Power Step PSA-EX5500-FRS User manual

Hitachi EX 5500 3-8-15
FOLDING RETRACTABLE STAIRWAY
Manual for Hitachi EX5500 Excavator
Model No.:PSA-EX5500-FRS
Serial No.:
Date Manufactured:

FOLDING RETRACTABLE STAIRWAY
To suit Hitachi EX5500 Excavator
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Hitachi EX 5500 3-8-15
CONTENTS
Page 3Section 1 Installation Notes
Installation Drawings
9Section 2 Operating Procedure
10 Section 3 Recommended Maintenance Procedure
Section 4 Drawings and Repair Parts lists
11 4-1 Assembly Complete
Parts List
13 4-2 Mounting Assembly
Parts List
15 4-3 Landing Assembly
Parts List
17 4-4 Stair Upper Assembly
Parts List
19 4-5 Stair Lower Assembly
Parts List
21 4-6 Pivot Assembly
Parts List
23 4-7 Hydraulic Cylinder Assembly
Parts List
26 4-8 Power Pack Assembly
Parts List
29 4-9 Electrical Controls
Parts List
Wiring Diagrams

FOLDING RETRACTABLE STAIRWAY
To suit Hitachi EX5500 Excavator
Section 1 Installation Notes and Drawings
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Hitachi EX 5500 3-8-15
PROCEDURE
See Drawing 21-591 Walkway modifications Page 4
1. Remove ladder module.
2. Cut holes in landing skins front and back of ladder module, on machine with
template or on ground with measurements.
The fascia beam is fully exposed.
See Drawings 21 910 & 21 911Page 5 & 6
1. Cut holes in front and back of fascia beam.
2. Fit plates into box beams that support fascia beam. Weld gussets
into corners & bolt sealer plates onto gussets. Gussets are there to take
away sharp corners in holes in back plate of fascia. Sealers are there to
keep rain out of box beams.
3. Box in the open spaces between front & back of fascia.
See Drawing 21 912 Page 7
1. Cut holes in original walkways per Drg 21 591
2. Fit Support Arms 21 585 to Bolting Plates fitted per Drg 21 911, Fit bolted-in Closer.
See View 2.
3. Re-install original walkways per View 3.
4. Per View 4, fit Landing Mounting Plate 21 586B, Ladder Peplacement
Platform 21 592, Skirt Panel 21 593 and Wlkway Support brackets
21 587
5. (Not shown.) Fit RFS Landing and Stairs and related handrails.
Refer to drg 21 594 for bolt details.
NOTE
Follow all on-site/Mine lifting and safety procedures when installing
PSFS to Excavator.

FOLDING RETRACTABLE STAIRWAY
To suit Hitachi EX5500 Excavator
Section 1 Installation Notes and Drawings PS-21591
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Hitachi EX 5500 3-8-15

FOLDING RETRACTABLE STAIRWAY
To suit Hitachi EX5500 Excavator
Section 1 Installation Notes and Drawings PS-21910
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Hitachi EX 5500 3-8-15

FOLDING RETRACTABLE STAIRWAY
To suit Hitachi EX5500 Excavator
Section 1 Installation Notes and Drawings PS-21911
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Hitachi EX 5500 3-8-15

FOLDING RETRACTABLE STAIRWAY
To suit Hitachi EX5500 Excavator
Section 1 Installation Notes and Drawings PS-21912
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Hitachi EX 5500 3-8-15

FOLDING RETRACTABLE STAIRWAY
To suit Hitachi EX5500 Excavator
Section 1 Stair General Arrangement PS-21099
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Hitachi EX 5500 3-8-15

FOLDING RETRACTABLE STAIRWAY
To suit Hitachi EX5500 Excavator
Section 1 Operating Procedure
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Hitachi EX 5500 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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Hitachi EX 5500 3-8-15
FOLDING RETRACTABLE STAIRWAY
To suit Hitachi EX5500 Excavator
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 all grease nipples. Lower or raise stairway for accessibility.
Check hydraulic oil level in power pack and top up as necessary. (Stairway in
lowered position).
Check main mounting bolts for torque.
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
Check all M12 bolts & nuts holding rubber isolators to body and rear support plate
of truck.
These can be checked by hand.
Repeat daily check as above.

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Hitachi EX 5500 3-8-15
FOLDING RETRACTABLE STAIRWAY
To suit Hitachi EX5500 Excavator
Section 4 Assembly Complete

FOLDING RETRACTABLE STAIRWAY
To suit Hitachi EX5500 Excavator
Section 4 Assembly Complete
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Hitachi EX 5500 3-8-15
ITEM PART NO. PART NAME QTY
1 - MOUNTING ASSEMBLY1
2PS-21079-55-A LANDING ASSEMBLY1
3PS-21843-A STAIR - UPPER - ASSEMBLY1
4PS-21572-A STAIR - LOWER - ASSEMBLY1
5PS-35029 PIVOT ASSEMBLY1
6PS-63009-ASSY HYDRAULIC ASSEMBLYCOMPLETE 1
7PS-80104P-RFS HYDRAULIC POWER UNIT - ASSEMBLY
(INCLUDING CRADLE) 1

FOLDING RETRACTABLE STAIRWAY
To suit Hitachi EX5500 Excavator
Section 4-2 Mounting Assembly
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Hitachi EX 5500 3-8-15

FOLDING RETRACTABLE STAIRWAY
To suit Hitachi EX5500 Excavator
Section 4-2 Mounting Assembly
Parts List
See Drawing Page 13
Hitachi EX 5500 3-8-15 Pg14
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-21592-01
PS-21593
PS-21585
PS-21586
PS-21584-01
PS-21589
PS-M24X110MM
PS-M24X100MM
PS-M24X70MM
CPS-M16X40MM
CPS-M12X80MM
CPS-M12X30MM
PS-M24NZP
PS-M16NZP
CPS-M12NZP
PS-M24WH
CPS-M16WHH
CPS-M12WHH
WALKWAY STEP
GRID- STEP - TOP
GRID- STEP - BOTTOM
TRIM PANEL
SKIRT PANEL
SUPPORT - ARM
LANDING PLATE
WELD IN BOLTING PLATE
SPANNER PLATE
BOLT-M24 x 110
BOLT-M24 x 100
BOLT-M24 x 70
BOLT-M16 x 40
BOLT-M12 x 80
BOLT-M12 x 30
NUT-M24
NUT-M16
NUT-M12
WASHER - HARDENED- M24
WASHER - HARDENED- M16
WASHER - HARDENED- M12
1
.
.
.
1
2
1
2
4
8
22
4
8
4
6
34
8
10
64
16
20

FOLDING RETRACTABLE STAIRWAY
To suit Hitachi EX5500 Excavator
Section 4-3 Landing Assembly PS-21079-55-A
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Hitachi EX 5500 3-8-15

FOLDING RETRACTABLE STAIRWAY
To suit Hitachi EX5500 Excavator
Section 4-3 Landing Assembly PS-21079-55-A
Parts List
See Drawing Page 15
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Hitachi EX 5500 3-8-15
Item Part No. Part Name Qty
1
2
3
4
5
6
7
8
9
PS-21079
PS-21583-LHR
PS-21055
PS-M24X100ZP
CPS-M12X30ZP
CPS-W 1”
PS-M24NZP
PS-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

FOLDING RETRACTABLE STAIRWAY
To suit Hitachi EX5500 Excavator
Section 4-4 Stair - Upper Assembly PS- 21843-A
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Hitachi EX 5500 3-8-15

FOLDING RETRACTABLE STAIRWAY
To suit Hitachi EX5500 Excavator
Section 4-4 Stair - Upper Assembly PS- 21843-A
Parts List
See Drawing Page 17
Hitachi EX 5500 3-8-15 Pg18
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-21843
PS-21583-USH
PS-21556
PS-21043
PS-21044
PS-21077
PS-40001
PS-21844
PS-21056
CPS-M10X100PR
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-M12 x 30
WASHER-HARDENED-M12
NUT-M12
FRS-SPRING SET (Not included in Assy)
NON-SLIP NOSING (Not included in Assy)
1
2
7
4
2
2
4
1
1
2
2
2
18
32
100
58
1
6
(1Set of 2)

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FOLDING RETRACTABLE STAIRWAY
To suit Hitachi EX5500 Excavator
Section 4-5 Stair Lower Assembly PS-21572-A
Hitachi EX 5500 3-8-15

FOLDING RETRACTABLE STAIRWAY
To suit Hitachi EX5500 Excavator
Section 4-5 Stair Lower Assembly PS-21572-A
Parts List
See Drawing Page 19
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Hitachi EX 5500 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
124
62
8