Power Step Caterpillar 854G, Manual

Page 1: ...FOLDING STAIRWAY Manual for Caterpillar 854G PSA CAT854G FS 18 10 12 Model No PSA CAT854G FS Serial No PSA 854G 001 Date Manufactured Oct 2012 ...

Page 2: ...Section 4 Drawings and Repair Parts lists 14 4 Assembly Complete Parts List 16 4 1 Base Frame and Mounting Assembly Parts List 18 4 2 Stair Assembly Parts List 20 4 3 Latch Assembly Parts List 22 4 4 Hydraulic Cylinders Parts List Hydraulic Layout 25 4 5 Power Pack Parts List 28 4 6 Electrical Controls Wiring Diagrams Pg 2 PSA CAT854G FS 18 10 12 FOLDING STAIRWAY Caterpillar 854G Wheel Dozer ...

Page 3: ... protrudes past the alignment of the bumper 3 Try the stair assembly on the isolator plate as shown in Detail W Fit per drawing 24 313 except that the rubber isolator elements need not be fitted at this time stair fitment not shown in this drawing If the stair assembly as fitted would interfere with the hoses and fittings used for fuelling of the machine it will be necessary to move the whole stai...

Page 4: ...Pg 4 PSA CAT854G FS 18 10 12 FOLDING STAIRWAY Caterpillar 854G Wheel Dozer Section 1 Installation Drawings Bolting Pads PS 24308 DETAIL X VIEW Y VIEW Z DETAIL W ...

Page 5: ...ote ii re instate the strength of the stair frame by welding 24 304 05 OEM Stair Support to the front plate support as shown above drill matching bolt holes in the stair frame and bolt the two together If the stair frame was not cut away this step can be omitted The bumper box wall must be reinforced to accommodate the loads applied by the installation and use of the stair set per the above image ...

Page 6: ...e with weld to a level averaging 2mm above the floor plate that is leaving 2mm NOT FILLED with weld Grind back any protrusions to the alignment of the underside of the floor USE SAFE WORKING PRACTICES AT ALL TIMES including if necessary making the fuel tank safe from the effects of heat caused by the cutting welding and grinding Refer also to drawing 24 308 PROCEDURE See Drawing 24312 Page 8 1 Att...

Page 7: ...Pg 7 PSA CAT854G FS 18 10 12 FOLDING STAIRWAY Caterpillar 854G Wheel Dozer Section 1 Installation Drawings Bumper Reinforcements PS 24311 x w DETAIL X DETAIL W VIEW Z 1 VIEW Z 2 VIEW Y ...

Page 8: ...Pg 8 PSA CAT854G FS 18 10 12 FOLDING STAIRWAY Caterpillar 854G Wheel Dozer Section 1 Installation Drawings Bumper Reinforcements PS 24312 DETAIL V DETAIL U DETAIL T VIEW W VIEW Z VIEW X VIEW Y ...

Page 9: ...post base components per Detail W Attach the Bolting Block to the wall of the bumper in a location to suit with a 6mm continuous fillet weld Cut and bend the Post to suit Observe previously mentioned precautions when cutting grinding or welding in the vicinity of the fuel tank 3 Fit the hydraulic power unit to the loader in a suitable location and connect and fasten the hydraulic hoses Complete th...

Page 10: ...FOLDING STAIRWAY Caterpillar 854G Wheel Dozer Section 1 Installation Drawings Stair Set PS24313 Pg 10 PSA CAT854G FS 18 10 12 VIEW Z VIEW X VIEW Y ...

Page 11: ... Lock in raised position Re tighten hydraulic fittings SECURE THE PLATFORM 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 platform to lowest position using alternate safety approved means fully retracting cylinder Ensure all personnel are clear of step radius Op...

Page 12: ...ting bolts for torque Check hydraulic oil level in power pack and top up as necessary Stairway in raised position Top up using same hydraulic oil as used in hydraulics of machine Thoroughly check all electrical wiring for damage replace as necessary Repeat 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 b...

Page 13: ...nto operate the electrical switch to the raise position up Hold the switch in the up position until the ladder is in the fully raised position The ladder is now raised and stored Pg 13 PSA CAT854G FS 18 10 12 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...

Page 14: ...Pg 14 PSA CAT854G FS 18 10 12 FOLDING STAIRWAY Caterpillar 854G Wheel Dozer Section 4 Assembly Complete ...

Page 15: ...e Drawing Page 14 Pg 15 PSA CAT854G FS 18 10 12 ITEM PART NO PART NAME QTY PSA CAT854G FS ASSEMBLY COMPLETE 1 1 PS 23838A STAIR BASE FRAME MOUNTING 1 2 PS 23852A STAIR ASSEMBLY 1 3 PS 23847A LATCH ASSEMBLY 1 4 PS 62996 A HYDRAULIC CYLINDERS Stair 1 5 PS 80103A SLD POWER PACK 1 ...

Page 16: ...Pg 16 PSA CAT854G FS 18 10 12 FOLDING STAIRWAY Caterpillar 854G Wheel Dozer Section 4 1 Stair Base Frame and Mounting Assembly PS 23838A See Parts List Pg 17 ...

Page 17: ...CPS M20NZP PS M12NZP PS M8NZP CPS M16WH CPS M12WH CPS M8WH BASE FRAME ISOLATOR MOUNTING PLATE FRONT PLATE SUPPORT FRONT BOLTING PAD REAR BOLTING PAD MIDDLE BOLTING PAD TOP STAIR TREAD STRIKER LEFT SIDE STRIKER RIGHT SIDE MANUAL RELEASE LEVER HINGE PIN SHEAR ISOLATOR ELEMENT SHEAR ISOLATOR CAP ISOLATOR COVER PLATE FACE ISOLATOR ELEMENT BUMPER WALL REINFORCEMENT LATCH BUSH RELEASE LEVER SPACER LIFT ...

Page 18: ...FOLDING STAIRWAY Caterpillar 854G Wheel Dozer Section 4 2 Stair Assembly PS 23 852A See Parts List Page 19 Pg 18 PSA CAT854G FS 18 10 12 14 ...

Page 19: ... M12X20ZP CPS M10X85ZP CPS M8X75ZP CPS M6X15ZP CPS M10NN CPS M8NN CPS M12WH CPS M10WH CPS M8WH STAIR STILE 6 Tread STAIR EXTENSION Single Tread STAIR HANDRAILS HANDRAIL LINK POST STAIR ACTUATOR BEAM STAIR TREAD STAIR TREAD TOP HINGE BUSH HANDRAIL BUSH BUMPER PAD Rubber BUFFER RUBBER MACKAY M12402055 M8 BUFFER RUBBER MACKAY M12503555 M10 BUSH Stair Actuator Beam WASHER BOLT M12 x 30 BOLT M12 x 20 B...

Page 20: ...Pg 20 PSA CAT854G FS 18 10 12 FOLDING STAIRWAY Caterpillar 854G Wheel Dozer Section 4 3 Latch Assembly PS 23847A See Parts List Pg 21 ...

Page 21: ...S 39008 SPRING PS 23844 02 PS S245 PS M12X110ZP CPS M12X55ZP CPS M12X40ZP CPS M12X35ZP CPS M12X25ZP CPS M10X75ZP CPS M10X15ZP CPS M12NZP CPS M10NZP CPS M12WH CPS M10WH CYLINDER LATCH BASE LATCH WRIST ACTUATOR ARM BOLT LINK LATCH BOLT LATCH BUSH WRIST SPACER SPRING WASHER LATCH BUSH WRIST PLATE S245 BOLT M12 x 110 BOLT M12 x 55 Striker BOLT M12 x 40 BOLT M12 x 35 BOLT M12 x 25 BOLT M10 x 75 BOLT M1...

Page 22: ...Pg 22 PSA CAT854G FS 18 10 12 FOLDING STAIRWAY Caterpillar 854G Wheel Dozer Section 4 4 Hydraulic Cylinder Plumbing Cyl P No PS 62996 AH Latch Cyl PS 62997 A ...

Page 23: ...SHOWN HYDRAULIC CYLINDER LATCH SEAL KIT LATCH NOT SHOWN CYLINDER PINS VALVE PILOT OPERATED LOCKING FITTING T 7 16 FITTING 9 16 JIC SWIVEL FITTING T 9 16 FITTING ELBOW 7 16 FITTING ELBOW 7 16 FITTING ELBOW 9 16 FITTING 1 4 BSPPx7 16 STRAIGHT FITTING ELBOW O RING 1 4BSPPx9 16 JIC FITTING STRAIGHT 1 4 BSPPx9 16 JIC FITTING 5mm RESTRICTION 90 DEG FITTING ELBOW 9 16 REDUCER JIC x BSPP TUBE 900 1200 HOS...

Page 24: ...FOLDING STAIRWAY Caterpillar 854G Wheel Dozer Section 4 4 Hydraulics Valve Diagram Pg 24 PSA CAT854G FS 18 10 12 Double Acting Hydraulic System with directional Control Valve and Cylinder Lock Valve ...

Page 25: ...Y Caterpillar 854G Wheel Dozer Section 4 5 Power Pack PS 80103A SLD See Parts List Pg 27 Pg 25 PSA CAT854G FS 18 10 12 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 ...

Page 26: ...g 26 PSA CAT854G FS 18 10 12 15 20 21 23 9 View B 9A View A 32 33 24 14 19 11 16 28 10 18 31 17 12 NOTE THE RELIEF PRESSURE OF THE POWERPACK IS TO BE SET TO 1500PSI 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 ...

Page 27: ...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 HYDRAULIC FITTING 7 16 HYDRAULIC FITTING 9 16 HYDRAULIC FITTING 7 16 135A CIRCUIT BREAKER 5A CIRCUIT BREAKER ISOLATION SWITCH INCLUDING BRACKET SEALED WIRING BOX TOGGLE SWITCH KIT BATTERY ...

Page 28: ...Wheel Dozer Section 4 6 Electrical Controls Pg 28 PSA CAT854G FS 18 10 12 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 29: ...STAIRWAY Caterpillar 854G Wheel Dozer Section 4 6 Electrical Controls See Page 28 Item Part No Part Name Qty 1 2 3 4 5 6 7 8 PS 73013 PS 73013 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...

Page 30: ...Pg 30 PSA CAT854G FS 18 10 12 FOLDING STAIRWAY Caterpillar 854G Wheel Dozer Section 4 6 Electrical Controls Wiring Diagrams Page 1 WIRING HARNESS ...

Page 31: ...Pg 31 PSA CAT854G FS 18 10 12 FOLDING STAIRWAY Caterpillar 854G Wheel Dozer Section 4 6 Electrical Controls Wiring Diagrams Page 2 Non Auto Raise ...

Page 32: ...Pg 32 PSA CAT854G FS 18 10 12 FOLDING STAIRWAY Caterpillar 854G Wheel Dozer Section 4 6 Electrical Controls Wiring Diagrams Page 3 Auto Raise ...

Page 33: ...Pg 33 PSA CAT854G FS 18 10 12 FOLDING STAIRWAY Caterpillar 854G Wheel Dozer Section 4 6 Electrical Controls Wiring Diagrams Page 4 WIRING HARNESS 1 ...

Page 34: ...Pg 34 PSA CAT854G FS 18 10 12 FOLDING STAIRWAY Caterpillar 854G Wheel Dozer Section 4 6 Electrical Controls Wiring Diagrams Page 5 WIRING HARNESS 2 ...