Power Step PSA-WA1200-FS User manual

FOLDING STAIRWAY
Manual for Komatsu WA1200
PSA-KOM-WA1200-FS 30-8-18A
Model No.:PSA-WA1200-FS
Serial No.:WA1200-FS-001C
Date Manufactured:

CONTENTS
Page 3Section 1 Installation and Mounting Instructions
Installation Drawings
8Section 2 Recommended Maintenance procedure
9Section 3 Operating Procedure
Section 4 Drawings and Repair Parts lists
10 4 Assembly Complete
Parts List
12 4-1 Base Frame and Mounting Assembly
Parts List
14 4-2 Stair Assembly
Parts List
16 4-3 Latch Assembly
Parts List
18 4-4 Hydraulic Cylinder
Parts List
Valve Diagram
21 4-5 Power Pack
Parts List
25 4-6 Electrical Controls
Parts Lists
Wiring Diagrams
Pg2
PSA-KOM-WA1200-FS 30-8-18A
FOLDING STAIRWAY
Komatsu WA1200 Loader

FOLDING STAIRWAY
Komatsu WA1200 Loader
Section 1 Installation and Mounting Instructions
As per Drawing PSA-WA1200-CW : Sheet 1 of 3 Page 4
Stair Mounting Pads Installation Procedure
1. Bolt on pads (CO2 + CO3) with the template (CO4) plate supplied. If they are not
already done from factory. You may have to add extra washers as the bolts could
be too long. VIEW X
2. Clean the paint where the weld will be applied, to avoid contamination.
3. Position the assembled template with pads in a way so that the pads faces sit with
no clearance to the skin of the machine CW. The top lip of the template should sit
on the top face of the OEM landing. VIEW Z
4. Check dimension is 305mm to the edge of the CW body as shown in VIEW Z. Tack
weld pads to skin of CW.
5. Unbolt and remove template. Weld pads with an 8mm fillet all around. Follow
welding procedure for cold weather.
As per Drawing PSA-WA1200-CW : Sheet 2 of 3 Page 5
Stair To Mounting Pads Installation Procedure
1. Fit base mounting plate (A01) against mounting pads and bolt firmly with the 8 Bolts
M20x60 supplied.
2. Lift stair (in lowered position) and align 4 threaded bars and push firmly against
base mounting plate. Insert washers and nuts to the threaded bar and tighten nuts
firmly. Assure the rubber isolators are in place on the stair and fit the bolt supplied
to fix them.
3. Fit extension steps as required to reach the minimum standard height from the
ground.
NOTE
Follow all on-site/Mine lifting and safety procedures when installing
PSFS to Loader
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PSA-KOM-WA1200-FS 30-8-18A

FOLDING STAIRWAY
Komatsu WA1200 Loader
Section 1 Installation Instructions - Drawing PSA- WA1200-CW Sheet. 1
Stair Mounting Pads See Procedure Pg. 3
Pg4
PSA-KOM-WA1200-FS 30-8-18A

FOLDING STAIRWAY
Komatsu WA1200 Loader
Section 1 Installation Instructions Drawing PSA- WA1200-CW Sheet. 2
Stair Mounting Pads See Procedure Pg. 3
Floor and Handrails
Pg5
PSA-KOM-WA1200-FS 30-8-18A

FOLDING STAIRWAY
Komatsu WA1200 Loader
Section 1 Installation Instructions - Drawing PSA- WA1200-CW Sheet. 3
Pg6
PSA-KOM-WA1200-FS 30-8-18A

FOLDING STAIRWAY
Komatsu WA1200 Loader
Section 1 Installation and Mounting Instructions (cont.)
Pg7
PSA-KOM-WA1200-FS 30-8-18A
WARNING
Raising the POWER STEP platform 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 platform must be used,
please follow the following instructions:
Loosen hard plumbed hydraulic lines on cylinder side of lock valve on cylinder.
Raise platform by available means.
Note: Make necessary arrangements to collect displaced oil, and be aware that air enters
the piston side of the cylinder as platform is raised.
Lock in raised position.
Re-tighten hydraulic fittings.
SECURE THE PLATFORM 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 platform 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 valves to restriction fittings.
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 STAIRWAY
Komatsu WA1200 Loader
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 2 grease nipples on 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 (5.0 litres)
It is recommended that the same hydraulic oil be used in the power pack as the
hydraulics of the machine.
Check and inspect all main bolts on stairway system.
Retorque if required.
Repeat daily check as above
Pg8
PSA-KOM-WA1200-FS 30-8-18A

FOLDING STAIRWAY
Komatsu WA1200 Loader
Section 3 Operating Procedure
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 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 truck 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 ladder with caution.
To Raise Stairway
Ascend the ladder onto the landing of the Loader.
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.
Pg9
PSA-KOM-WA1200-FS 30-8-18A
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.

Pg10
PSA-KOM-WA1200-FS 30-8-18A
FOLDING STAIRWAY
Komatsu WA1200 Loader
Section 4 Assembly Complete PSA-WA1200-FS

FOLDING STAIRWAY
Komatsu WA1200 Loader
Section 4 Assembly Complete PSA-WA1200-FS
See Drawing Page 10
Pg11
PSA-KOM-WA1200-FS 30-8-18A
ITEM PART NO. PART NAME QTY
PSA-WA1200-FS ASSEMBLYCOMPLETE 1
1PS-23838-A STAIR BASE FRAME 1
2PS-23851-A STAIR ASSEMBLY1
3PS-23847-A LATCH ASSEMBLY1
4PS-62996-A HYDRAULIC CYLINDERS (Stair) 1
5PS-80103A-SLD POWER PACK 1

Pg12
PSA-KOM-WA1200-FS 30-8-18A
FOLDING STAIRWAY
Komatsu WA1200 Loader
Section 4.1 Base Frame and Mounting Assembly PS-23838-A
See Parts List Pg. 13

FOLDING STAIRWAY
Komatsu WA1200 Loader
Section 4.1 Base Frame and Mounting PS-23838-A
See Drawing Page 12
Pg13
PSA-KOM-WA1200-FS 30-8-18A
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
25
26
27
28
29
30
31
32
33
34
PS-23838
PSA-WA1200-C01
PSA-WA1200-C02
PSA-WA1200-C03
PS-23839
PS-23841-98
PS-23841-99
PS-23854
PS-23828
PS-23836-02
PS-23834-01
PS-23833-99
PS-23836-01
PS-23846-02
PS-23846-03-8
PS-23860
PS-1066553
PS-23834-03
PS-M20X250
CPS-M20X60ZP
CPS-M16X30ZP
CPS-M12X75ZP
CPS-M12X40ZP
CPS-M12X25ZP
CPS-M12X20ZP
CPS-M8X35ZP
CPS-M20NZP
PS-M12NZP
PS-M8NZP
CPS-M20WH
CPS-M16WH
CPS-M12WH
CPS-M8WH
PS-61002-2
BASE FRAME
BASE MOUNTING PLATE
WELD PAD-OUTER
WELD PAD -INNER
TOP STAIR TREAD
STRIKER-LEFT SIDE
STRIKER-RIGHT SIDE
MANUAL RELEASE LEVER
HINGE PIN
SHEAR ISOLATOR ELEMENT
SHEAR ISOLATOR CAP
ISOLATOR COVER PLATE
FACE ISOLATOR ELEMENT
LATCH BUSH
RELEASE LEVER SPACER
LIFT LUG
LATCH LEVER BUFFER Mackay 12252555 M6
FACE ISOLATOR WASHER
THREADED ROD-M20 x 250
BOLT-M20 x 60
BOLT-M16 x 30
BOLT-M12 x 75
BOLT-M12 x 40
BOLT-M12 x 25
BOLT-M12 x 20
BOLT-M8 x 35
NUT-M20
NUT-M12
NUT-M8
WASHER-HARDENED-M20
WASHER-HARDENED-M16
WASHER-HARDENED-M12
WASHER-HARDENED-M8
GREASE NIPPLE
1
1
2
1
1
1
1
1
2
4
4
8
8
4
1
2
2
8
4
6
4
1
1
4
8
1
4
2
1
6
4
16
1
2
PS-23838-A (Inc.Items 1,5,6,7,8,9,10,11,12,13,14,15,17,18,22,23,24,25,26,27,28,29,32,33 & 34)

FOLDING STAIRWAY
Komatsu WA1200 Loader
Section 4-2 Stair Assembly PS- 23851-A
See Parts List Page 15
Pg14
PSA-KOM-WA1200-FS 30-8-18A

FOLDING STAIRWAY
Komatsu WA1200 Loader
Section 4-2 Stair Assembly PS- 23851-A
See Drawing Page 14
Pg15
PSA-KOM-WA1200-FS 30-8-18A
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
25
26
PS-23852
PS-23862
PS-23863
PS-23849
PS-22266
PS-23839
PS-23857
PS-23848-07
PS-40002
PS-40003
PS-63009-B
PS-23862-05-3
PS-23865-LH
PS-23865-LH
CPS-M12X75ZP
CPS-M12X30ZP
CPS-M12X20ZP
CPS-M10X85ZP
CPS-M8X75ZP
CPS-M6X15ZP
CPS-M12NZP
CPS-M10NN
CPS-M8NN
CPS-M12WH
CPS-M10WH
CPS-M8WH
STAIR STILE (6 Tread)
STAIR HANDRAIL
HANDRAIL LINK POST
STAIR ACTUATOR BEAM
STAIR TREAD
STAIR TREAD -TOP
HINGE BUSH
BUMPER PAD
BUFFER-RUBBER-MACKAYM12402055 M8
BUFFER-RUBBER-MACKAYM12503555 M10
BUSH-Stair Actuator Beam
WASHER
STAIR EXTENSION-LEFT
STAIR EXTENSION-RIGHT
BOLT-M12 x 75
BOLT-M12 x 30
BOLT-M12 x 20
BOLT-M10 x 85
BOLT-M8 x 75
BOLT-M6 x 15
NUT-M12
NUT-NYLOC-M10
NUT-NYLOC-M8
WASHER-HARDENED-M12
WASHER-HARDENED-M10
WASHER-HARDENED-M8
1set
1set
1
1
7
1
2
2
2
2
1
4
1
1
4
16
20
4
2
4
4
6
6
36
4
2

Pg16
PSA-KOM-WA1200-FS 30-8-18A
FOLDING STAIRWAY
Komatsu WA1200 Loader
Section 4-3 Latch Assembly PS-23847-ASSY
See Drawing Page 17

FOLDING STAIRWAY
Komatsu WA1200 Loader
Section 4-3 Latch Assembly PS-23847-ASSY
See Drawing Page 16
Pg17
PSA-KOM-WA1200-FS 30-8-18A
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
25
26
PS-62997
PS-23842
PS-23845-99
PS-23845-98
PS-23844-01-10
PS-23843
PS-23846-02
PS-23846-01
PS-23847
PS-23844-02-5
PS-S245
PS-75430
PS-M12X110ZP
CPS-M12X55ZP
CPS-M12X40ZP
CPS-M12X35ZP
CPS-M12X25ZP
CPS-M10X75ZP
CPS-M10X15ZP
CPS-M5X45ZP
CPS-M12NZP
CPS-M10NZP
CPS-M5NN
CPS-M12WH
CPS-M10WH
CPS-M5WH
CYLINDER
LATCH BASE
LATCH WRIST
ACTUATOR ARM
BOLT LINK
LATCH BOLT
LATCH BUSH
WRIST SPACER
SPRING
WASHER
LATCH BUSH-(WRIST PLATE) S245
PROXIMITY SWITCH
BOLT-M12 x 110
BOLT-M12 x 55 (Striker)
BOLT-M12 x 40
BOLT-M12 x 35
BOLT-M12 x 25
BOLT-M10 x 75
BOLT-M10 x 15
BOLT-M5 x 50
NUT-M12
NUT-M10
NUT-NYLOC-M5
WASHER-HARDENED-M12
WASHER-HARDENED-M10
WASHER-M5
1
1
1
1
2
2
6
2
2
4
2
1
1
1
4
1
4
2
4
2
1
6
2
12
6
2

FOLDING STAIRWAY
Komatsu WA1200 Loader
Section 4-4 Hydraulic Cylinders and Plumbing
Cyl P/No. PS- 62996-AH
See Parts list Pg. 19 Latch Cyl PS- 62997-A
Pg18
PSA-KOM-WA1200-FS 30-8-18A

FOLDING STAIRWAY
Komatsu WA1200 Loader
Section 4-4 Hydraulic Cylinders & Plumbing
See Drawing Pg. 18
Pg19
PSA-KOM-WA1200-FS 30-8-18A
STAIR & LATCH CYLINDERS
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
PS-62996-A
PS-63103
PS-62997
PS-62997-SK
PS-23856
PS-63201
PS-61140
PS-61145
PS-61149
PS-61150
PS-61151
PS-61152
PS-61153
PS-61154
PS-61157
PS-61158-5mm
PS-61159
PS-61163
PS-61160
PS-60051-1.2M 9/16
PS-60050-1.2M 7/16
PS-60051-1.65M 9/16
PS-60050-1.8M 7/16
PS-60031-FT
HYDRAULIC CYLINDER ASSEMBLY
SEAL KIT-STAIR (NOT SHOWN)
HYDRAULIC CYLINDER - LATCH
SEAL KIT-LATCH (NOT SHOWN)
CYLINDER PINS
VALVE - PILOT OPERATED LOCKING
FITTING-T -7/16”
FITTING - 9/16” JIC SWIVEL
FITTING - T 9/16”
FITTING - ELBOW 7/16”
FITTING - ELBOW 7/16”
FITTING - ELBOW 9/16”
FITTING - 1/4” BSPPx7/16” STRAIGHT
FITTING - ELBOW- O RING 1/4BSPPx9/16”JIC
FITTING - STRAIGHT 1/4”BSPPx9/16”JIC
FITTING - 5mm RESTRICTION 90 DEG
FITTING- ELBOW 9/16”
REDUCER JIC x BSPP
TUBE-900/1200
HOSE-HYDR. (9/16”JIC ST. SWIVEL 1.2M)
HOSE-HYDR. (7/16”JIC ST. SWIVEL 1.2M)
HOSE-HYDR. (9/16”JIC ST. SWIVEL 1.65M)
HOSE-HYDR. (7/16”JIC ST. SWIVEL 1.8M)
FERRULES
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
2
3
2
1
1
1
1
1
2
MOUNTINGS
Item Part No. Part Name Qty
1
2
PS-23855-98
PS-23855-02-5
PORT SHIELD PLATE
PORT SHIELD CLAMP
1
2
PS-62996-HPK-FS Hard Plumbing Kit (Items 4, 6, 9, 11 - 15, 17 & 22)

FOLDING STAIRWAY
Komatsu WA1200 Loader
Section 4-4 Hydraulic Cylinder (Valve Diagram)
Pg20
PSA-KOM-WA1200-FS 30-8-18A
Double Acting Hydraulic System with
directional Control Valve and Cylinder
Lock Valve