Manual Liebherr 996 - Power Step

LIGHT STAIRWAYManual for Liebherr 996 (M.A.C.)

Model No.PSA-LIE996-L/STAIRSerial No.LIE996-001Date manufactured June 2007

CONTENTS

Page 3 Section 1 Installation and Mounting instructionsInstallation Drawings

9 Section 3 Operating Procedure

10 Section 3 Recommended Maintenance Procedure

Section 4 Drawings and Repair Parts lists

11 4 Assembly CompleteParts List

13 4-1 Stair AssemblyParts List

15 4-2 Noise Control Door AssemblyParts List

17 4-3 Main Frame AssemblyParts List

19 4-4 Portal AssemblyParts List

21 4-5 Handrail Restraint AssemblyParts List

23 4-6 Hydraulic Latch AssemblyParts List

25 4-7 Stair Bumper AssemblyParts List

26 4-8 Pad AssemblyParts List

27 4-9 Electrical Controls,Components,Switches & Wiring DiagramParts List

31 4-10 Power Pack (Hydraulic Diagram)

Pg2

LIGHT STAIRWAYLIEBHERR 996 (M.A.C.)

Pg3


Section 1

Installation and Mounting Instructions

GENERAL NOTES:While the actuator mounting is clamped but not welded to the frame, the stair may be proneto movement in the frame. Take care to avoid injury.All welding is to be Cat SP to AS 1554, 6cfw uno.Flat washer under each bolt head and nut, uno.

See Installation Drawings Pg 5 &61. Remove external acoustic enclosure (if fitted). Remove existing, original access ladder.

2. Using Mounting Frame as a template fit and weld 22631-01 Bolting Pads to the plate skinof the excavator house, per Views 1A.

3. Bolt Stair Assembly to Mounting Frame per View 2A.

4. Fit fixed handrails to excavator and Mounting Frame

5. Fit Power Unit Enclosure in position to suit near/below second window opening where itwill be accessible from floor in acoustic attenuator enclosure. Weld Bolting Pads to skin.

As per Drawing Pgs 5,6 & 7:1. Fit the acoustic enclosure with any flared skirt eliminated (provision for access on originalladder), with a 1115 wide opening down the full depth of the side and 1115 x (100) notch intop.

2. Fit Stair Mounted Acoustic Door to the underside of the lowered stairs, per View 2A.Note that the single-skinned end of the door goes to the bottom in the lowered orientation.Fit Handrail Locking Hook to lower acoustic door mountings, per View 2A.Fit seal to suit (insertion rubber or similar) around door where it contacts/approaches doorportal.

3. Fit Noise Door Guides to the door mounting frames per Views 2A, 2B and 2C aligned (witha 2.5mm gap each side) with the inside of Portal Noise Control Door.

4.Fit handrail Restraint as to Drawing 22 657 (See page 7)

NOTEFollow all on-site/Mine lifting and safety procedures when installingLight Stairway to Liebherr 996 Excavator

Pg4


Section 1

Installation and Mounting Instructions (cont.)

WARNINGRaising the POWER STEP Light Stair by external means can create a vacuum in thehydraulic 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 and to avoiddamage to the cylinders and step assembly.

In instances where the use of external means to raise the Light Stair must be used, please follow the following instructions:

Tag or lock out the Power pack assembly.Loosen hard plumbed hydraulic lines on cylinder side of lock valve on cylinder.Raise Light Stair by available means.

NOTE: Make necessary arrangements to collect displaced oil, and be aware that air entersthe piston side of the cylinder as Light Stair is raised. Lock in raised position.Tagout the POWER STEP.SECURE THE LIGHT STAIR IN THE RAISED POSITION, MECHANICALLY, CHAIN &RETIGHTEN HYDRAULIC FITTINGS.

To recommission the POWER STEP:

Connect Step to the correct lifting device.Remove the lock out device and take the load.Loosen hydraulic fittings on cylinder side of lock valve.Note: Collect displaced oil.Lower Light Stair 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 valve to restriction fitting.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 tothe incorrect operation of the lock valve).Once step is working correctly check the oil level in the Power Pack.

Clean up work area and remove all safety Tags.

Pg5


Section 1 Installation Drawing 1

Pg6



Pg7



HA

ND

RA

ILR

ES

TRA

INT

22 6

57

Pg8


Section 1 Installation Assembly Drawing

SECTION 2

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, by pressing the down switch down.Hold the switch in the down position until ladder is fully lowered.If the Excavator is parked on uneven ground, the bottom of the stairway may touchthe ground before the ladder is in the fully lowered position.Should this occur, descend the ladder with caution or raise the ladder and move themachine to a clear flat area.

To Raise StairwayAscend the ladder onto the landing of the Excavator.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) Switch.Hold the switch in the up position until the ladder is in the fully raised position.The ladder is now raised and stored.

Pg9


SECTION 3

Recommended Maintenance Procedure

DailyVisually check stairway and structure for damage, loose components, handrails, cylinder pins,split pins and up and down switches.

Check for hydraulic oil leaks from hydraulic cylinders, plumbing and hoses.Check all rubber stops.Notify the appropriate supervisor for any observed damage or malfunction.

500 HoursGrease any nipples where used.

Check and adjust all rubber stops and safety latches/ladder

Check main mounting bolts for torque.

Check hydraulic oil level in power pack and top up as necessary. (Stairway in raisedposition).

Top up using same hydraulic oil as used in hydraulics of machine.(Val 68)

Thoroughly check all electrical wiring for damage, replace as necessary.

Check all switches,up,down,slew blocks,go switches(magnetic)

Repeat daily check as above

5000 HoursChange hydraulic oil in tank of hydraulic power pack (10 litres) (Val 68)

It is recommended that the same hydraulic oil be used in the power pack as the hydraulics of the machine.

Carry out daily and 500 hour service procedure.

Check and inspect all main bolts on light stair system.Retorque if required.

Repeat daily check as above

Pg10


Pg11


Section 4 Assembly Complete

Pg12


Section 4 Assembly Complete

ITEM PART NO. PART NAME QTY

1 PS-642A STAIR ASSEMBLY 1

2 PS-641A NOISE CONTROL DOOR ASSEMBLY 1

3 PS-22643 MAIN FRAME ASSEMBLY 1

4 PS-22636 PORTAL ASSEMBLY 1

5 PS-22657 HANDRAIL RESTRAINT ASSEMBLY 1

6 PS-22693 HYDRAULIC LATCH ASSEMBLY 1

7 PS-22651 STAIR BUMPER ASSEMBLY 1

8 PS-22628A PAD ASSEMBLY 1

9 - ELECTRICAL CONTROLS, COMPONENTS,SWITCHES, WIRING DIAGRAM

1

10 PS-80104A POWER PACKHYDRAULIC DIAGRAM

1

Pg13


Section 4-1 Stair Assembly

Pg14


Section 4-1 Stair Assembly

Item Part No. Part Name Qty

123456789

10111213

PS-22642PS-22629PS-22625PS-22640PS-CB-12MMCPS-M12X215ZPCPS-M12X165ZPCPS-M12X130ZPCPS-M8X25ZPCPS-M12NNCPS-M8NNCPS-M12WHPS-S245

STAIR FABRICATIONSTAIR HANDRAILSHANDRAIL LINK POSTSTAIR TREADANTI - VIBRATION PADS (Conv. Belting)BOLT-M12 x 215BOLT-M12 x 165BOLT-M12 x 130BOLT PAN HD.M8 x 25NUT-NYLOC-M12NUT-NYLOC-M8WASHER-HARDENED-M12RUBBER BUSHES (Mackay S245)

111

162222464

1214

Pg15


Section 4-2 Noise Control Door Assembly

Pg16

LIGHT STAIRWAYLIEBHERR 996 (M.A.C.) (M.A.C.)

Section 4-2 Noise Control Door Assembly


123456789

10

PS-22641PS-22760PS-22639-98PS-22639-97PS-22645PS-22637CPS-M12X75ZPCPS-M12X25CPS-M12ZPCPS-M12WH

PANEL FABRICATIONMOUNTINGMOUNTING POSTMOUNTING POST(SPECIAL)NOISE DOOR GUIDE“J” HOOKBOLT-M12 x 75 BOLT-M12 x 25NUT-M12WASHER-HARDENED-M12

1342229

242124

Pg17


Section 4-3 Main Frame Assembly

Pg18


Section 4-3 Main Frame Assembly


123456789

1011121314

PS-22643PS-22309PS-22322PS-400043PS-22306PS-22303-06CPS-M12X30CPS-M12X25CPS-M10MMC/SCPS-M8NLCPS-M12WHPS-63016PS-61174PS-63009-P

MAIN PORTALACTUATOR MOUNTINGBUFFER BRACKETRUBBER STOPPIVOT PIN-1’ x 65MMSPACER 50OD x 26ID x 6MMBOLT-M12 x 30MMBOLT-M12 x 25MMALLEN SCREW-M10 x 75NYLOC NUT-M8WASHER-HARDENED-M12CYLINDER 2.5” 1.5”Rod 48”stroke Port 45 degFITTINGSPINS-CYLINDER

1222244822

12244

Pg19


Section 4-4 Portal Assembly

Pg20


Section 4-4 Portal Assembly


12345

6A6B789

10111213

PS-22630PS-22635PS-22620-99PS-22620-98PS-21930-10PS-22626-99PS-22626-98PS-22620-06PS-22620-07CPS-M12X25CPS-M12X20CPS-1/2”NNCPS-W008ZPCPS-M12WH

MOUNTING FRAMEFRAME INNERLOWER ISOLATOR BRACKETUPPER ISOLATOR BRACKETISOLATORHANDRAILS OUTER (opp.hands)HANDRAILS INNER (opp.hands)ISOLATOR PIN 310lg x 1/2”BMSISOLATOR PIN 225lg x 1/2”BMSBOLT-M12 x 25BOLT-M12 x 20NYLOC NUT-1/2UNCWASHER-FLAT-1/2”WASHER-M12

1122

102222

362488

40

Pg21


Section 4-5 Handrail Restraint Assembly

Pg22


Section 4-5 Handrail Restraint Assembly


123456789

10111213

PS-22655PS-22654PS-22656PS-22656-01PS-21930-10PS-22656-04 PS-M12X75ZPPS-M12X75ZPCPS-M6X20CPS-M12ZPCPSM6NNCPSM12WHPS-S229

HANDRAIL RESTRAINT ARMRESTRAINT MOUNTING FRAMERESTRAINT PLATES (2 sets)CLAMP PLATESISOLATOR BRACKETBELT-RUBBER (12thk Cut to suit)BOLT-M12 x 100BOLT-M12 x 75BOLT-PAN Hd.-M6 x 20NUT-M12NUT-NYLOC-M6WASHER-HARDENED-M12ISOLATOR BUSH

112 8444

16241624164

Pg23


Section 4-6 Hydraulic Latch Assembly

Pg24


Section 4-6 Hydraulic Latch Assembly


123456789

1011121314151617181920

PS-22690MAC-REFMAC-REFPS-22691-99PS-22691-98CPS-M12RODPS-SKF-S112CPS-22691-09PS-22691-10PS-22691-11PS-22691-04PS-22691-03CPS-M12X50ZPCPS-M12X40ZPCPS-M8X15ZPCPS-M16NNCPS-M12NZPCPS-M8XNZPCPS-M12WHCPS-M8WH

LATCH ACTUATOR BASECYLINDER GSN 1.5” x 4”PINLEVER BRACKETSECTOR BRACKETROD-M12 Threaded Rod x 100LgROD END(SKF S112 C Fem. course M12)SPACER-40 x 5Thk-NylonSPRING-40 x 10Thk-RubberWASHER-40 x 5 ThkBUSH-NYLON-35.3OD x 30.8ID x 30LgBUSH-NYLON-20.3OD x 16.8ID x 50LgBOLT-M12 x 50BOLT-SOCKET Hd.-M12 x 40BOLT-M8 x 15NUT-NYLOC-M16NUT-M12NUT-M8WASHER-M12WASHER-M8

11211121111121516585

--

supplied byLiebherr

Pg25


Section 4-7 Stair Bumper Assembly


123456789

10

PS-22650PS-22650-10PS-22650-11PS-22650-97CPS-M12X25ZPCPS-M12X20CPS-M12X45PS-M12NZPPS-M8NZPCPS-M12WH

BUMPER MOUNTING FABRICATIONSIDE BUMPER BLOCK-LargeSIDE BUMPER BLOCK-SmallENTRY GUIDEBOLT-M12 x 40BOLT-M12 x 20BOLT-M8 x 45 (Machined to suit)NUT-M12NUT-M8WASHER-HARDENED-M12

122288

10121016

Pg26


Section 4-8 Pad Assembly


12345678

PS-22628PS-22766-97PS-22606 98CPS-M12X100ZPCPS-M6X25ZPCPS-M12NZPCPS-M6NZPCPS-M12WH

MOUNTINGPADFLANGE PLATEBOLT-M12 x 100BOLT-M6 x 25 Pan Hd screwNUT-M12NUT-M6WASHER-HARDENED-M12

22888

1688

Pg27


Section 4-9 Electrical Controls

Proximity Switch AssemblyMounted on Fixed Landing

PS-75430Proximity Switch

PS-77004Harness forProximity Switch

PS-73013Control Pendant Switch

PS-73013BPendant Bracket

Control Pendant SwitchMounted on Handrail

Pg28


Section 4-9 Electrical Controls


16 PS-73013 SWITCH-PENDANT 1

Pendant Switch

PS-73013

Pg29


Section 4-9 Electrical ControlsParts List


1234

5A5B678

9A9B101112

CPS-GOSWHARNESS 6MCPS-NC12CPS-CAB12M20PS-75430PS-75430-APS-75430-BCPS-3/16”x2”S/SCPS-BSW3/16” NUT S/SCPS-WS/S316”x 1/2”CPS-WASHER S/S 3/16”X3/4”CPS-WS/S SPRING3/16”CPS-M10X25ZP 10.9CPS-W006ZPCPS-M10NZP

GO-SWITCH-HARNESS 6MHARNESS FLEX-NC12 - 5.8MSEALING GLANDSWITCH-MAGNETICBRACKET-MOUNTING-PROX.SWITCHBRKT-MTG-PROX.SWITCH R/ANGLESCREW-M3/16” x 2 -S/SNUT-M3/16”S/SWASHER-M3/16” x 1/2”OD S/SWASHER-3/16” x 3/4”OD S/SSPRINGWASHER 3/16” S/SBOLT-M10 x 25WASHER-FLAT-M10NUT-M10-1.5

15.8m

111122222284

1 2

4

3

7 86

5A

5B

1211 13

Pg30


Section 4-9 Electrical Diagram

Pg31


Section 4-10 Power Pack Assembly(PS-80104A-RFS)

10

8

7

6

3

4

9

11

12A

12

12B

17

16

15

14

20

21

19

18 13

2

1

5

FRONTDRAWER& LOCK

Pg32


Section 4-10 Power Pack AssemblySee Drawing Page 33


123456789

101112

12A12B1314151617181920212223

PS-21613PS-149.101.002PS-147.690.149PS-147.020.121PS-149.115.624PS-149.160.20017PS-509.005.015PS-147.182.301PS-106.014.180PS-106.00.185PS-41022PS-30113-1APS-30113-1PS-550.004.180PS-122-011-322PS-149.011.90KPS-147.481.311PS-82402PS-149.200.20312PS-500.017.055PS-149.115.61PS-541.003.126PS-118.064PS-82493PS-73013

MOUNTING FRAMETANK ASSEMBLY-OILCOVER-TOPSEAL24V SOLENOID VALVEJUNCTION BOXCAP/BREATHER DIPSTICKALARMPUMP-HANDLEVER-HAND-PUMPPOWERSTEP STICKERLATCH-CLAMPLATCH-OVERCENTER-ST/STLATCH-RUBBERSWITCH-ISOLATOR24V ELECTRIC MOTOR &PUMPELECTRIC MOTOR(with solenoid start)24V ELECTRIC MOTOR SOLENOIDGEAR PUMPBELL HOUSING WITH RELIEF VALVESUB-PLATEPICK UP TUBEPICK UP FILTERBATTERY-TERMINALSPENDANT SWITCH

1111111111122211111111121

(includes It. 16)

NOTEItem 14 Part No PS-149-011-90K Complete Motor & Pump Assembly includes items15.16.17.18.20 & 21

Pg33


Section 4-10 Power Pack Assembly (PS-80104A-RFS)See Drawing

Battery terminals

Top Cover

Hydraulic Hose Connections

PS-82493

9/16” JIC Fitting

(PS-147.690.149)

+ -

Pg34


Section 4-11 Hydraulic Layout

Manual Liebherr 996 - Power Step

Documents

Transcript of Manual Liebherr 996 - Power Step