and

obstacles, and lower Stair by operating the two position electrical switch adjacent

to the stair, to the down position by pressing the switch down.

Hold the switch in the down position until Stair 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 Stair with caution.

To Raise Stairway

Ascend the Stair onto the landing of the Dozer.

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

of the area the handrails and Stair raises into, operate the electrical switch to the

raise position (up).

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

The Stair 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.


SECTION 3. 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.

- Open Power Pack cover and check inside the enclosure to ensure there are no oil

leaks and that all switch gear and hose connections are tight. Clean enclosure

and replace cover securely back in its original position.

5000 Hours

- Change the Hydraulic oil in tank of Hydraulic power pack (5 Litres).

- It is recommended that the same hydraulic oil be used in the Power Pack as the

hydraulics of the machine.

- Grease 2 grease nipples on pivot shaft.

- Retorque all main mounting bolts.

6x M20 x 65 Grade 10.9

6x M12 x 65 Grade 10.9

- Check all M12 bolts and Nuts holding rubber isolators to body and rear support

plate of truck.

- Repeat daily check as above.



SECTION 4. Assembly Complete - PSA-HD785-FSSee Drawing Pg 8


Assy. Assy. No. Assy. Name Qty

1 PS-KDH785-B03-A LANDING FRAME ASSEMBLY

(Refer 4-1 for Details) Pg 9

1

2 PS-30002-A STAIR LANDING ASSEMBLY

(Refer to 4-2 for Details) Pg 10

1

3 PS-30020-A

STAIR ASSEMBLY

(Refer to 4-3 for Details) Pg 12 1

5 PS-62999-AH

HYDRAULIC CYLINDER

(Refer to 4-5 for Details) Pg 20 1

6 PS-80103A-SLD POWER PACK ASSEMBLY

(Refer to 4-6 for Details) Pg 221

FOLDING STAIRWAY

Komatsu HD785 Water Truck

SECTION 4. Assembly Complete PSA-KHD785-FS



FOLDING STAIRWAY


SECTION 4-1. Landing Frame Assembly PS-KHD785-B03-A

Item Part No. Part Name Qty

1

2

3

4

5

6

7

8

9

10

PSA-KHD785-B03

PSA-KHD785-B01

PSA-KHD785-B02

-

CPS-M12X50ZP

CPS-M12X25ZP

CPS-M10X30ZP

CPS-M12NZP

CPS-M12WH

CPS-M10WH

LANDING FRAME FABRICATION

LANDING FLOOR PLATE

CORNER HANDRAIL

FLEXIBLE LADDER-OEM

BOLT-M12 x 50

BOLT-M12 x 25

BOLT-M10 x 30

NUT-M12

WASHER-HARDENED-M12

WASHER-HARDENED-M10

1

1

1

1

4

8

1

4

17

1


SECTION 4-2 Stair Landing Assembly PS-30002-A

Pg 10PSA-KHD785-FS 31-8-11

Hydraulic Cylinder

See page 20


SECTION 4-2 Stair Landing Assembly PS-30002-A

Parts ListSee Drawing Pg 10

The Landing Assembly includes Items 1, 2, 3, 4, 6, 7,8, 9, 10, 11, 12, 13, 14, 15, 16, 17,

18, 19, 20, 24, 25.

Pg 11PSA-KHD785-FS 31-8-11


1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

PS-30002

PS-30001

PS-30042

PS-30021-01

PS-75430

PS-30008-02

PS-30009-01/02

PS-30009-03

PS-30021-02

PS-61006-2

CPS-M16X40ZP

CPS-M12X30ZP

CPS-M10X20ZP

CPS-M8X16ZP

CPS-M6X50ZP

CPS-M6X20ZP

CPS-M5X50ZP

CPS-M6NN

CPS-M5NN

CPS-M16WH

CPS-M12WH

CPS-M10WH

CPS-M8WH

CPS-WS-M5

LANDING FRAME-BASE

LANDING DECK-STEP TREAD

LANDING FLOOR INFILL

HANDRAIL BUMPER

GO- SWITCH

BUSH-(Ertalon)

STAIR HINGE PIN/HEAD PLATE

WASHER-(Dia 55)

HANDRAIL BUMPER LINER

GREASE NIPPLE-M6 Str.

BOLT-M16 X 40 Bolt

BOLT-M12 x 30 (For infill)

BOLT-M10 x 20

BOLT-M8 x 16

BOLT- M6 x 50 Socket head

BOLT-M6 x 20 Pan Head

BOLT - M5 x 50MM (Go Switch)

NUT-NYLOC-M6

NUT-NYLOC-M5

WASHER - HARDENED - M16




FLAT WASHER-M5

1

1

1

2

1

1

2

2

2

2

8

4

8

4

2

6

2

8

2

8

4

8

4

4

FOLDING STAIRWAY


SECTION 4-3 Stair Assembly PS-30020-A

Pg 12PSA-KHD785-FS 31-8-11


SECTION 4-3 Stair Assembly PS-30020-A

Parts ListSee Drawing Page 12

Pg 13PSA-KHD785-FS 31-8-11


1

1A

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

PS-30019 R

PS-30019 L

PS-30014

PS-30015

PS-30016-98

PS-30016-99

PS-30006

PS-30021-01

PS-30021-02

PS-30011 LH/RH

PS-30012 LH/RH

PS-30010

PS-40002

PS-30008-02

CPS-M12X35ZP

CPS-M12X30ZP

CPS-M10X30ZP

CPS-M6X20ZP

CPS-M12NZP

CPS-M10NZP

CPS-M6NN

CPS-M12WH

CPS-M10WH

CPS-M6WH

STAIR STILES FABRICATION-RIGHT

STAIR STILES FABRICATION-LEFT

STAIR TREADS

STAIR TREAD (Modified)

HANDRAIL-LEFT

HANDRAIL-RIGHT

STAIR ACTUATOR ATTACHMENT

HANDRAIL BUMPER (Matched Pair)

HANDRAIL BUMPER LINER

HANDRAIL BUMPER MOUNTING(pair)

STAIR BUFFER BRACKET (Matched Pair)

GO SWITCH TRIGGER

RUBBER STOP

BUSH

BOLT-M12 x 35

BOLT-M12 x 30

BOLT-M10 x 30

BOLT-M6 x 20 Pan Head

NUT-M12

NUT-M10

NUT-NYLOC-M6

WASHER-HARDENED-M12

WASHER-HARDENED-M10

WASHER-HARDENED-M6

1

1

4

1

1

1

1

2

2

2

2

2

2

1

16

32

4

6

48

4

6

76

8

6

Pg 14PSA-KHD785-FS 31-8-11


SECTION 4-4 Electrical System - Controls

Cab Harness & Equipment

Refer Wiring Harness Drawing

Proximity Switch AssemblyMounted on Fixed Landing

Control Pendant SwitchMounted on Handrail

1

3

5

2

4

6 7

Pg 15PSA-KHD785-FS 31-8-11


SECTION 4-4 Electrical System - Controls See Pg 14


1

2

3

4

5

6

7

PS-73013

PS-73013-B

PS-75430

PS-77005

PS-77004

PS-77002

PS-77003

CONTROL PENDANT SWITCH

CONTROL PENDANT BRACKET

PROXIMITY SWITCH

HAND RAIL SWITCH HARNESS

PROXIMITY MAGNETIC SWITCH HARNESS

HARNESS FOR INDICATOR BOX

WIRING HARNESS

1

1

1

1

1

1

1

WARNING

LOW OR FAULTY BATTERIES WILL VOID

WARRANTY ON THE POWER PACK AND ALL

ELECTRICAL SWITCHES AND COMPONENTS

Pg 16PSA-KHD785-FS 31-8-11


SECTION 4-4 Electrical System Wiring - Diagram - Pg 1

KO

M 9

30

E

Pg 17PSA-KHD785-FS 31-8-11


SECTION 4-4 Electrical System - Wiring Diagram - Pg 2

Pg 18PSA-KHD785-FS 31-8-11

FOLDING STAIRWAYKomatsu HD785 Water TruckHydraulic Operation

SECTION 4-4 Electrical System Wiring Harness - Pg 3

Pg 19PSA-KHD785-FS 31-8-11


SECTION 4-4 Electrical System - Wiring Harness Pg-4

Pg 20PSA-KHD785-FS 31-8-11


SECTION 4-5 Hydraulic Cylinder PS-62999-AH


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

PS-62999-P

CPS-M8X50ZP

PS-63103

PS-63201

PS-61151

PS-61154

PS-61157

PS-61158-1MM

PS61163

PS-61160

PS-61147

PS-61158-1MM

PS-61145

PS-60050-3.5

PS-60051-3.5

PS-61153

HYDRAULIC CYL.

HARD PLUMBING KIT

HYDRAULIC CYLINDER 2 1/2”

PIN - CYLINDER

SPLIT PIN-M8-CLEVIS PIN-BOTTOM & TOP

SEAL KIT (Not shown)

VALVE - PILOT OPERATED LOCKING

FITTING - ELBOW-7/16” 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

HOSE 7/16” (SWIVEL FITTINGS)

HOSE- HYDR. ( 9/6”JIC SWIVEL FITTING)

FITTING-HYDR.-STRAIGHT

1

1

1

2

4

1

1

1

1

1

1

2

1

2

1

1

1

1

1

CYL. END

ROD END

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

Pg 21PSA-KHD785-FS 31-8-11


SECTION 4-5 Hydraulic Cylinder - Diagram

Double Acting Hydraulic System with

directional Control Valve and Cylinder

Lock Valve

1 mm 1 mm

Pg 22PSA-KHD785-FS 31-8-11


SECTION 4-6 Power Pack PS-80103A-SLD

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

Pg 23PSA-KHD785-FS 31-8-11


SECTION 4.6 Power Pack PS-80103A-SLD

16 2223

25

9

9A

View B

View A

34

35

24

15

21

11

17

18

30

10

20

33

19

12

Pg 24PSA-KHD785-FS 31-8-11


SECTION 4.6 Power Pack PS-80103A-SLDSee Photos Pages 22 & 23

Item Parte No. Nombre de Parte Cant

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

Documents

Manual Komatsu HD785 START - Power Step...2011/08/31 · Valve Diagram Parts List 22 4-6 Power Pack Parts List FOLDING STAIRWAY Komatsu HD785 Water Truck SECTION 1. Mounting and Installation