Power Step Cat 980G User manual

PSA-CAT-980G-FL 21-11-12
FOLDING STAIRWAY
Manual for Cat 980G Wheel Dozer
Model No.: PSA-CAT980G-FL
Serial No.: 980G - FL- 001 - ~
Date Manufactured: 2012

FOLDING STAIRWAY
Cat 980G Wheel Dozer
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PSA-CAT-980G-FL 21-11-12
CONTENTS
Page 3Section 1 Mounting and Installation
Drawings and Notes
18 Section 2 Recommended Maintenance Procedure
19 Section 3 Operating Procedure
Section 4 Drawings and Repair Parts lists
20 4 Assembly Complete
22 4-1 Mounting Column Assembly
Parts List
24 4-2 Ladder Assembly
Parts List
29 4-3 Hydraulic Cylinder
Valve Diagram
Parts List
29 4-4 Power Pack
Parts List
32 4-5 Electrical System
Controls
Wiring Diagrams

INSTALLATION PROCEDURE
1. Remove the handrails, access ladder, floor and skirt from the landing on the left
hand side of the loader.
2. Fit mounting components per Drg 24 640 (See page 5)
3. Fit the Mounting Column per Drg 24 641 (See page 7)
4. Fit the Mounting Column Braces per Drg 24 642 (See page 10)
5. Modify and re-instet left side landing per Drg 24 643 (See page 14)
6. Fit the Ladder Set per Drg 24 644. (See page 15)
7. Re-instate/modify the landing handrails and install the hydraulic power unit per Drg
24 645. (See page 16)
All welding must comply with AS1554 Cat SP unless specifically directed otherwise.
Vary the order of activities set out above and on the listed drawings if necessitated by site
practicalities, such as availability of cranes etc
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PSA-CAT-980G-FL 21-11-12
FOLDING STAIRWAY
Cat 980G Wheel Dozer
Section 1. Mounting and Installation PS-24639
NOTE
Follow all on-site/Mine lifting and safety procedures when installing
PSFS to Dozer.

FOLDING STAIRWAY
Cat 980G Wheel Dozer
Section 1. Mounting and Installation Mountings PS-24640
Pg 4
PSA-CAT-980G-FL 30-1-13
See Drawings Pg 5 and 6
PROCEDURE
1. Support the fuel tank with blocks and/or jacks to suit. Per View 1,remove the 3
bolts that attach the underside of the fuel tank to the chassis of the machine.
Compare threads of original bolts and Tank Studs. If identical, fit the Tank Studs to
replace the bolts. Per View 2.2, fit the bottom mounting block. Do the same for the
top tank mounting - View 2.1
NOTE THATthe tank might be constructed with it’s back wall continuing down past the
tank floor to the alignment of the bottom mounting boltsper View 1 and View 6.1, or it
might be constructed with the wall plate terminating at floor level per View 6.2. There is
a rebate in the back of the Bottom Mounting Block 23 901 02 to accomodate the continued
back wall plate. If the wall plate terminates at floor level, the Mounting Block Spacer
24 637 should be attached to the Mounting Block per View 6.2 to fill the rebate.
2. Per View 3, check that the M12 tapped holes in the top mounting block are aligned
with the holes in the bottom mounting block. Adjust to suit using the slotted holes in
the mounting blocks. Tighten the nuts on the studs.
3. Per Views 4.1 & 4.2, fit the top and bottom mounting angles to the mounting
blocks.
4. Per Views 5.1 & 5.2, fit the isolators, already assembled with isolator fingers. Note
that the top and bottom isolator fingers are not the same and all have to be fitted
the right way up.
5. Apply post-tightening thread locking compound to all bolts
Use safe lifting and working practices at all times.
NOTE
Follow all on-site/Mine lifting and safety procedures when installing
PSFS to Dozer.

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PSA-CAT-980G-FL 30-1-13
FOLDING STAIRWAY
Cat 980G Wheel Dozer
Section 1. Mounting and Installation Mountings PS-24640 Sht. 1
VIEW 3
VIEW 6.2
VIEW 6.1

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PSA-CAT-980G-FL 21-11-12
FOLDING STAIRWAY
Cat 980G Wheel Dozer
Section 1. Mounting and Installation Mountings PS-24640 Sht. 2
VIEW 2.1
VIEW 1
VIEW 4.1
VIEW 2.2
VIEW 5.1
VIEW 4.2
VIEW 5.2

FOLDING STAIRWAY
Cat 980G Wheel Dozer
Section 1. Mounting and Installation Mounting Frame PS-24641 Sht.1
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PSA-CAT-980G-FL 30-1-13
NOTE
Follow all on-site/Mine lifting and safety procedures when installing
PSFS to Dozer.
Z
Y

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PSA-CAT-980G-FL 30-1-13
FOLDING STAIRWAY
Cat 980G Wheel Dozer
Section 1. Mounting and Installation Mounting Frame PS-24641 Sht.2
DETAIL Y

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PSA-CAT-980G-FL 30-1-13
FOLDING STAIRWAY
Cat 980G Wheel Dozer
Section 1. Mounting and Installation Mounting Frame PS-24641 Sht.3
DETAIL Z

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PSA-CAT-980G-FL 30-1-13
FOLDING STAIRWAY
Cat 980G Wheel Dozer
Section 1. Mounting and Installation Handrails PS-24642 Sht. 1 of 4
PROCEDURE.
1. Per Views 1.1 - 1.4, 2.1 & 2.2 and 3.0, fit the Front Brace and Rear Brace,
clamping the split clamp rings around the raised hubs of the cabin mounting
isolators on the mounting plates on top of the top of the left side chassis member.
NOTE. Orientate the Braces per the instructions given on View 1.1, that is with the
straight run of the Rear Brace parallel with the front panel of the mudguard and the Front
Brace parallel with the fuel tank and/or at 55 Deg to the centre line of the machine, but
change their orientation if necessitated by the shape and encumbrance of the landing
frame (see Drawing 24 643).
NOTE ALSO. It will be necessary to cut an opening in a mudguard panel
to allow the Rear Hold-Down Cleat to lie towards the back of the rear
cabin mounting plate, per Detail 5.0
2. Weld around Brace Isolator T-Plates on top surface of top Mounting Frame
Arm per Detail 4.0.
3. Fit the Brace Hold-Down components per Views 6.1 & 6.2
4. Apply post-tightening thread locking compound to the clamp bolts and the
hold-down bolts.
All welding must comply with AS1554 Cat SP unless specifically directed otherwise.
Use safe lifting and working practices at all times.
NOTE
Follow all on-site/Mine lifting and safety procedures when installing
PSFS to Dozer.

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PSA-CAT-980G-FL 30-1-13
FOLDING STAIRWAY
Cat 980G Wheel Dozer
Section 1. Mounting and Installation Handrails PS-24642 Sht. 2
VIEW 1.2
VIEW 1.4
VIEW 1.1
VIEW 1.3
DETAIL 4.0

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PSA-CAT-980G-FL 30-1-13
FOLDING STAIRWAY
Cat 980G Wheel Dozer
Section 1. Mounting and Installation Handrails PS-24642 Sht. 3
VIEW 5.0
VIEW 2.1
VIEW 3.0
VIEW 2.2

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PSA-CAT-980G-FL 30-1-13
FOLDING STAIRWAY
Cat 980G Wheel Dozer
Section 1. Mounting and Installation Handrails PS-24642 Sht. 4
VIEW 6.1
VIEW 6.2

PROCEDURE.
1. Fit the Ladder Set to the Mounting Frame, per View 1.0 & Detail 1.1
NOTE that the ladder back plate could be erroneously bolted to the mounting frame using
boltholes (in the backplate) intended for fitment of the ladder on other machines. Fit the
ladder back plate as shown on Detail 1.1
2. Fit the Flooring Infill as shown in View 2.0 and Detail 2.1. Fit bolts to the back of
the Mounting Frame bolting plate, already fitted with Clamp Plates and washers and
slide the Flooring Infill down vertically from above. Tighten the bolts. Bolt the
Floor Mounting Angle to the bolting plate. Weld the Floor Mounting Angle to the
Flooring Infill, to suit.
NOTE that the floorplate extension on the otherwise gridmesh Flooring Infill might have to
be trimmed to fit in the space available.
Mesh Clamps or welding can be used to attach mesh to ‘L’Brackets
Use safe lifting and working practices at all times.
Pg 14
PSA-CAT-980G-FL 30-1-13
FOLDING STAIRWAY
Cat 980G Wheel Dozer
Section 1. Mounting and Installation Re-Instate Landing PS-24643
Cut notches to suit in left side Landing Frame to accommodate ladder mounting
components, especially the Front Brace and Mounting Frame, but also other components
as required. Re-install Landing Frame and Deck Plate.
If the Landing Frame is significantly weakened by the notches cut in it’s sides, reinforce it
to suit.
Ladder Set PS-24644 See Dwg Pg 15
NOTE
Follow all on-site/Mine lifting and safety procedures when installing
PSFS to Dozer.

Pg 15
PSA-CAT-980G-FL 30-1-13
FOLDING STAIRWAY
Cat 980G Wheel Dozer
Section 1. Mounting and Installation Ladder Set PS-24644
VIEW 1.0 VIEW 2.0
DETAIL 1.1
DETAIL 2.1

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PSA-CAT-980G-FL 30-1-13
FOLDING STAIRWAY
Cat 980G Wheel Dozer
Section 1. Mounting and Installation Handrails PS-24645
VIEW 1 VIEW 2 VIEW 3

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PSA-CAT-980G-FL 30-1-13
FOLDING STAIRWAY
Cat 980G Wheel Dozer
Section 1. Mounting and Installation - Bumpers
Ladder Bumpers
The rubber bumpers fitted to the ladder styles must be adjusted so that when the ladder is
stowed it is firm and prevents any movement which can cause wear.
For lateral position use packers.
NOTE
Follow all on-site/Mine lifting and safety procedures when installing
PSFS to Dozer.
Ladder lowered
Packers as
required
Ladder stowed

FOLDING STAIRWAY
Cat 980G Wheel Dozer
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 grease nipples on Stair 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.
It is recommended that the same hydraulic oil be used in the power pack as the
hydraulics of the machine.
Grease grease nipples on Stair Hinge Pins.
Check and inspect all main bolts on stairway system.
Retorque if required.
Repeat daily check as above.
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PSA-CAT-980G-FL 30-1-13

FOLDING STAIRWAY
Cat 980G Wheel Dozer
Section 3. Operating Procedure
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PSA-CAT-980G-FL 30-1-13
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 Stair Access System is clear of people and
obstacles, and lower Stair by operating the two position electrical switch adjacent
to the stair, to the down position by pressing the switch down.
Hold the switch in the down position until Stair is fully lowered.
If the Dozer 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 Stair with caution.
To Raise Stairway
Ascend the Stair onto the landing of the Dozer.
Ensure the area around the Stair is clear of people and standing to the side, clear
of the area the handrails and Stair raises into, operate the electrical switch to the
raise position (up).
Hold the switch in the up position until the Stair is in the fully raised position.
The Stair 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.

FOLDING STAIRWAY
Cat 980G Wheel Dozer
Section 4. Assembly Complete - Main Assemblies
See Pg 21
Pg 20
PSA-CAT-980G-FL 30-1-13
Item Part No. Part Name Qty
1
PSA-980G-FL
PS-24625A
ASSEMBLYCOMPLETE
MOUNTING COLUMN ASSEMBLY
REFER TO 4.1 FOR DETAILS 1
2PS-23894A LADDER SET ASSEMBLY
(INC.HANDRAILS)
REFER TO 4.2 FOR DETAILS
1
3PS-62999-AH HYDRAULIC CYLINDER
REFER TO 4.3 FOR DETAILS 1
4PS-80103A-SLD POWER PACK
REFER TO 4.4 FOR DETAILS 1