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Power Step Cat D10R Dozer Manual

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FOLDING LADDER
Manual for Cat D10R Dozer
Complete with Wrap-around Walkways
PSA-D10R FL+RHW 31-3-14
Model No.: PSA-D10R FL+RHWW
Serial No.: LD10RW-001 - ~
Date Manufactured: Oct 2006

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Summary of Contents for Power Step Cat D10R Dozer

  • Page 1 FOLDING LADDER Manual for Cat D10R Dozer Complete with Wrap-around Walkways Model No.: PSA-D10R FL+RHWW Serial No.: LD10RW-001 - ~ Date Manufactured: Oct 2006 PSA-D10R FL+RHW 31-3-14...
  • Page 2 FOLDING LADDER Caterpillar D10R Dozer CONTENTS Page 3 Section 1 Installation and Mounting instructions Installation Drawings Section 2 Electrical System Wiring Diagrams Section 3 Recommended Maintenance procedure Section 4 Operating Procedure Section 5 Drawings and Repair Parts lists 5 Assembly Complete 5-1 Ladder Assembly Parts List 5-2 Landing Assembly LHS (+ NG Version)
  • Page 3 FOLDING LADDER Caterpillar D10R Dozer NOTE Follow all on-site/Mine lifting and safety procedures when installing Power Step Ladder System to the Dozer. Section 1 Installation and Mounting Instructions See Drawing 22 053 (Page 4) Remove grille plates from the rear of both mudguards. Remove the light and/or horn from the rear of the left-side mudguard.
  • Page 4 FOLDING LADDER Caterpillar D10R Dozer Section 1 Installation Instruction Drawings - 22 053 PSA-D10R FL+RHW 31-3-14...
  • Page 5 FOLDING LADDER Caterpillar D10R Dozer Section 1 Installation Instruction Drawings - 22 054 See Drawings 22 054 - Page 6 & 7 Procedure Fit Mounting Blocks per Drg 22 053 Per REAR VIEW: Fit Spreader Plate 22 287 to rear mounting blocks. Use Washer Plates 22.281 and washers under bolt heads.
  • Page 6 FOLDING LADDER Caterpillar D10R Dozer Section 1 Installation Instruction Drawings - 22 054 Pg 1 PSA-D10R FL+RHW 31-3-14...
  • Page 7 FOLDING LADDER Caterpillar D10R Dozer Section 1 Installation Instruction Drawings - 22 054 PSA-D10R FL+RHW 31-3-14...
  • Page 8 FOLDING LADDER Caterpillar D10R Dozer Section 1 Drive Arrangement - 22 054 Pg 3 PSA-D10R FL+RHW 31-3-14...
  • Page 9 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).
  • Page 10 FOLDING LADDER Caterpillar D10R Dozer Section 2 Electrical System - Wiring Diagrams Page 1 Pg10 PSA-D10R FL+RHW 31-3-14...
  • Page 11 FOLDING LADDER Caterpillar D10R Dozer Section 2 Electrical System - Wiring Diagrams Page 2 Non Auto-Raise Pg11 PSA-D10R FL+RHW 31-3-14...
  • Page 12 FOLDING LADDER Caterpillar D10R Dozer Auto-Raise Section 2 Electrical System - Wiring Diagrams Page 3 Toggle Switch Operated Pg12 PSA-D10R FL+RHW 31-3-14...
  • Page 13 FOLDING LADDER Caterpillar D10R Dozer Section 2 Electrical System - Wiring Diagrams Page 4 WIRING HARNESS 1 Pg13 PSA-D10R FL+RHW 31-3-14...
  • Page 14 FOLDING LADDER Caterpillar D10R Dozer Section 2 Electrical System - Wiring Diagrams Page 5 WIRING HARNESS 2 Pg14 PSA-D10R FL+RHW 31-3-14...
  • Page 15 FOLDING LADDER Caterpillar D10R Dozer 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 the nipples on the rotation shaft and sector gears.
  • Page 16 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.
  • Page 17 FOLDING LADDER Caterpillar D10R Dozer Section 5 Assembly Complete PSA-D10R-RHW Pg17 PSA-D10R FL+RHW 31-3-14...
  • Page 18 FOLDING LADDER Caterpillar D10R Dozer Section 5-1 Ladder Assembly Item Part No. Part Name PS-22002 LADDER & HANDRAIL FABRICATION PS-22012 ROTATION SHAFT PS-21958 PINION & KEEPER PLATE PS-21926-01 LADDER SHAFT PIVOT BUSH-MIDDLE PS-21926-02 LADDER SHAFT PIVOT BUSH-NON DRIVE END PS-21926-03 LADDER SHAFT PIVOT BUSH- DRIVE END CPS-M12X45ZP BOLT-M12 x 45...
  • Page 19 FOLDING LADDER Caterpillar D10R Dozer Section 5-2 Landing Assembly LHS PS- 22017A Pg19 PSA-D10R FL+RHW 31-3-14...
  • Page 20 FOLDING LADDER Caterpillar D10R Dozer Section 5-2 Landing Assembly LHS PS-22017A See Drawing Page 19 Item Part No. Part Name PS-22017 LANDING ASSEMBLY PS-22010-A HANDRAIL-FRONT-LHS PS-22010-B HANDRAIL-REAR-LHS PS-22014-98 ISOLATOR PIN BRACKET-REAR PS-22014-99 ISOLATOR PIN BRACKET-FRONT PS-21930A ISOLATOR MOUNTINGS ASSY. PS-21976 FRONT PIVOT PIN BRACKET PS-21941 ANTI VIBRATION BEARING...
  • Page 21 FOLDING LADDER Caterpillar D10R Dozer Section 5-2 Landing Assembly LHS PS- 22017A-NG Upgraded Handrails See Parts List Page 22 Pg21 PSA-D10R FL+RHW 31-3-14...
  • Page 22 FOLDING LADDER Caterpillar D10R Dozer Section 5-2 Landing Assembly LHS PS- 22017A-NG Upgraded Handrails See Drawing Page 21 Item Part No. Part Name PS-22017 LANDING ASSEMBLY PS-22010-A-NG HANDRAIL-FRONT LHS- NEW GENERATION PS-22010-B-NG HANDRAIL-REAR LHS- NEW GENERATION PS-22014-98 ISOLATOR PIN BRACKET-REAR PS-22014-99 ISOLATOR PIN BRACKET-FRONT PS-21930A...
  • Page 23 FOLDING LADDER Caterpillar D10R Dozer Section 5-3 Landing Assembly RHS PS- 22016A See Parts Llist Page 24 Pg23 PSA-D10R FL+RHW 31-3-14...
  • Page 24 FOLDING LADDER Caterpillar D10R Dozer Section 5-3 Landing Assembly RHS PS- 22016A See Drawing Page 23 Item Part No. Part Name PS-22-284 LANDING ASSEMBLY RHS PS-22285 HANDRAIL RHS PS-22086 ISOLATOR PIN BRACKETS PS-21930A ISOLATOR MOUNTING ASSY. PS-21933 ISOLATOR BUSH PIN PS-22018-04 SIDE MOUNTING PAD PS-22005-01...
  • Page 25 FOLDING LADDER Caterpillar D10R Dozer Section 5-3 Landing Assembly RHS PS- 22016A-NG Upgraded Handrails See Parts List Page 26 Pg25 PSA-D10R FL+RHW 31-3-14...
  • Page 26 FOLDING LADDER Caterpillar D10R Dozer Section 5-3 Landing Assembly RHS PS- 22016A-NG Upgraded Handrails See Drawing Page 25 Item Part No. Part Name PS-22-616 LANDING ASSEMBLY RHS PS-22285-NG HANDRAIL RHS- NEW GENERATION PS-22086 ISOLATOR PIN BRACKETS PS-21930A ISOLATOR MOUNTING ASSY. PS-21933 ISOLATOR BUSH PIN PS-22018-04...
  • Page 27 FOLDING LADDER Caterpillar D10R Dozer Section 5-4 Landing Assembly - Rear PS- 22051A Item Part No. Part Name PS-22051 LANDING - REAR PS-22052 HANDRAILS- REAR PS-22006-99 WALKWAY MOUNTING-OUTER PS-22006-98 WALKWAY MOUNTING-INNER PS-22005-01 ANGLE BRACKET CPS-M16X50ZP BOLT-M16 x 50 CPS-M16X35ZP BOLT-M16 x 35 CPS-M12X40ZP BOLT-M12 x 40 CPS-M16NZP...
  • Page 28 FOLDING LADDER Caterpillar D10R Dozer Section 5-4 Landing Assembly - Rear PS- 22051A-NG Upgraded Handrails Item Part No. Part Name PS-22051 LANDING - REAR PS-22052-NG HANDRAILS- REAR- NEW GENERATION PS-22006-99 WALKWAY MOUNTING-OUTER PS-22006-98 WALKWAY MOUNTING-INNER CPS-M16X50ZP BOLT-M16 x 50 CPS-M16X35ZP BOLT-M16 x 35 CPS-M12X40ZP BOLT-M12 x 40...
  • Page 29 FOLDING LADDER Caterpillar D10R Dozer Section 5-5 Spreader Assembly PS-22287A- D10R See Parts List Page 30 Pg29 PSA-D10R FL+RHW 31-3-14...
  • Page 30 FOLDING LADDER Caterpillar D10R Dozer Section 5-5 Spreader Assembly PS-22287A- D10R See Drawing Page 29 Item Part No. Part Name PS-22287 SPREADER PS-21931 98 ISOLATOR PIN BRACKET-OUTER LHS PS-21931-97 ISOLATOR PIN BRACKET-OUTER RHS PS-21931-99 ISOLATOR PIN BRACKET-INNER PS-21930A ISOLATOR MOUNTINGS PS-21933 ISOLATOR BUSH PIN PS-22281-04...
  • Page 31 FOLDING LADDER Caterpillar D10R Dozer Section 5-6 Drive Unit Assembly See Parts List Page 32 Pg31 PSA-D10R FL+RHW 31-3-14...
  • Page 32 FOLDING LADDER Caterpillar D10R Dozer Section 5-6 Drive Unit Assembly See Drawing Page 31 Item Part No. Part Name PS-63014 HYDRAULIC CYLINDER (Refer Page 22) PS-21974 DRIVE MOUNTING FRAME PS-21959 SECTOR GEAR PS-21984 DRIVE GUARD PS-21954 ACTUATOR CYL. MOUNTING ASSEMBLY PS-21991-02 MOUNTING BAR-PROXIMITY SWITCH PS-21991-01...
  • Page 33 FOLDING LADDER Caterpillar D10R Dozer Section 5-7 PROP Assembly PS- 22013A Item Part No. Part Name PS-22013 PROP MOUNTING FRAME PS-21945 PROP PS-22091-16 ROOF BUTTON PS-22087 PROP MOUNTING BEAM PS-22091-14 BOLTING PAD PS-22091-13 SPACER PS-21930A ISOLATOR MOUNTING PS-40003 BUFFER CPS-M12X120 BOLT M12 x 120 CPS-M12X40ZP BOLT-M12 x 40...
  • Page 34 FOLDING LADDER Caterpillar D10R Dozer Section 5-8 Hydraulic Cylinder Incl. Items 1A,1B,2,3,4,5,6,7,8,9,11,12,13. Item Part No. Part Name PS-63014A HYDRAULIC CYLINDER PS-63014-P PIN - CYLINDER- (WITH RETAINER) PS-63011K SEAL KIT (NOT SHOWN) PS-63201 VALVE - PILOT OPERATED LOCKING PS-61158-0.30 FITTING - RESTRICTION 90 DEG PS-61154 FITTING - ELBOW- O RING 1/4BSPPx9/16”JIC PS-61157...
  • Page 35 FOLDING LADDER Caterpillar D10R Dozer Section 5-8 Hydraulic Cylinder (Valve Diagram) See also Drawing Page 34 Double Acting Hydraulic System with directional Control Valve and Cylinder Lock Valve 0.030” 0.030” Pg35 PSA-D10R FL+RHW 31-3-14...
  • Page 36 FOLDING LADDER Caterpillar D10R Dozer Section 5-9 Power Pack (Electrical Controls & Accessories) See Parts List Pg 38 View B View A Hoses shown dotted Pg36 PSA-D10R FL+RHW 31-3-14...
  • Page 37 FOLDING LADDER Caterpillar D10R Dozer Section 5-9 Power Pack (Electrical Controls & Accessories) See Parts List Pg 38 View A View B NOTE. THE RELIEF PRESSURE OF THE POWERPACK IS TO BE SET TO 2800SI. IF THE POWERPACK IS REPLACED,THIS RELIEF PRESSURE WILL NEED TO BE RESET USING INLINE GAUGES.
  • Page 38 FOLDING LADDER Caterpillar D10R Dozer Section 5-9 Power Pack (Electrical Controls & Accessories) See Photos Pg 36 & 37 Item Part No. Part Name PS-80103A-SLD POWER PACK ASSEMBLY PS-21107-METAL MOTOR ENCLOSURE- SEALED ST/ST PS-80103A POWER PACK PS-80103-CLAMP CLAMP ELECTRIC MOTOR PS-84201-100 HEAT SENSOR PS-82415...
  • Page 39 FOLDING LADDER Caterpillar D10R Dozer Section 5-10 Electrical Controls Refer also Wiring drawings page 10 - 14 Control Pendant Switch Mounted on Handrail Proximity Switch Assembly Mounted on Fixed Landing Cab Harness & Equipment Refer Wiring Harness Drawings Pg39 PSA-D10R FL+RHW 31-3-14...
  • Page 40 FOLDING LADDER Caterpillar D10R Dozer Section 5-10 Electrical Controls Refer also Wiring Drawings See Photos Page 39 Item Part No. Part Name PS-73013 CONTROL PENDANT SWITCH PS-73013-B CONTROL PENDANT BRACKET PS-77005 HAND RAIL SWITCH HARNESS PS-77009AR AUTO RAISE HARNESS Optional only PS-77004 CABIN TO SWITCH HARNESS PS-75430...
  • Page 41 FOLDING LADDER Caterpillar D10R Dozer Material Kit supplied PS-P/PACK-ISO. KIT LOCTITE 243 TO APPLY ON HYDRAULIC TANK SCREWS 4 EACH RUBBER MOUNTS WITH HARDWARE MALE & FEMALE 7/16 TANK PAD MADE OF AND 9/16 HYDRAULIC RUBBER CAPS FOR THE HOSES 2 EACH 3/8"...