Power Step PSA-EX2500-FRS User manual

EX2500-FRS 3-8-15
FOLDING RETRACTABLE STAIRWAY
Manual for Hitachi EX2500 Excavator
Model No. PSA-EX2500-FRS
Serial No.: ~
Date Manufactured:

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FOLDING RETRACTABLE STAIRWAY
To suit Hitachi EX2500 Excavator
EX2500-FRS 3-8-15
CONTENTS
Page 3Section 1 Installation Notes
Installation Drawings
7Section 2 Recommended Maintenance procedure
8Section 3 Operating Procedure
Section 4 Drawings and Repair Parts lists
94 Assembly complete
Parts List
11 4-1 Mounting Assembly
Parts List
12 4-2 Landing Assembly
Parts List
14 4-3 Stair - Upper Assembly
Parts List
16 4-4 Stair - Lower Assembly
Parts List
18 4-5 Pivot Assembly
Parts List
20 4-6 Hydraulic Cylinders
Parts List
23 4-7 Power Pack Assembly
Parts List
26 4-8 Electrical Controls
Parts List
Wiring Diagrams

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FOLDING RETRACTABLE STAIRWAY
To suit Hitachi EX2500 Excavator
Section 1 Installation Notes
EX2500-FRS 3-8-15
Remove the sliding ladder & its' floor module - all one piece.
Remove landing/walkway panel in front of where the ladder module was.
Shorten it per 21.607A
Temporarily fit 21 605 infill platform where the ladder module cam.e out. Per
21 608, cut holes in landing/ww skin behind the ladder spot. Remove 21 605.
Using Jig 21 604 as required, fit extension cleats to Stub Beams as per 21 603A
Drawing 21 609 (see Notes on Drawing)
Fit stub beam extensions using shims if needed 21 611.
Fit infill platform 21 605.
Fit the shortened landing back in front of ladder space.
Fit the Side Beam(21-606) to the ends of the outrigger beam extensions
Fit the landing to the Side Beam.
NOTE
Follow all on-site/Mine lifting and safety procedures when installing
PSFS to Truck.

FOLDING RETRACTABLE STAIRWAY
To suit Hitachi EX2500 Excavator
Installation Drawings - Stub Beams 21.603
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EX2500-FRS 3-8-15

FOLDING RETRACTABLE STAIRWAY
To suit Hitachi EX2500 Excavator
Installation Drawings - Mounting Arrangement
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EX2500-FRS 3-8-15

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FOLDING RETRACTABLE STAIRWAY
To suit Hitachi EX2500 Excavator
Installation Drawings - Landing and Stair Assembly
EX2500-FRS 3-8-15

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FOLDING RETRACTABLE STAIRWAY
To suit Hitachi EX2500 Excavator
EX2500-FRS 3-8-15
Section 2
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 all grease nipples. Lower or raise stairway for accessibility.
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 (10.0 litres).
It is recommended that the same hydraulic oil be used in the power pack as the
hydraulics of the machine.
Grease all grease nipples. Lower or raise stairway for accessibility.
Retorque all main mounting bolts
Repeat daily check as above.

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FOLDING RETRACTABLE STAIRWAY
To suit Hitachi EX2500 Excavator
Section 3 Operating Procedure
EX2500-FRS 3-8-15
To Lower Stairway (from the machine)
Position excavator in a level, safe area, away from the work face, whenever possible.
Position the excavator body square to the tracks, lower bucket, apply park brake and
lower engine speed to idle.
Descend stairway behind cabin to lower walkway.
Check that the area below and behind the Folding Raising Stairway (FRS) is clear of
people and obstacles, and lower stairway by operating the two position electrical switch
adjacent to the stairway, to the down position by pressing the switch down.
Hold the switch in the down position until stairway is fully extended and lowered.
If the excavator is parked on uneven ground, the bottom of the stairway may touch the
ground before the FRS is in the fully extended and lowered position.
Should this occur, descend the stairway with caution.
Bottom of stairway is designed to rest on the ground in the fully lowered and extended
position, but can be used in the fully lowered position without resting on the ground.
To Raise Stairway
Ascend the stairway onto the lower walkway of the excavator
Ensure the area around the stairway is clear of people and standing to the side, clear of
the area the handrails and stairway raises into, operate the electrical switch to the raise
position (up).
Hold the switch in the up position until the stairway is in the fully raised position.
The stairway is now raised and stored.
Note:
The stairway is interlocked with the swing interlock of the excavator, and the machine will
not swing with the stairway out of the fully raised position.
Operation of the FRS mechanically extends the lower stair section as the stairway is
lowered by means of the link rods to the upper platform of the FRS.
There is no method of individual control of the upper and lower sections.
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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FOLDING RETRACTABLE STAIRWAY
To suit Hitachi EX2500 Excavator
Section 4 Assembly Complete
EX2500-FRS 3-8-15

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FOLDING RETRACTABLE STAIRWAY
To suit Hitachi EX2500 Excavator
List of Assemblies
See Drawing Page 9
EX2500-FRS 3-8-15
ITEM PART NO. PART NAME QTY
1MOUNTING ASSEMBLY1
2PS-21079-25A LANDING ASSEMBLY- EX 2500 1
3PS-21038-A STAIR - UPPER - ASSEMBLY1
4PS-21036-A STAIR - LOWER - ASSEMBLY1
5PS-35030-A PIVOT ASSEMBLY1
6PS-63009-ASSY HYDRAULIC ASSEMBLY1
7PS-80104P-RFS HYDRAULIC - POWER UNIT-ASSEMBLY
(INCLUDING CRADLE) 1

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FOLDING RETRACTABLE STAIRWAY
To suit Hitachi EX2500 Excavator
Section 4-1 Mounting Assembly
EX2500-FRS 3-8-15
Item Part No. Part Name Qty
1
2
3
4
5
6
7
8
9
10
11
12
13
14
-
PS-21605
PS-21086
PS-21606
PS-21601
PS-M24x145MM
PS-M20x60MM
PS-M20X50MM
CPS-M16x50MM
PS-M24NZP
PS-M20NZP
CPS-M16NZP
PS-M24NN
CPS-M20WH
CPS-M16WH
MOUNTING ASSEMBLYCOMPLETE
PLATFORM INFILL
REAR OUTRIGGER BEAM
SIDE BEAM
FRONT OUTRIGGER BEAM
BOLT - M24 x 150
BOLT - M20 x 60
BOLT - M20 x 50
BOLT - M16 x 50
NUT - M24
NUT - M20
NUT - M16
WASHER - HARDENED- M24
WASHER - HARDENED- M20
WASHER - HARDENED- M16
1
1
1
1
1
8
48
12
8
8
60
6
16
120
12

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FOLDING RETRACTABLE STAIRWAY
To suit Hitachi EX2500 Excavator
Section 4-2 Landing Assembly PS-21079-25A
EX2500-FRS 3-8-15

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FOLDING RETRACTABLE STAIRWAY
To suit Hitachi EX2500 Excavator
Section 4-2 Landing Assembly PS-21079-25A
See Drawing Page 12
EX2500-FRS 3-8-15
Item Part No. Part Name Qty
1
2
3
4
5
6
7
8
9
10
PS-21079
PS-21571-LHR
PS-21055
PS-M24 x 100ZP
CPS-M12 x 30ZP
CPS-M24WH
PS-M24NZP
CPS-M12WH
PS-63009-B
PS-21610
LANDING
HANDRAIL-LANDING
LANDING-GRID
BOLT- M24 x 100
BOLT- 12 x 30
WASHER-HARDENED-M24
NUT- M24
WASHER-HARDENED-M12
BUSHES-CLEVIS
INFILL PANEL
1
1
1
8
19
16
8
19
2
1

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FOLDING RETRACTABLE STAIRWAY
To suit Hitachi EX2500 Excavator
Section 4-3 Stair - Upper Assembly PS-21038-A
EX2500-FRS 3-8-15

EX2500-FRS 3-8-15
FOLDING RETRACTABLE STAIRWAY
To suit Hitachi EX2500 Excavator
Section 4-3 Stair Upper Assembly PS-21038-A
See Drawing Page 14
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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
PS-21038
PS-21571-USH
PS-21556
PS-21043
PS-21044
PS-21077
PS-40001
PS-21081
PS-21056
CPS-M10x 100 PR
PS-21049-15
PS-63009-B
CPS-M12x 35ZP
CPS-M12x 30ZP
CPS-M12WH
CPS-M12NZP
PS-38998-C
PS-32266-SAN
STRINGER ASSEMBLY
HANDRAIL - UPPER
TREAD STEP
BUSHING UPPER & CRANK PIVOT
BUSHING-CENTER-PIVOT
BUFFER-FRAME-TRAVEL
RUBBER STOP
BUFFER-FRAME-LOWER - STAIR
PIVOT-PIN-TOP
ROLL-PIN-M10 x 100
WASHER-MACHINED
BUSHES-CLEVIS
BOLT-M12 x 35
BOLT-M12x 30
WASHER-HARDENED-M12
NUT M12
FRS-SPRING SET (Not included in Assy)
NON-SLIP NOSING (Not included in Assy)
1
2
6
4
2
2
4
1
1
2
2
2
18
20
80
42
1
6
(Set of 2)

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EX2500-FRS 3-8-15
FOLDING RETRACTABLE STAIRWAY
To suit Hitachi EX2500 Excavator
Section 4-4 Stair - Lower Assembly PS-21036-A

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EX2500-FRS 3-8-15
FOLDING RETRACTABLE STAIRWAY
To suit Hitachi EX2500 Excavator
Section 4-4 Stair - Lower Assembly PS-21036-A
See Drawing Page 16
Item Part No. Part Name Qty
1
2
3
4
5
6
7
8
9
10
11
12
13
PS-21036L
PS-21036R
PS-21034L
PS-21034R
PS-21553
PS-21556
PS-21058LSH
PS-36021
CPS-M12X35ZP
CPS-M12X30ZP
CPS-M12NZP
CPS-M12WH
PS-32266-SAN
STAIR STRINGER-LH
STAIR STRINGER-RH
STAIR-STILE-CAP-LH
STAIR-STILE-CAP-RH
TREAD-STEP-SMALL
TREAD-STEP-STD
HANDRAIL-LOWER SECTION
LINKAGE-TORQUE-TUBE
BOLT-M12 x 35
BOLT- M12 x 30
NUT M12
WASHER-HARDENED-M12
NON-SLIP NOSING (Not included in Assy)
1
1
1
1
1
6
2
1
4
50
54
108
7

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EX2500-FRS 3-8-15
FOLDING RETRACTABLE STAIRWAY
To suit Hitachi EX2500 Excavator
Section 4-5 Pivot Assembly PS-35030-A

EX2500-FRS 3-8-15
FOLDING RETRACTABLE STAIRWAY
To suit Hitachi EX2500 Excavator
Section 4-5 Pivot Assembly PS-35030-A
See Drawing Page 18
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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
20
21
PS-21042
PS-21039
PS-21040
PS-21041
PS-21039-P
PS-21045
PS-29004
PS-29003
CPS-M10X80PR
PS-M24X120ZP
PS-M20X100ZP
PS-M20X60ZP
CPS-3/4”X5”UNF
CPS-3/4”X4 1/2”UNF
PS-29004-N
PS-29003-N
PS-M24NN
CPS-M20NN
CPS-3/4” N/L UNF
PS-M24WH
CPS-M20WH
CRANK-PRIMARY
CRANK-SECONDARY
CRANK-TIE BAR
CRANK-LINKAGE-SLIDING
PIN-PIVOT-PRIMARY
ROD-LINKAGE-(1738MM)
ROD END-LH
ROD END-RH
ROLL PIN
BOLT- M24 x 120 10.9
BOLT- M20 x 100 10.9
BOLT- M20 x 60 10.9
BOLT- 3/4” x 5” Gr 8
BOLT- 3/4” x 4 1/2” Gr 8
NUT- LOCKING-LH
NUT- LOCKING-RH
NUT- M24-NYLOC
NUT- M20-NYLOC
NUT- NYLOC-3/4”
WASHER-HARDENED-M24
WASHER-HARDENED-M20
2
2
2
2
2
2
2
2
4
4
4
4
2
2
2
2
4
8
4
8
24

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EX2500-FRS 3-8-15
FOLDING RETRACTABLE STAIRWAY
To suit Hitachi EX2500 Excavator
Section 4-6 Hydraulic Cylinders PS-63009-ASSY.