Power Step PSA-D11R-FL User manual

FOLDING LADDER
Manual for Cat D11R Dozer
Half Rear Walkway
Includes HARNESS MASTER ELECTRICAL WIRING DETAILS AND DIAGRAMS.
PSA-D11R-F/L 210610
Model No.PSA-D11R-FL
Serial No.:LD11-001 to LD11-021
Date Manufactured: Feb. 2003 to date

FOLDING LADDER
Caterpillar D11R Dozer (Half Rear Walkway)
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PSA-D11R-F/L 210610
CONTENTS
Page 3Section 1 Installation and Mounting instructions
Installation Drawings
9Section 2 Electrical System Wiring Diagrams
11 Section 3 Recommended Maintenance procedure
12 Section 4 Operating Procedure
Section 5 Drawings and Repair Parts lists
13 5 Assembly Complete
14 5-1 Ladder Assembly
Parts List
16 5-2 Landing Assembly LHS
Parts List
18 5-3 Landing Assembly Rear
Parts List
19 5-4 Spreader Assemly
Parts List
21 5-5 Drive Unit Assembly
Parts List
23 5-6 PROP Assembly
Parts List
24 5-7 Hydraulic Cylinder
Parts List
26 5-8 Power Pack
Parts List
28 Access System Electrical overview
30 5-9 Electrical Controls
35 Controls Installation Diagram
36 5-10 Bill of Materials

FOLDING LADDER
Caterpillar D11R Dozer
Section 1 Installation and Mounting Instructions
See Drawing 21-985 (Page 4)
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PSA-D11R-F/L 210610
PROCEDURE
1Remove grille plates from the rear of both mudguards.
Remove the light and/or horn from the rear of the left-side mudguard.
Draw out wiring for future re-use.
2 Weld the Mounting Pads to the rear of the mudguards, in the corners made by the
mudguard top plate and vertical inner plate, and in the corner made by the rolled
outer edge of the mudguard top plate. All the rear mounting pads fit hard against
the folded rear mudguard infill. All these mounting pads have bevelled edges to
clear existing welds in the corners.
3Measure forward from the back surfaces of the rear mounting pads and down from
the top surface of the mudguard decks to locate the side mounting pads. Weld
these mounting pads in position.
NOTE
Follow all on-site/Mine lifting and safety procedures when installing
Power Step Landings to Dozer.

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Caterpillar D11R Dozer
Installation and Mounting Instructions 21-985
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FOLDING LADDER
Caterpillar D11R Dozer
Installation and Mounting Instructions
See Drawings Page 6 and 7
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PSA-D11R-F/L 210610
PROCEDURE
1. Fit Mounting Blocks per Drg 21-985
2. Per View 2, Spreader Plate: Fit Spreader Plate 22 937 to rear mounting blocks. Use
Washer Plates and washers under bolt heads - ensure maximum
engagement of bolt threads in blind threaded holes. Washer Plates not shown in
most Views in this drawing.
3. Fit Isolator Brackets: 21 930 (See View A).
Fit Side Landing Beam 22 970 with Ladder Shaft and Drive already
assembled,supported by Isolators.
4. Fit Ladder. Using Spacers (within Actuator Cylinder Mounting 21 954), adjust drive
so gears are not loaded when ladder is lowered.
Clamp PROP Mtg Beams in position shown in View 1 and mount PROP 21 945
Adjust position so that, with PROP attached to Isolators ladder gear drive is not
loaded when ladder is fully raised. Attach PROP System Mounting Frame 21 987
atop cabin, on ROPS unless similar is already fitted by customer.
Weld Beams to Frame, 6cfw where visible from above
5. Per Drawings Complete Assembly and PROP System.
6. Fit Rear Walkway. Fit Handrails.
NOTES.
The drive, ladder stops and/or PROP system are to be adjusted so that in both the
Ladder Up (Travel) position and Ladder Down (Climb) position, the actuator gears
and cylinder are not loaded.

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Caterpillar D11R Dozer
Section 1 Installation Instruction Drawings - 21.986 Page 1
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FOLDING LADDER
Caterpillar D11R Dozer
Section 1 Installation Instruction Drawings - 21.986 Page 2
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PSA-D11R-F/L 210610

FOLDING LADDER
Caterpillar D11R Dozer
Section 1 Installation and Mounting Instructions (cont.)
Maintenance Notes
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PSA-D11R-F/L 210610
NOTE
Follow all on-site/Mine lifting and safety procedures when installing
Power Step Landings to Dozer.
WARNING
Raising the POWER STEP Landing 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 landing must be used,
please follow the following instructions:
Loosen hard plumbed hydraulic lines on cylinder side of lock valve on cylinder.
Raise landing by available means.
Note: Make necessary arrangements to collect displaced oil, and be aware that air enters
the piston side of the cylinder as landing is raised.
Lock in raised position.
Re-tighten hydraulic fittings.
SECURE THE LANDING 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 landing 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 valve to restriction fitting.
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).

FOLDING LADDER
Caterpillar D11R Dozer
Electrical System - Wiring Diagram Page 1
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PSA-D11R-F/L 210610
Power Step D11 Machine and Dash Wiring for Ladder Lamps
Power Step D11 Shutdwn Circuit

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Caterpillar D11R Dozer
Electrical System - Wiring Diagram Page 2
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PSA-D11R-F/L 210610
Power Step D11 Electrical Circuit

Daily
Visually check ladder 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 the nipples on the rotation shaft and sector gears.
Check main mounting bolts for torque.
Check hydraulic oil level in power pack and top up as necessary. (Ladder 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.
Grease 4 grease nipples on rotation shaft and sector gears, all of these are
accessible with the ladder lowered, and accessed from under the ladder.
Check and inspect all main bolts on ladder system.
Retorque if required.
Repeat daily check as above
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Caterpillar D11R Dozer
Section 3 Recommended Maintenance Procedure
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Caterpillar D11R Dozer
Section 4 Operating Procedure
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PSA-D11R-F/L 210610
To Lower Ladder (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 Dozer is parked on uneven ground, the bottom of the ladder may touch the
ground before the ladder is in the fully lowered position.
Should this occur, descend the ladder with caution.
To Raise Ladder
Ascend the ladder onto the landing of the Dozer.
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.

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Caterpillar D11R Dozer
Section 5 Assembly Complete
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FOLDING LADDER
Caterpillar D11R Dozer
Section 5-1 Ladder Assembly
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PSA-D11R-F/L 210610

FOLDING LADDER
Caterpillar D11R Dozer
Section 5-1 Ladder Assembly
See Drawing Page 14
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PSA-D11R-F/L 210610
Item Part No. Part Name Qty
1
2
3
4
5
6
7
8
9
10
PS-21924
PS-21977
PS-21958
PS-21926-01
PS-21926-02
PS-21926-03
CPS-M12X50
CPS-M12X20
CPS-M12NZP
CPS-M8NZP
LADDER & HANDRAIL FABRICATION
ROTATION SHAFT
PINION ASSEMBLY
LADDER SHAFT PIVOT BUSH-MIDDLE
LADDER SHAFT PIVOT BUSH-NON DRIVE END
LADDER SHAFT PIVOT BUSH- DRIVE END
BOLT-M12 x 50
BOLT-M12 x 20
NUT-M12
WASHER-M12
1
1
1
1
1
1
8
8
8
8

FOLDING LADDER
Caterpillar D11R Dozer
Section 5-2 Landing Assembly LHS.
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PSA-D11R-F/L 210610

FOLDING LADDER
Caterpillar D11R Dozer
Section 5-2 Landing Assembly LHS.
See Drawing Page 16
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PSA-D11R-F/L 210610
Item Part No. Part Name Qty
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
PS-21970
PS-21982
PS-21983
PS-21932
PS-21930
PS-21976
PS-21941-02
PS-21941-06
PS-21933
PS-21925
PS-22005-01
PS-22005-03/02
CPS-M12X85ZP
CPS-M12X65ZP
CPS-M12X40ZP
CPS-M12X30ZP
CPS-M12X25ZP
CPS-M8X35ZP
CPS-M12NZP
CPS-1/2”NN
CPS-M8NN
CPS-M12WH
CPS-1/2”WH
CPS-M8WH
LANDING BEAM
LANDING FLOOR
HANDRAIL
ISOLATOR PIN BRACKETS
ISOLATOR MOUNTINGS
FRONT PIVOT PIN BRACKET
ANTI VIBRATION BEARING
RUBBER BUSH
ISOLATOR BUSH PIN
MIDDLE BEARING MOUNTING
ANGLE BRACKET
ISOLATOR RUBBER/CLAMP
BOLT-M12 x 85
BOLT-SOCKET HEAD-M12 x 65
BOLT-M12 x 40
BOLT-M12 x 30
BOLT-M12 x 25
BOLT-M8 x 35
NUT-M12
NUT-NYLOC-1/2”UNC
NUT-NYLOC-M8
WASHER-HARDENED-M12
WASHER-HARDENED-1/2”
WASHER-HARDENED-M8
1
1
1
2
6
1
2
2
2
1
2
2
2
2
20
6
20
8
20
4
8
54
4
8

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Caterpillar D11R Dozer
Section 5-3 Landing Assembly Rear
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Item Part No. Part Name Qty
1
2
3
4
5
6
7
8
9
10
11
12
13
PS-21935
PS-21936
PS-21928
PS-22005-01
PS-21990
PS-M16X50ZP
PS-M16X30ZP
PS-M12X40ZP
PS-M12X30ZP
CPS-M16NZP
CPS-M12NZP
CPS-M16WH
CPS-M12WH
LANDING ASSEMBLY-REAR
HANDRAILS- REAR
REAR LANDING BRACKET
ANGLE BRACKET
RIPPER LIGHT BRACKET
BOLT-M16 x 50
BOLT-M16 x 30
BOLT-M12 x 40
BOLT-M12 x 30
NUT-M16
NUT-M12
WASHER-HARDENED-M16
WASHER-HARDENED-M12
1
1
2
1
1
6
4
16
2
6
18
10
18

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Caterpillar D11R Dozer
Section 5-4 Spreader Assembly
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FOLDING LADDER
Caterpillar D11R Dozer
Section 5-4 Spreader Assembly
See Drawing Page 19
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Item Part No. Part Name Qty
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
PS-21937
PS-21931 98
PS-21931 99
PS-21929
PS-22785 01
PS-22785 02
PS-22785 03
PS-22785 06
PS-22933 05
PS-22933
PS-21930
CPS-M20X60ZP
CPS-M12X40ZP
CPS-M12X25ZP
CPS-M12NZP
CPS-1/2”NN
CPS-M20WH
CPS-M12WH
CPS-1/2”WH
SPREADER
ISOLATOR PIN BRACKET-OUTER LEFT
ISOLATOR PIN BRACKET-INNER
REAR LANDING POST
REAR TOP INNER MOUNTING BLOCK
REAR LOWER INNER MOUNTING BLOCK
REAR OUTER MOUNTING BLOCK
WASHER PLATES
WASHER PLATES
ISOLATOR BUSH PIN
ISOLATOR MOUNTING
BOLT-M20 x 60
BOLT-M12 x 40
BOLT-M12 x 25
NUT-M12
NUT-NYLOC-1/2” UNC
WASHER-HARDENED-M20
WASHER-HARDENED-M12
WASHER-HARDENED-1/2”
1
1
1
1
2
2
1
1
4
2
6
10
2
20
2
4
10
22
4