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Power Step Komatsu 960E Manual

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FOLDING STAIRWAY
Manual for Komatsu 960E Truck
PSA-K960E-FS
23-1-15
Model No.: PSA-K960E-FS
Serial No.:960E-001 ~
Date Manufactured: October 2009

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Summary of Contents for Power Step Komatsu 960E

  • Page 1 FOLDING STAIRWAY Manual for Komatsu 960E Truck Model No.: PSA-K960E-FS Serial No.:960E-001 ~ Date Manufactured: October 2009 PSA-K960E-FS 23-1-15...

  • Page 2: Table Of Contents

    FOLDING STAIRWAY Komatsu 960E Truck CONTENTS Page 3 Section 1 Mounting and Installation Section 2 Electrical Installation Section 3 Operating Procedure Mechanical & Hydraulic Adjustment procedure Section 4 Recommended Maintenance Procedure Section 5 Assembly Complete-Main Assemblies 5-1 Assembly Complete Parts List...

  • Page 3: Section 1 Mounting And Installation

    FOLDING STAIRWAY Komatsu 960E Truck Section 1. Mounting and Installation See Page 4 NOTE Follow all on-site/Mine lifting and safety procedures when installing PSFS to Truck. PROCEDURE (Drawings 23635 & 23636) See Drawing 23635 (Adjustments) Set up the stair set with bolting faces of the landing vertical,like it will be when installed on the truck.
  • Page 4 FOLDING STAIRWAY Komatsu 960E Truck Section 1. Mounting and Installation 23635 PSA-K960E-FS 23-1-15...
  • Page 5 FOLDING STAIRWAY Komatsu 960E Truck Section 1. Mounting and Installation 23636 PSA-K960E-FS 23-1-15...
  • Page 6 FOLDING STAIRWAY Komatsu 960E Truck Section 1. Mounting and Installation (Dimensions) 23678 PSA-K960E-FS 23-1-15...

  • Page 7: Section 2 Electrical Installation

    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.

  • Page 8: Section 3 Operating Procedure

    FOLDING STAIRWAY Komatsu 960E Truck Section 3 . Operating Procedure To Lower Stair · Position truck in a leveled, safe area (whenever possible). · Ensure that the area below is clear of obstacles and people. · Apply the park brake.
  • Page 9 FOLDING STAIRWAY Komatsu 960E Truck Section 3 . Operating Procedure - Notes Mechanical Adjustment ENSURE THE STEP IS IN THE LOWER POSITION 1. PUT STEP IN THE LOWERED POSITION & LOOSEN 8 BOLTS HOLDING THE CYLINDER BEAM 2. ENSURE THE CYLINDER IS IN THE...
  • Page 10 FOLDING STAIRWAY Komatsu 960E Truck Section 3 . Operating Procedure- Notes Mechanical Adjustment 6. LOOSEN BRACKETS AND 3. RE TIGHTEN 8 BOLTS ADJUST AS REQUIRED AND RAISE THE STAIR UNTIL THE CYLINDER IS FULLY EXTENDED 4. ADJUST THE BUFFER TO...
  • Page 11 FOLDING STAIRWAY Komatsu 960E Truck Section 3 . Operating Procedure- Notes Hydraulic Adjustment RELEASE LOCK NUT(27MM) REMOVE BLACK CAP TURN THE ADJUSTING SCREW IN OR OUT USING A 6mm ALLEN KEY SETTING THE PRESSURE TO 1725 PSI. (+/- 25PSI.) WHEN RAISING THE STAIR...
  • Page 12 FOLDING STAIRWAY Komatsu 960E Truck Section 3 . Operating Procedure- Notes To Bleed a Cylinder Lower the stair. Remove the Cylinder with hoses attached. Turn the Cylinder over so the Hydraulic hoses are on top of the cylinder. This is also puts any air in the Cylinder on top.

  • Page 13: Section 4 Recommended Maintenance Procedure

    FOLDING STAIRWAY Komatsu 960E Truck Section 4. Recommended Maintenance Procedure Daily Visually check stairway and structure for damage, loose components, handrails, etc. Check for any back and forth motion when the Stair is stowed. Adjustments may be required. Check for hydraulic oil leaks from Hydraulic Cylinders, Plumbing and Hoses.

  • Page 14: Section 5 Assembly Complete-Main Assemblies

    FOLDING STAIRWAY Komatsu 960E Truck Section 5. Assembly Complete - Main Assemblies See Pg 15 Item Part No. Part Name PSA-K960E-FS ASSEMBLY COMPLETE PS-23667-A LANDING ASSEMBLY (INC.HANDRAILS) REFER TO 5-1 FOR DETAILS PS-23662-A FOLDING STAIRS ASSEMBLY (INC.HANDRAILS) REFER TO 5-1 FOR DETAILS...
  • Page 15 FOLDING STAIRWAY Komatsu 960E Truck Hydraulic Operation Section 5-1 Assembly Complete PSA-K960E-FS Pg15 PSA-K960E-FS 23-1-15...
  • Page 16 FOLDING STAIRWAY Komatsu 960E Truck Section 5-2 Landing Assembly PS 23667-A Hydraulic Cylinder See page 16 Pg16 PSA-K960E-FS 23-1-15...

  • Page 17: Parts List

    FOLDING STAIRWAY Komatsu 960E Truck Section 5-2 Landing Assembly PS-23667-A Parts List See Drawing Pg 16 Item Part No. Part Name PS-23667 LANDING FRAME PS-23671 LANDING DECK-STEP TREAD PS-23673 HAND SHIELD PS-23669 LANDING FLOOR INFILL PS-23651-01 HANDRAIL BUMPER PS-23668B BOLTING PADS-MAIN MOUNTING BLOCKS...
  • Page 18 FOLDING STAIRWAY Komatsu 960E Truck Section 5-3 Stair Assembly PS-23662-A Pg18 PSA-K960E-FS 23-1-15...

  • Page 19: Parts List

    FOLDING STAIRWAY Komatsu 960E Truck Section 5-3 Stair Assembly PS23662-A Parts List See Drawing Page 18 Item Part No. Part Name PS-23662 LH STAIR STILES FABRICATION-LH PS-23662 RH STAIR STILES FABRICATION-RH PS-23465 LH STAIR EXTENSION-LH PS-23465 RH STAIR EXTENSION-RH PS-22266A...
  • Page 20 FOLDING STAIRWAY Komatsu 960E Truck Section 5-4 Hydraulics -Cylinder Assembly P/No. PS-62999-AH-960E NOTE: HYDRAULIC CYLINDER ASSEMBLY P/No PS- 62999-AH-960E includes Part No.s 1 to 12 Item Part No. Part Name PS-62999-AH-960E HYDRAULIC CYL. (with hard plumbing ) PS-62999-HPK HARD PLUMBING KIT PS-62999-A HYDRAULIC CYLINDER 2 1/2”...

  • Page 21: Cylinder And Components

    FOLDING STAIRWAY Komatsu 960E Truck Section 5-4 Hydraulics Cylinder and Components EMERGENCY VALVE (CYLINDER) PS-63203A Auto build as below Item Part No. Part Name PS-73013-HEV HYDRAULIC EMERGENCY VALVE PLATE PS-63203 1/4”BALL VALVE PS-61157 FITTING-STRAIGHT PS-61153 FITTING PS-61140 FITTING-TEE-7/16” JIC PS-60050-130MM Hyd.
  • Page 22 FOLDING STAIRWAY Komatsu 960E Truck Section 5-4 Hydraulics Cylinder Pins (See Page 20 Items 1B & 1C) Cylinder End Pin (Lubricated) PS-63009-P Rod End Pin PS-62999-P Pg22 PSA-K960E-FS 23-1-15...
  • Page 23 FOLDING STAIRWAY Komatsu 960E Truck Section 5-4 Hydraulics Control Box Assembly PS-960E-HCB Item Part No. Part Name PS-81101 PRESSURE REDUCER PS-81102 CETOP3 DCV-NO COILS PS-81103 STATION MANIFOLD PS-81104 COILS-24V PS-61160-960E ST. TUBING & FLARED FITTINGS (Made to suit) 1SET PS-61177...
  • Page 24 FOLDING STAIRWAY Komatsu 960E Truck Section 5-4 Hydraulics Valve Diagram Pg24 PSA-K960E-FS 23-1-15...
  • Page 25 FOLDING STAIRWAY Komatsu 960E Truck Section 5-5 Electrical Cabinet Assembly PS-960E-PBVC Item Part No. Part Name PS-TMR05 UP-TIMER - Set 20-22 Seconds PS-TMR05 DOWN TIMER - Set 20-22 Seconds PS-82418 ALARM RELAY BEACON & HORN PS-84219 BRIDGE RECTIFIER 40A PS-84216...
  • Page 26 FOLDING STAIRWAY Komatsu 960E Truck Section 5-5 Electrical System Sheet 1 of 3 Pg26 PSA-K960E-FS 23-1-15...
  • Page 27 FOLDING STAIRWAY Komatsu 960E Truck Section 5-5 Electrical System Wiring Diagrams Sheet 2 of 3 Pg27 PSA-K960E-FS 23-1-15...
  • Page 28 FOLDING STAIRWAY Komatsu 960E Truck Section 5-5 Electrical System Wiring Diagrams Sheet 3 of 3 Pg28 PSA-K960E-FS 23-1-15...
  • Page 29 FOLDING STAIRWAY Komatsu 960E Truck Section 5-5 Electrical System Components & Wiring Harnesses Alarm Stair Up/Down PS- 82415 Cabin Indicator Box PS- 77002 Warning Beacon Warning Beacon Guard ELSB905 ELSB905-METAL GUARD Main Harness - Electrical Box PS- 960 - MBC...
  • Page 30 FOLDING STAIRWAY Komatsu 960E Truck Section 5-5 Electrical System Components & Wiring Harnesses Main Harness PS-960E - ABS Electrical Harness Electrical Box to Main 24V Cabinet PS-960E - PSH Wiring Harness - Go Switch to Accelerator PS-960E - AIH Pg30...
  • Page 31 FOLDING STAIRWAY Komatsu 960E Truck PS-960E-HVK-MK2-Kit Assy. Connect hose from the raise side of the PowerStep Cylinder here Connect to the pressure side of the PowerStep Hyd.Box Connect to the Tank port of the Green (67B) PowerStep Hydraulic box. Black (GB31)

  • Page 32: Mounting Plates

    FOLDING STAIRWAY Komatsu 960E Truck Mounting Plates Pg32 PSA-K960E-FS 23-1-15...

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