Power Step Komatsu 960E Manual Download

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PSA-K960E-FS 23-1-15

Model No.: PSA-K960E-FS
Serial No.:960E-001 ~
Date Manufactured: October 2009

FOLDING STAIRWAY

Manual for Komatsu 960E Truck

Summary of Contents for Komatsu 960E

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

Page 2: ...3 Section 4 Recommended Maintenance Procedure 14 Section 5 Assembly Complete Main Assemblies 15 5 1 Assembly Complete Parts List 16 5 2 Landing Assembly Parts List 18 5 3 Stair Assembly Parts List 20 5 4 Hydraulics Cylinder Assembly Cylinder and Components Control box Assembly Valve Diagram 25 5 5 Electrical Cabinet Assy Parts List 26 5 6 Electrical System Wiring Diagrams Harnesses 31 Hydraulic Va...

Page 3: ...st 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 ...

Page 4: ...FOLDING STAIRWAY Komatsu 960E Truck Section 1 Mounting and Installation 23635 Pg4 PSA K960E FS 23 1 15 P30 006 ...

Page 5: ...FOLDING STAIRWAY Komatsu 960E Truck Section 1 Mounting and Installation 23636 Pg5 PSA K960E FS 23 1 15 VIEW 1 VIEW 6 VIEW 3 VIEW 4 VIEW 5 VIEW 2 ...

Page 6: ...FOLDING STAIRWAY Komatsu 960E Truck Section 1 Mounting and Installation Dimensions 23678 Pg6 PSA K960E FS 23 1 15 ...

Page 7: ...ain 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 fu...

Page 8: ...k is parked in uneven ground the bottom of the stair may touch the ground before the stair is in a fully lowered position should this occur descend the stair with caution To Raise the Stair Ascend the stair Ensure area around the stair is clear of people Release the park brake and the stair will rise and stow into a vertical position Note that the stair does have a pressure valve that senses if so...

Page 9: ...n 3 Operating Procedure Notes Mechanical Adjustment Pg9 PSA K960E FS 23 1 15 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 RETRACTED POSITION ...

Page 10: ...MOVE SIDE COVER HELD ON BY 4 SCREWS 3 INSERT GAUGE INTO THE LIFT SIDE OF THE CYLINDER MIN 5000PSI RATED GAUGE 3 RE TIGHTEN 8 BOLTS AND RAISE THE STAIR UNTIL THE CYLINDER IS FULLY EXTENDED 4 ADJUST THE BUFFER TO GET SOME CRUSH WHEN IN THE RAISED POSITION 6 LOOSEN BRACKETS AND ADJUST AS REQUIRED 5 MAKE SURE THE GO SWITCH STRIKER IS ABOUT 5MM FROM THE SWITCH ...

Page 11: ... 40KG WEIGHT ON THE BOTTOM STEP IF NEEDED ADJUST THE PRESSURE SO THE STEP DOES NOT RAISE WITH THE WEIGHT ON BUT DOES LIFT WHEN IT IS NOT ON TURN THE ADJUSTING SCREW IN OR OUT USING A 6mm ALLEN KEY SETTING THE PRESSURE TO 1725 PSI 25PSI WHEN RAISING THE STAIR THIS PRESSURE IS A GUIDE BEFORE FINAL ADJUSTMENT RELEASE LOCK NUT 27MM REMOVE BLACK CAP ...

Page 12: ... so the Rod end is higher and fully extend the Cylinder 8 Repeat Step 6 above 9 All air should now be out of cylinder 10 Turn cylinder over and refit to the stair 11 Ensure the Power Pack tank is full of oil There should be no more problems NOTE If a problem persists it may be required to remove the Cylinder hard plumbing and bleed the Cylinder first Also join the hoses from the PowerPack together...

Page 13: ...any observed damage or malfunction See attached Mechanical and Hydraulic adjustment Cylinder bleeding procedures if required 500 Hours Grease on regular service Check daily service as above Check the Cylinder Clevis s Pins etc for wear Check all Rubber Buffers for damage or wear Replace where required Re adjust all Mechanical Hydraulic parts as per the Mechanical Hydraulic adjustment procedure NOT...

Page 14: ...0E FS 23 1 15 Item Part No Part Name Qty 1 2 PSA K960E FS PS 23667 A ASSEMBLY COMPLETE LANDING ASSEMBLY INC HANDRAILS REFER TO 5 1 FOR DETAILS 1 1 3 PS 23662 A FOLDING STAIRS ASSEMBLY INC HANDRAILS REFER TO 5 1 FOR DETAILS 1 4 PS 62999 AH HYDRAULIC CYLINDER 1 5 PS 960E PBVC ELECTRICAL CABINET ASSEMBLY 1 ...

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 Pg16 PSA K960E FS 23 1 15 Hydraulic Cylinder See page 16 ...

Page 17: ...M6NN CPS M5NN CPS M16WH CPS M10WH CPS M8WH CPS M5WH PS 75430 B 930 CPS M5X20ZP PS 22655 02 LANDING FRAME LANDING DECK STEP TREAD HAND SHIELD LANDING FLOOR INFILL HANDRAIL BUMPER BOLTING PADS MAIN MOUNTING BLOCKS GO SWITCH BUSH 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 B...

Page 18: ...FOLDING STAIRWAY Komatsu 960E Truck Section 5 3 Stair Assembly PS 23662 A Pg18 PSA K960E FS 23 1 15 ...

Page 19: ...ZP CPS M6X20ZP CPS M12NZP CPS M10NZP CPS M6NZP CPS M12WH CPS M10WH PS 23639 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 TRIG...

Page 20: ... with hard plumbing HARD PLUMBING KIT HYDRAULIC CYLINDER 2 1 2 PIN CYLINDER RETAINING CLIPS PIN LUBRICATED Incl Nipple Splt Pin 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 ...

Page 21: ...S 60050 145MM CPS M8X20ZP CPS M8WH PS 63203 MTG BL PS 63203 BLK HYDRAULIC EMERGENCY VALVE PLATE 1 4 BALL VALVE FITTING STRAIGHT FITTING FITTING TEE 7 16 JIC Hyd Hose 130mm 2x7 16 JIC STRAIGHT Hyd Hose 145mm 1x7 16 JIC Str 1x7 16 JIC Elbow BOLT M8 x 20 FLAT WASHER M8 VALVE MOUNTING BLOCKS MOUNTING BLOCKS FOR PLATE ASSEMBLY 1 2 2 2 1 1 1 4 4 2 2 1 9 10 11 11 2 3 7 4 5 6 8 EMERGENCY VALVE CYLINDER PS...

Page 22: ...Pg22 PSA K960E FS 23 1 15 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 ...

Page 23: ...rt No Part Name Qty 1 2 3 4 5 6 7 8 9 PS 81101 PS 81102 PS 81103 PS 81104 PS 61160 960E PS 61177 PS 61143 PS CAB12M20 PS ST2315 PRESSURE REDUCER CETOP3 DCV NO COILS STATION MANIFOLD COILS 24V ST TUBING FLARED FITTINGS Made to suit BULKHEAD FITTINGS CAP ELECTRICAL GLAND BOX ASSEMBLY KEY 1 1 1 2 1SET 4 4 1 4 4 1 3 2 4 5 8 7 6 9 ...

Page 24: ...FOLDING STAIRWAY Komatsu 960E Truck Section 5 4 Hydraulics Valve Diagram Pg24 PSA K960E FS 23 1 15 ...

Page 25: ...6 7 8 9 10 PS TMR05 PS TMR05 PS 82418 PS 84219 PS 84216 PS HD10 3 96P PS HD10 5 16P PS HD10 9 16P PS HD10 9 96P PS 960E EC PL UP TIMER Set 20 22 Seconds DOWN TIMER Set 20 22 Seconds ALARM RELAY BEACON HORN BRIDGE RECTIFIER 40A GROUND BUS BAR LINK 3 PIN PLUG 5 PIN PLUG 9 PIN PLUG 9 PIN PLUG MOUNTING PLATE KIT 1 1 1 1 1 1 1 2 1 1 set 2 5 4 3 1 9 8 6 10 7 ...

Page 26: ...Pg26 PSA K960E FS 23 1 15 FOLDING STAIRWAY Komatsu 960E Truck Section 5 5 Electrical System Sheet 1 of 3 ...

Page 27: ...Pg27 PSA K960E FS 23 1 15 FOLDING STAIRWAY Komatsu 960E Truck Section 5 5 Electrical System Wiring Diagrams Sheet 2 of 3 ...

Page 28: ...Pg28 PSA K960E FS 23 1 15 FOLDING STAIRWAY Komatsu 960E Truck Section 5 5 Electrical System Wiring Diagrams Sheet 3 of 3 ...

Page 29: ...9 PSA K960E FS 23 1 15 Cabin Indicator Box PS 77002 Main Harness Electrical Box PS 960 MBC Wiring Harness Cab Indicator Up Down PS 960E IWH Alarm Stair Up Down PS 82415 Warning Beacon ELSB905 Warning Beacon Guard ELSB905 METAL GUARD Park Brake Harness Electrical Box to Park Brake Switch PS 960E PBH ...

Page 30: ...Truck Section 5 5 Electrical System Components Wiring Harnesses Pg30 PSA K960E FS 23 1 15 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 ...

Page 31: ...RAIGHT FITTING REDUCER CAP STRAIGHT FITTING ELBOW CHECK VALVE SPOOL VALVE VALVE BODY 24V COIL 1 1 3 1 1 1 1 1 1 1 1 1 1 3 2 5 6 6 3 7 9 8 4 10 12 Connect to the pressure side of the PowerStep Hyd Box Connect hose from the raise side of the PowerStep Cylinder here Connect to the Tank port of the PowerStep Hydraulic box Connect to the Audible Alarm of the PowerStep unit Green 67B Black GB31 FOLDING ...

Page 32: ...Pg32 PSA K960E FS 23 1 15 FOLDING STAIRWAY Komatsu 960E Truck Mounting Plates ...

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