Power Step PSA-EX3600-FRS User manual

EX3600-FRS 3-8-15
FOLDING RETRACTABLE STAIRWAY
Manual for Hitachi EX3600 Excavator
Model No.: . PSA-EX3600-FRS
Serial No.: ~
Date Manufactured:

Pg2
FOLDING RETRACTABLE STAIRWAY
To suit Hitachi EX3600 Excavator
EX3600-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
94-1 Assembly complete
Parts List
11 4-2 Mounting Assembly
Parts List
12 4-3 Landing Assembly
Parts List
14 4-4 Stair - Upper Assembly
Parts List
16 4-5 Stair - Lower Assembly
Parts List
18 4-6 Pivot Assembly
20 4-7 Hydraulic Cylinder
23 4-8 Power Pack Assembly
26 4-9 Electrical Controls
Wiring Diagrams
Optional extras

Pg3
FOLDING RETRACTABLE STAIRWAY
To suit Hitachi EX3600 Excavator
EX3600-FRS 3-8-15
Section 1
Installation Notes
Remove ladder module + landing/ww (walkway) panel in front, exposing what I
call the fascia beam. (In front as in, towards the front of the machine).
Per 21 569
- cut through the front and back of the fascia beam.
- fit the big plate into the now-open beam.
- fit the cleat mountings to the face of the fascia beam.
- box in the space between the front and back plates of the fascia.
beam.
Modify the removed landing/ww per 21 565 and put it back where it came off.
Template 21 578.
Bolt the main mtg plate to the plate inside the beam per 21 562. DON'T RISK
ARM/HAND BY REACHING IN TO LOCATE NUTS - USE 21 573 to reach in, at least
for the first two.
Fit struts per 21 568 and then our landing to the big plate and also skirt
21 566 behind/beneath our landing (to pretty up the external view). Also the
separate floor piece that goes into the space where the ladder module floor
was - leveling if necessary.
NOTE
Follow all on-site/Mine lifting and safety procedures when installing
PSFS to Truck.

FOLDING RETRACTABLE STAIRWAY
To suit Hitachi EX3600 Excavator
Installation Drawings - Mounting Mods. 21.569
Pg4
EX3600-FRS 3-8-15

FOLDING RETRACTABLE STAIRWAY
To suit Hitachi EX3600 Excavator
Installation Drawings - Mounting Position
Pg5
EX3600-FRS 3-8-15

Pg6
FOLDING RETRACTABLE STAIRWAY
To suit Hitachi EX3600 Excavator
Installation Drawings - Landing and Stair Assembly
EX3600-FRS 3-8-15

Pg7
FOLDING RETRACTABLE STAIRWAY
To suit Hitachi EX3600 Excavator
EX3600-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.

Pg8
FOLDING RETRACTABLE STAIRWAY
To suit Hitachi EX3600 Excavator
Section 3 Operating Procedure
EX3600-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.

Pg9
FOLDING RETRACTABLE STAIRWAY
To suit Hitachi EX3600 Excavator
Section 4-1 Assembly Complete
EX3600-FRS 3-8-15

Pg10
FOLDING RETRACTABLE STAIRWAY
To suit Hitachi EX3600 Excavator
Section 4-1 Assembly Complete List
See Drawing Page 9
EX3600-FRS 3-8-15
ITEM PART NO. PART NAME QTY
1MOUNTING ASSEMBLY1
2PS-21079-36A LANDING ASSEMBLY1
3PS-21038-A STAIR - UPPER - ASSEMBLY1
4PS-21572-A STAIR - LOWER - ASSEMBLY1
5PS-35030-A PIVOT ASSEMBLY1
6PS-63009-ASSY HYDRAULIC ASSEMBLY1
7PS-80104P-RFS HYDRAULIC - POWER UNIT-ASSEMBLY
(INCLUDING CRADLE) 1

Pg11
FOLDING RETRACTABLE STAIRWAY
To suit Hitachi EX3600 Excavator
Section 4-2 Mounting Assembly
EX3600-FRS 3-8-15
Item Part No. Part Name Qty
1
2
3
4
5
6
7
8
9
10
PS-21562
PS-21567
PS-21566
PS-21575
PS-M24X100ZP
CPS-M12X85ZP
PS-M24NZP
CPS-M12NZP
PS-M24WH
CPS-M12WH
MOUNTING ASSEMBLY
FLOOR GRID
SKIRT
FLOORING INFILL
BOLT-M24 x 100
BOLT-M12 x 85
NUT M24
NUT M12
WASHER - HARDENED- M24
WASHER - HARDENED- M12
1
1
1
1
14
4
14
4
28
8
Parts List

Pg12
FOLDING RETRACTABLE STAIRWAY
To suit Hitachi EX3600 Excavator
Section 4-3 Landing Assembly PS-21079-36A
EX3600-FRS 3-8-15

Pg13
FOLDING RETRACTABLE STAIRWAY
To suit Hitachi EX3600 Excavator
Section 4-3 Landing Assembly PS-21079-36A
Parts List
See Drawing Page 12
EX3600-FRS 3-8-15
Item Part No. Part Name Qty
1
2
3
4
5
6
7
8
9
PS-21079
PS-21571-LHR
PS-21055
PS-M24 x 100ZP
CPS-M12 x 30ZP
CPS-M24WH
PS-M24NZP
CPS-M12WH
PS-63009-B
LANDING
HANDRAIL-LANDING
LANDING-GRID
BOLT- M24 x 100
BOLT- 12 x 30
WASHER - HARDENED - M24
NUT- M24
WASHER - HARDENED - M12
BUSHES-CLEVIS
1
1
1
8
16
16
8
16
2

Pg14
FOLDING RETRACTABLE STAIRWAY
To suit Hitachi EX3600 Excavator
Section 4-4 Stair Upper Assembly PS-21038-A
EX3600-FRS 3-8-15

FOLDING RETRACTABLE STAIRWAY
To suit Hitachi EX3600 Excavator
Section 4-4 Stair Upper Assembly PS-21038-A
Parts List
See Drawing Page 14
EX3600-FRS 3-8-15 Pg15
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-M12X35ZP
CPS-M12X30ZP
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
6Set of 2

Pg16
FOLDING RETRACTABLE STAIRWAY
To suit Hitachi EX3600 Excavator
Section 4-5 Stair - Lower Assembly PS-21572-A
EX3600-FRS 3-8-15

Pg17
FOLDING RETRACTABLE STAIRWAY
To suit Hitachi EX3600 Excavator
Section 4-5 Stair - Lower Assembly PS-21572-A
Parts List
See Drawing Page 16
EX3600-FRS 3-8-15
Item Part No. Part Name Qty
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
PS-21036-L
PS-21036-R
PS21037L
PS21037R
PS-21034L
PS-21034R
PS-21553
PS-21556
PS-21571-LSH
PS-36021
CPS-M12X35ZP
CPS-M12X30ZP
CPS-M12NZP
CPS-M12WH
PS-32266-SAN
STAIR STRINGER-LH
STAIR STRINGER-RH
STAIR-EXTENSION-LH
STAIR-EXTENSION-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
1
1
7
2
1
54
8
62
124
8

Pg18
FOLDING RETRACTABLE STAIRWAY
To suit Hitachi EX3600 Excavator
Section 4-6 Pivot Assembly PS-35030-A
EX3600-FRS 3-8-15

FOLDING RETRACTABLE STAIRWAY
To suit Hitachi EX3600 Excavator
Section 4-6 Pivot Assembly PS-35030-A
Parts List
See Drawing Page 18
EX3600-FRS 3-8-15 Pg19
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

Pg20
FOLDING RETRACTABLE STAIRWAY
To suit Hitachi EX3600 Excavator
Section 4-7 Hydraulic Cylinder Assembly PS-63009-ASSY
EX3600-FRS 3-8-15