Power Step Cat D10R Dozer, Manual

Page 1: ...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 ...

Page 2: ...5 Drawings and Repair Parts lists 17 5 Assembly Complete 18 5 1 Ladder Assembly Parts List 19 5 2 Landing Assembly LHS NG Version Parts Lists 23 5 3 Landing Assembly RHS NG Version Parts Lists 27 5 4 Landing Assembly Rear NG Version Parts List 29 5 5 Spreader Assembly Parts List 31 5 6 Drive Unit Assembly Parts List 33 5 7 PROP Assembly Parts List 34 5 8 Hydraulic Cylinder Parts List Valve Diagram...

Page 3: ...ounting Pads to the rear of the mudguards against the mudguard vertical inner plate and up against the mudguard top plate notch the inclined plate to suit to get the correct protrusion dimension and at the outer top corner of the mudguards this time set against the mudguard plates rather than in the corner Fit the gusset piece to tie the Pad to the inclined plate 3 Measure forward from the back ed...

Page 4: ...FOLDING LADDER Caterpillar D10R Dozer Section 1 Installation Instruction Drawings 22 053 Pg4 PSA D10R FL RHW 31 3 14 ...

Page 5: ...ndings 22 014 98 shallow at the rear and 22 014 99 deep at the front Both are orientated so the hole for the isolator pin is close to the machine rather than away from the machine 4 Fit Ladder Using Spacers within Actuator Cylinder Mounting 21 954 adjust drive so gears are not loaded when ladder is lowered 5 Per SIDE VIEW REAR VIEW and VIEW 5 PROP System Attach PROP System Mounting Frame 22 0013 a...

Page 6: ...Pg6 PSA D10R FL RHW 31 3 14 FOLDING LADDER Caterpillar D10R Dozer Section 1 Installation Instruction Drawings 22 054 Pg 1 ...

Page 7: ...Pg7 PSA D10R FL RHW 31 3 14 FOLDING LADDER Caterpillar D10R Dozer Section 1 Installation Instruction Drawings 22 054 Pg2 ...

Page 8: ...FOLDING LADDER Caterpillar D10R Dozer Section 1 Drive Arrangement 22 054 Pg 3 Pg8 PSA D10R FL RHW 31 3 14 ...

Page 9: ...he piston side of the cylinder as ladder is raised Lock in raised position Re tighten hydraulic fittings SECURE THE LADDER IN THE RAISED POSITION MECHANICALLY CHAIN TAGOUT THE POWER STEP To recommission the POWER STEP Loosen hydraulic fittings on cylinder side of lock valve Note Collect displaced oil Lower ladder to lowest position using alternate safety approved means fully retracting cylinder En...

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 Pg11 PSA D10R FL RHW 31 3 14 Non Auto Raise ...

Page 12: ...Pg12 PSA D10R FL RHW 31 3 14 FOLDING LADDER Caterpillar D10R Dozer Section 2 Electrical System Wiring Diagrams Page 3 Auto Raise Toggle Switch Operated ...

Page 13: ...Pg13 PSA D10R FL RHW 31 3 14 WIRING HARNESS 1 FOLDING LADDER Caterpillar D10R Dozer Section 2 Electrical System Wiring Diagrams Page 4 ...

Page 14: ...Pg14 PSA D10R FL RHW 31 3 14 WIRING HARNESS 2 FOLDING LADDER Caterpillar D10R Dozer Section 2 Electrical System Wiring Diagrams Page 5 ...

Page 15: ...t daily check as above 5000 Hours Change hydraulic oil in tank of hydraulic power pack 5 0 litres It is recommended that the same hydraulic oil be used in the power pack as the hydraulics of the machine Grease 4 grease nipples on rotation shaft and sector gears all of these are accessible with the stairway lowered and accessed from under the stairway Check and inspect all main bolts on stairway sy...

Page 16: ... in the up position until the ladder is in the fully raised position The ladder is now raised and stored FOLDING LADDER Caterpillar D10R Dozer Section 4 Operating Procedure Pg16 PSA D10R FL RHW 31 3 14 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 o...

Page 17: ...FOLDING LADDER Caterpillar D10R Dozer Section 5 Assembly Complete PSA D10R RHW Pg17 PSA D10R FL RHW 31 3 14 ...

Page 18: ... 22002 PS 22012 PS 21958 PS 21926 01 PS 21926 02 PS 21926 03 CPS M12X45ZP CPS M12X30ZP CPS M12NZP CPS M12WH LADDER HANDRAIL FABRICATION ROTATION SHAFT PINION KEEPER PLATE LADDER SHAFT PIVOT BUSH MIDDLE LADDER SHAFT PIVOT BUSH NON DRIVE END LADDER SHAFT PIVOT BUSH DRIVE END BOLT M12 x 45 BOLT M12 x 30 NUT M12 WASHER M12 1 1 1 1 1 1 8 8 16 34 Set ...

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: ...30ZP CPS M12X25ZP CPS M8X35ZP CPS M12NZP CPS 1 2 NN CPS M8NN CPS M12WH CPS 1 2 WH CPS M8WH LANDING ASSEMBLY HANDRAIL FRONT LHS HANDRAIL REAR LHS ISOLATOR PIN BRACKET REAR ISOLATOR PIN BRACKET FRONT ISOLATOR MOUNTINGS ASSY FRONT PIVOT PIN BRACKET ANTI VIBRATION BEARING RUBBER BUSH ISOLATOR BUSH PIN MIDDLE BEARING MOUNTING ANGLE BRACKET ISOLATOR RUBBER CLAMP SIDE MOUNTING PAD BOLT M12 x 75 BOLT SOCK...

Page 21: ...Pg21 PSA D10R FL RHW 31 3 14 FOLDING LADDER Caterpillar D10R Dozer Section 5 2 Landing Assembly LHS PS 22017A NG Upgraded Handrails See Parts List Page 22 ...

Page 22: ...PS 1 2 NN CPS M10NN CPS M8NN CPS M12WH CPS 1 2 WH CPS M10WH CPS M8WH LANDING ASSEMBLY HANDRAIL FRONT LHS NEW GENERATION HANDRAIL REAR LHS NEW GENERATION ISOLATOR PIN BRACKET REAR ISOLATOR PIN BRACKET FRONT ISOLATOR MOUNTINGS ASSY FRONT PIVOT PIN BRACKET ANTI VIBRATION BEARING RUBBER BUSH ISOLATOR BUSH PIN MIDDLE BEARING MOUNTING RUBBER HOSE Pirtek IRR 032 x 120 HANDRAIL POST DOUBLE CLAMP ASSY SIDE...

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: ...21933 PS 22018 04 PS 22005 01 PS 22005 03 PS 22005 02 CPS M12X75ZP CPS M12X35ZP CPS M12X25ZP CPS M12NZP CPS 1 2 NN CPS M12WH CPS 1 2 WH LANDING ASSEMBLY RHS HANDRAIL RHS ISOLATOR PIN BRACKETS ISOLATOR MOUNTING ASSY ISOLATOR BUSH PIN SIDE MOUNTING PAD ANGLE BRACKET ISOLATOR RUBBER ISOLATOR CLAMP BOLT M12 x 75 BOLT M12 x 35 BOLT M12 x 25 NUT M12 NUT NYLOC 1 2 UNC WASHER HARDENED M12 WASHER HARDENED ...

Page 25: ...Pg25 PSA D10R FL RHW 31 3 14 FOLDING LADDER Caterpillar D10R Dozer Section 5 3 Landing Assembly RHS PS 22016A NG Upgraded Handrails See Parts List Page 26 ...

Page 26: ...A06 PS HRI C11 CPS M10X75ZP CPS M12X35ZP CPS M12X25ZP CPS M12NZP CPS M10NN CPS 1 2 NN CPS M12WH CPS 1 2 WH CPS M10WH LANDING ASSEMBLY RHS HANDRAIL RHS NEW GENERATION ISOLATOR PIN BRACKETS ISOLATOR MOUNTING ASSY ISOLATOR BUSH PIN SIDE MOUNTING PAD HANDRAIL POST DOUBLE CLAMP ASSY RUBBER HOSE Pirtek IRR 032 x 120 BOLT M10 x 75 BOLT M12 x 35 BOLT M12 x 25 NUT M12 NUT NYLOC M10 NUT NYLOC 1 2 UNC WASHER...

Page 27: ...0 11 12 PS 22051 PS 22052 PS 22006 99 PS 22006 98 PS 22005 01 CPS M16X50ZP CPS M16X35ZP CPS M12X40ZP CPS M16NZP CPS M12NZP CPS M16WH CPS M12WH LANDING REAR HANDRAILS REAR WALKWAY MOUNTING OUTER WALKWAY MOUNTING INNER ANGLE BRACKET BOLT M16 x 50 BOLT M16 x 35 BOLT M12 x 40 NUT M16 NUT M12 WASHER HARDENED M16 WASHER HARDENED M12 1 1 2 2 2 12 16 22 12 22 40 42 ...

Page 28: ...2 3 4 5 6 7 8 9 10 11 PS 22051 PS 22052 NG PS 22006 99 PS 22006 98 CPS M16X50ZP CPS M16X35ZP CPS M12X40ZP CPS M16NZP CPS M12NZP CPS M16WH CPS M12WH LANDING REAR HANDRAILS REAR NEW GENERATION WALKWAY MOUNTING OUTER WALKWAY MOUNTING INNER BOLT M16 x 50 BOLT M16 x 35 BOLT M12 x 40 NUT M16 NUT M12 WASHER HARDENED M16 WASHER HARDENED M12 1 1 2 2 12 16 22 12 22 42 44 ...

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: ...22281 01 PS 22018 03 PS 22018 01 PS M20X50ZP CPS M12X25ZP CPS 1 2 NN PS M20WH CPS M12WH CPS 1 2 WH SPREADER ISOLATOR PIN BRACKET OUTER LHS ISOLATOR PIN BRACKET OUTER RHS ISOLATOR PIN BRACKET INNER ISOLATOR MOUNTINGS ISOLATOR BUSH PIN WASHER PLATE 1 Hole WASHER PLATE 2 Holes WASHER PLATE 3 Holes WASHER PLATE 4 Holes MOUNT BLOCK REAR OUTER MOUNT BLOCK REAR INNER BOLT M20 x 50 BOLT M12 x 25 NUT NYLOC...

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: ... M24NN PS M20NZP CPS M12NZP CPS M12NN CPS M5NN CPS M24WH CPS M20WH CPS M12WH CPS M10WH CPS M5WH HYDRAULIC CYLINDER Refer Page 22 DRIVE MOUNTING FRAME SECTOR GEAR DRIVE GUARD ACTUATOR CYL MOUNTING ASSEMBLY MOUNTING BAR PROXIMITY SWITCH STRIKER GREASE NIPPLE M6 STR PIVOT PIN KEEPER PLATE SECTOR GEAR BUSH SECTOR GEAR HUB CLAMP RING SPACER RING BOLT M24 x 120 BOLT M20 x 65 BOLT M12 x 70 BOLT M12 x 25 ...

Page 33: ...10 11 12 13 PS 22013 PS 21945 PS 22091 16 PS 22087 PS 22091 14 PS 22091 13 PS 21930A PS 40003 CPS M12X120 CPS M12X40ZP CPS M12X25ZP CPS M12ZP CPSM12WH PROP MOUNTING FRAME PROP ROOF BUTTON PROP MOUNTING BEAM BOLTING PAD SPACER ISOLATOR MOUNTING BUFFER BOLT M12 x 120 BOLT M12 x 40 BOLT M12 x 25 NUT M12 WASHER HARDENED M12 1 1 2 2 2 2 4 4 4 8 14 20 38 ...

Page 34: ...S 61160 PS 60047 PS 60051 2 8 PS 61151 PS 61145 PS 61153 PS 60050 2 8 HYDRAULIC CYLINDER PIN CYLINDER WITH RETAINER SEAL KIT NOT SHOWN VALVE PILOT OPERATED LOCKING FITTING RESTRICTION 90 DEG FITTING ELBOW O RING 1 4BSPPx9 16 JIC FITTING O RING 1 4BSPPx 9 16 JIC REDUCER JIC x BSPP TUBE FERRULES NUTS 2 x each HOSE HYDR 9 6 JIC SWIVEL FITTING 2 8M FITTING ELBOW 7 16 JIC FITTING SWIVEL 9 16 JIC FITTIN...

Page 35: ...aterpillar D10R Dozer Section 5 8 Hydraulic Cylinder Valve Diagram See also Drawing Page 34 Pg35 PSA D10R FL RHW 31 3 14 Double Acting Hydraulic System with directional Control Valve and Cylinder Lock Valve 0 030 0 030 ...

Page 36: ...illar D10R Dozer Section 5 9 Power Pack Electrical Controls Accessories See Parts List Pg 38 Pg36 PSA D10R FL RHW 31 3 14 8 4 13 27 26 6 5 25 6 2 7 10 29 11 16 14 12 3 30 24 3A Hoses shown dotted View B View A 7A 9 9A 8A 3B ...

Page 37: ...CK IS TO BE SET TO 2800SI 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 Pg37 PSA D10R FL RHW 31 3 14 FOLDING LADDER Caterpillar D10R Dozer Section 5 9 Power Pack Electrical Controls Accessories See Parts List Pg 38 ...

Page 38: ...CLOSURE SEALED ST ST POWER PACK CLAMP ELECTRIC MOTOR HEAT SENSOR 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 HYDRAULIC FITTING 7 16 HYDRAULIC FITTING 9 16 HYDRAULIC FITTING 7 16 135A CIRCUIT BREAKER 5A CIRCUIT BREAKER ISOLATION SWITCH SEALED WIRING BOX TOGGLE SWITCH KIT BATTERY FEED STUDS 5 P...

Page 39: ...0 Electrical Controls Refer also Wiring drawings page 10 14 Pg39 PSA D10R FL RHW 31 3 14 Cab Harness Equipment Refer Wiring Harness Drawings Proximity Switch Assembly Mounted on Fixed Landing Control Pendant Switch Mounted on Handrail 7 3 8 4 2 5 6 1 ...

Page 40: ...3013 B PS 77005 PS 77009AR PS 77004 PS 75430 PS 77002 PS 77003 CONTROL PENDANT SWITCH CONTROL PENDANT BRACKET HAND RAIL SWITCH HARNESS AUTO RAISE HARNESS CABIN TO SWITCH HARNESS PROXIMITY SWITCH CABIN BOX LED LIGHT INDICATOR WIRING HARNESS IN CABIN 1 1 1 1 1 2 1 1 Optional only 1 x Optional WARNING LOW OR FAULTY BATTERIES WILL VOID WARRANTY ON THE POWER PACK AND ALL ELECTRICAL SWITCHES AND COMPONE...

Page 41: ... Caterpillar D10R Dozer Material Kit supplied PS P PACK ISO KIT LOCTITE 243 TO APPLY ON HYDRAULIC TANK SCREWS TANK PAD MADE OF RUBBER 2 EACH 3 8 X 1 BOLTS 4 EACH RUBBER MOUNTS WITH HARDWARE MALE FEMALE 7 16 AND 9 16 HYDRAULIC CAPS FOR THE HOSES ...