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Manual for Cat D8R Dozer
Model No.: PSA-CAT-D8R
Serial No.: D8R-001
Date Manufactured: March 2012
PSA-CAT D8R-FL 19-3-12
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Cat D8R Dozer
CONTENTS
Page 3 Section 1 Installation and Mounting Instructions
Installation Drawings
8 Section 3 Recommended Maintenance procedure
9 Section 4 Operating Procedure
Section 5 Drawings and Repair Parts lists
10 5 Assembly Complete
Parts List
11 5-1 Main Frame and Mounting Assembly
Parts List
13 5-2 Stair Assembly
Parts List
15 5-3 Hydraulic Cylinder Assembly
Parts List
Hydraulic Layout
17 5-4 Power Pack
Parts List
20 5-5 Electrical Controls
Wiring Diagrams
26 Material Kit Supplied
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Section 1 Installation Drawings PSA-CATD8R-INST-01-C Sheet. 1 of 4
See also PowerStep Mounting Procedure Document
Follow all on-site/Mine lifting and safety procedures when installing PSFS to Loader
NOTE
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Section 1 Installation Drawings PSA-CATD8R-INST-01-C Sheet. 2 of 4
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Section 1 Installation Drawings PSA-CATD8R-INST-01-C Sheet. 3 of 4
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Section 1 Installation Drawings PSA-CATD8R-INST-01-C Sheet. 4 of 4
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Section 1 Installation and Mounting Instructions (cont.)
WARNING
Raising the POWER STEP platform by external means can create a vacuum in the
hydraulic cylinder and create the opportunity to allow air into the hydraulic system,
defeating the inherent safety features of the POWER STEP.
This must be avoided, to maintain safe operation of the POWER STEP.
In instances where the use of external means to raise the platform must be used,
please follow the following instructions:
Loosen hard plumbed hydraulic lines on cylinder side of lock valve on cylinder.
Raise platform by available means.
Note: Make necessary arrangements to collect displaced oil, and be aware that air enters
the piston side of the cylinder as platform is raised.
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.
Operate electrical control switch to purge air from the hydraulic line systems, lock valve
and cylinder.
Tighten the hydraulic fittings either side of lock valves to restriction fittings.
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).
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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 2 grease nipples on hinge pins
Check main mounting 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 be used in the power pack as the
hydraulics of the machine.
Check and inspect all main bolts on stairway system.
Retorque if required.
Repeat daily check as above
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Section 4 Operating Procedure
To Lower Stairway (from the machine)
Position machine in a level, safe area, away from the work face, whenever possible.
Apply park brake and lower engine speed to idle.
Check that the area below the Ladder Access System is clear of people and
obstacles, and lower ladder by operating the two position electrical switch adjacent
to the ladder, to the down position by pressing the switch down.
Hold the switch in the down position until ladder is fully lowered.
If the truck is parked on uneven ground, the bottom of the stairway may touch the
ground before the ladder is in the fully lowered position.
Should this occur, descend the ladder with caution.
To Raise Stairway
Ascend the ladder onto the landing of the Loader.
Ensure the area around the ladder is clear of people and standing to the side, clear
of the area the handrails and ladder raises into, 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.
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 or right (clockwise) when the
step is being lowered, until it is lowering at a safe and reasonable speed.
When it is adjusted, lock the adjusting knob by tightening the grub screw located on the
side of the knob.
NOTE: MAGNETIC 'GO' SWITCH ADJUSTMENT:
The switch target trigger area is located on the opposite side and end from the cable entry
point on the switch. Once it is mounted to the switch bracket, adjust the switch in or out
from the stair steel trigger point, to be within 3mm - 10mm from touching each other when
the stair is in the desired rest position.
[DO NOT EXCEED 10MM DISTANCE BETWEEN THE SWITCH AND STRIKER PLATE].
Test by raising and lowering the Power Step a couple of times and adjust again if
necessary.
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Section 5 Assembly Complete
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Section 5.1 Main Frame & Mounting Assembly PS-FRA-A01
See Parts List Pg. 12
PSA-CAT D8R-FL 19-3-12 Pg. 11
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Section 5.1 Main Frame and Mounting Assembly PS-FRA-A01
See Drawing Page 11
Item Part No. Part Name Qty
1 PS-FRA-B01 MAIN FRAME ASSEMBLY 1
2 PS-ISO-C16 MOUNTING PLATES (Side & Front) 2
3 PSA-D8R-C01 MOUNTING PLATE - ADD-ON 1
4 PS-HRI-B03-01 HANDLE A 1
5 PS-HRI-B03-02 HANDLE B 1
6 PS-HRI-B02-03 HANDLE C 1
7 PS-HRI-B03-04 HANDLE D 1
8 PS-LOC-A06 NYLON STAIR GUIDE/PARK 2
9 PS-LOC-B02 MOUNT BRACKET WELDMENT (Set) 2
10 PS-21930A ISOLATOR ASSEMBLY 6
11 PS-ISO-C01 ISOLATOR MOUNTING 6
12 PS-LOC-C20 RUBBER BLOCK 2
13 PS-STR-C48 BUFFER PAD 2
14 CPS-M12X110ZP BOLT-M12 x 110 10
15 CPS-M12X25ZP BOLT-M12 x 25 4
16 CPS-M12X20ZP BOLT-M12 x 20 24
17 CPS-M10X90ZP BOLT-M10 x 90 8
18 CPS-M10X60ZP BOLT-M10 x 60 4
19 CPS-M6X16ZP BOLT-M6 x 16-C/Sunk Head 8
20 CPS-M12NN NUT-M12-NYLOC 34
21 CPS-M10NZP NUT-M10 12
22 CPS-M12WH WASHER-HARDENED-M12 52
23 CPS-M10WH WASHER-HARDENED-M10 12
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Section 5-2 Stair Assembly PS- STR-A02
See Parts List Page 14
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Section 5-2 Stair Assembly PS- STR-A02
See Drawing Page 13
Item Part No. Part Name Qty
1 PS-STR-B03 STAIR FABRICATION (7 Tread) 1
2 PS-STR-B05 ACTUATOR BEAM 1
3 PS-STR-B04 STAIR HANDRAILS (Set- LH & RH) 2
4 PS-63011 HYDRAULIC CYLINDER 1
5 PS-23032 STAIR PIVOT PIN 2
6 PS-22463 LADDER HINGE BUSH 2
7 PS-LOC-C19 ROUND BAR 2
8 - COLLAR (Unbrako 1x 1 5/8 x 5/8) 4
9 PS-C23-045-06 BUSH-(Stair Actuator Beam) 2
10 PS-STR-C48 BUFFER PAD (Rubber) 2
11 PS-61006-2 GREASE NIPPLE-M6 2
12 - SET SCREW-M6 2
13 CPS-M12X25ZP BOLT-M12 x 25 12
14 CPS-M16X16ZP BOLT-M6 x 16 Cap screw C/Sunk 8
15 CPS-M12WH WASHER-HARDENED-M12 12
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Section 5-3 Hydraulic Cylinder Assembly P/No. PS-63011-AH
See Also Drawing Pg. 16
Item Part No. Part Name Qty
1 PS-63011 HYDRAULIC CYLINDER 9/16”UNO PORTS 1
- PS-63011-SK SEAL KIT (NOT SHOWN) 1
- PS-LOC-C19 PIN-TOP 1
- PS-22468-03 WASHER 1
1A CPS-M6X60SS BOLT-M6 x 60 ST/ST 2
1B CPS-M6NN NUT-NYLOC-M6 S/S 2
1C PS-61006-2 GREASE NIPPLE 1
2 PS-63201 VALVE - PILOT OPERATED LOCKING 1
3 PS-61159 FITTING - ELBOW-9/16” JIC 1
4 PS-61154 FITTING - ELBOW- O RING 1/4BSPPx9/16”JIC 1
5 PS-61157 FITTING - O RING 1/4BSPPx 9/16”JIC 1
6 PS-61158-0.040” FITTING - 0.040” RESTRICTION 90 DEG 1
7 PS-61160-140MM TUBE -140MM (Cut to size to fit) 1
8 PS-60031-FT FERRULES 2
9 PS-60051-2.8 HOSE- HYDR. (9/6”JIC SWIVEL FITTING 2.8M) 2
10 PS-61158-0.030” FITTING - 0.03” RESTRICTION 90 DEG 1
11 PS-61145 FITTING 9/16 JIC SWIVEL 2
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Section 5-3 Hydraulic Cylinder (Valve Diagram)
Double Acting Hydraulic System with
directional Control Valves and Cylinder
Lock Valves
0.040” 0.030”
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Section 5-4 Power Pack PS- 80103A-SLD
See Parts List Pg 19
14 31 28 6 5 27
View B View A
10
11
17
9 9A 26 2 8 8A 7 3 3A 32
7A
Hoses shown 29
15 6
dotted
12 13
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Section 5-4 Power Pack PS-80103A-SLD
See Parts List Pg 19
30 20
10
18
17 33
11
19
21
15 12
34
35
View A 24
16
9
25
23
9A
22
View B
NOTE.
THE RELIEF PRESSURE OF THE POWERPACK IS TO BE SET TO 2800PSI.
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
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Section 5-4 Power Pack PS-80103A-SLD
See Photos Pg 17 & 18
Item Part No. Part Name Qty
1 PS-80103A-SLD POWER PACK ASSEMBLY 1
2 PS-21107-METAL MOTOR ENCLOSURE- SEALED ST/ST 1
3 PS-80103A POWER PACK 1
3A PS-80103-CLAMP CLAMP ELECTRIC MOTOR 1
4 PS-82415 AUDIBLE ALARM 1
5 PS-84214 BRIDGE RECTIFIER 1
6 PS-82492 SOLENOID 24V START MOTOR 1
7 PS-60050-900MM 9/16” HYDR. HOSES 9/16”JIC STRAIGHT SWIVEL 1
7A PS-60050-900MM 7/16” HYDR. HOSES 7/16”JIC STRAIGHT SWIVEL 1
8 PS-61152 HYDRAULIC FITTING 9/16” 1
8A PS-61150 HYDRAULIC FITTING 7/16” 1
9 PS-61177 HYDRAULIC FITTING 9/16” 1
9A PS-61176 HYDRAULIC FITTING 7/16” 1
10 PS-84213 135A CIRCUIT BREAKER 1
11 PS-84212 10A CIRCUIT BREAKER 1
12 PS-84303 ISOLATION SWITCH 1
13 PS-84303-B ISOLATION SWITCH BRACKET 1
14 PS-1712080 SEALED WIRING BOX 1
15 PS-73012 TOGGLE SWITCH KIT 1
16 PS-82493 BATTERY FEED STUDS 2
17 PS-HD10-5-16P 5 PIN SOCKET 1
18 PS-HD10-5-16S 5 PIN PLUG 1
19 PS-41010 DECAL-Battery Isolation 1
20 PS-41011 DECAL-Battery Supply C/B-135A 1
21 PS-41012 DECAL-Controller Supply C/B-10A 1
22 PS-41013 DECAL-Battery Supply-PosItive 1
23 PS-41014 DECAL-Battery Supply-Negative 1
24 PS-41023 DECAL-Up/Down 1
25 PS-41024 DECAL HYDRAULIC-HOSES 1
26 PS-41041 DECAL OIL TANK 1
27 PS-41019 DECAL BRIDGE RECTIFIER 1
28 PS-41017 DECAL SOLENOID 1
29 PS-41018 DECAL ALARM 1
30 PS-41016 DECAL RAISE/LOWER SWITCH 1
31 PS-73010 RUBBER BOOT RED 6
32 PS-73009 RUBBER BOOT BLACK 3
33 PS-HD10-3-16P 3 PIN SOCKET (PARK BREAK) 1
34 PS-HD10-5-16P 5 PIN SOCKET (AUTO-RAISE) 1
35 PS-41032 DECAL AUTO-RAISE SOCKET 1
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Section 5-5 Electrical Controls Control Pendant Switch
Mounted on Handrail
Proximity Switch Assembly 1
Mounted on Fixed Landing
5 2
Cab Harness & Equipment
Refer Wiring Harness Drawings
6 7
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Section 5-6 Electrical Controls
See Page 20
Item Part No. Part Name Qty
1 PS-73013 CONTROL PENDANT SWITCH 1
2 PS-73013-B CONTROL PENDANT BRACKET 1
3 PS-75430 PROXIMITYSWITCH 1
4 PS-77005 HAND RAIL SWITCH HARNESS 1
5 PS-77004 PROXIMITY MAGNETIC SWITCH HARNESS 1
6 PS-77002 CABIN BOX LED LIGHT INDICATOR 1
7 PS-77003 WIRING HARNESS 1
WARNING
LOW VOLTAGE BATTERIES WILL HARM THE FUNCTION
OF THE POWER PACK AND THE CONTROL SWITCHES.
DAMAGE RESULTING DUE TO LOW VOLTAGE
BATTERIES WILL VOID WARRANTY ON ALL
ELECTRICAL COMPONENTS.
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Section 5-5 Electrical Controls Wiring Harness
WIRING HARNESS
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Section 5-5 Electrical Controls Electrical Layout 1.
Hydraulic System
CAT D8R
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Section 5-5 Electrical Controls Electrical Layout 2.
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Section 5-5 Electrical Controls Electrical Layout 3.
WIRING HARNESS
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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" X 1 ¼" BOLTS
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