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Power Step Cat 789C Operation And Maintenance Manual

Folding stair assembly
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Operations and Maintenance Manual
Cat 789C
Folding Stair Assembly
Model No. PSA789C-FS
Serial No. 789C-FS004
Date Manufactured: June 09
PSA789C-ASSY 12-3-10

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Summary of Contents for Power Step Cat 789C

  • Page 1 Operations and Maintenance Manual Cat 789C Folding Stair Assembly Model No. PSA789C-FS Serial No. 789C-FS004 Date Manufactured: June 09 PSA789C-ASSY 12-3-10...

  • Page 2: Table Of Contents

    FOLDING STAIRWAY Caterpillar 789C Haul Truck CONTENTS Page 3 Section 1. Installation and Mounting Instructions Drawings and procedures Section 2. Electrical Installation Section 3. Installation of Hydraulic Lines & Cylinder Section 4. Operating Procedure Section 5. Recommended Maintaintence Procedure Section 6. Drawings and Repair Parts Lists 6 Stair Assembly Complete 6-1 Top Stair &...

  • Page 3: Section 1. Installation And Mounting Instructions

    Section 1. Installation and Mounting Instructions Bolting Pads 23 471 NOTE Follow all on-site/Mine lifting and safety procedures when installing Power Step Ladder System to the Truck PROCEDURE See Drawing 23471 Pg. 4. Remove the OEM steel ladder (above the bumper), the bumper-top landing plate and the flexible below-bumper ladder from the left side of the truck.
  • Page 4 FOLDING STAIRWAY Caterpillar 789C Haul Truck Section 1. Installation Instruction Drawings Bolting Pads VIEW 1.2 VIEW 1.1 VIEW 4.1 VIEW 3.1 Drawing 23471 VIEW 2.2 VIEW 2.3 PSA789C-ASSY 12-3-10...
  • Page 5 FOLDING STAIRWAY Caterpillar 789C Haul Truck Section 1. Installation and Mounting Instructions - Stair Set PROCEDURE Refer Drawing 23473 Pg. 6 Middle and Top part of stair to be bolted and lifted together but without the top landing floor panel fitted to the top stair. Combined assembly is bolted to pads on front of bumper.
  • Page 6 FOLDING STAIRWAY Caterpillar 789C Haul Truck Section 1. Installation Instruction Drawings Stair Set Drawing 23473 PSA789C-ASSY 12-3-10...
  • Page 7 FOLDING STAIRWAY Caterpillar 789C Haul Truck Section 1. Installation Instruction Drawings - Emergency Exit PROCEDURE See Drawing Pg 23474 Pg. 8. Shorten OEM Ladder as required -View 2.2 so that Emergemcy laddder will fit. Weld the Emergency Ladder Landing to the bumper as shown in View 1. Location and weld details per Views 2.1, 2.2 &...
  • Page 8 FOLDING STAIRWAY Caterpillar 789C Haul Truck Section 1. Installation Instruction Drawings Emergency Exit 23 474 PSA789C-ASSY 12-3-10...

  • Page 9: Section 2. Electrical Installation

    Install short blue wire to screw terminal of Caterpillar circuit breaker, and other end to fuse holder. Run wiring harness from Power Step Stairway magnetic proximity switch and follow cabling/hose routing up to air line/ electrical outlet on rear Right Hand Side of cabin.
  • Page 10 FOLDING STAIRWAY Caterpillar 789C Haul Truck Section 2 Electrical System - Wiring Diagram - Harnesses Pg10 PSA789C-ASSY 12-3-10...
  • Page 11 FOLDING STAIRWAY Caterpillar 789C Haul Truck Section 2. Electrical System - Wiring Harness Pg11 PSA789C-ASSY 12-3-10...

  • Page 12: Section 3. Installation Of Hydraulic Lines & Cylinder

    FOLDING STAIRWAY Caterpillar 789C Haul Truck Section 3. Installation of Hydraulic Lines and Cylinder See Drawing Page 13 NOTES (Fitment Hinge and Actuator Assembly) The stair hinge is not to be loaded by extending cylinder force, that is the cylinder must be able to extend to it’s full extention length without being restained by the assembly.
  • Page 13 FOLDING STAIRWAY Caterpillar 789C Haul Truck Section 3. Installation of Hydraulic Lines and Cylinder See Pg. 26 Hydraulics Diagram See hinge assembly details CYLINDER HINGE AND ACTUATOR ASSEMBLY HINGE ASSEMBLY DETAILS (Refer Parts list on Pg. 24) Pg13 PSA789C-ASSY 12-3-10...

  • Page 14: Section 4. Operating Procedure

    FOLDING STAIRWAY Caterpillar 789C Haul Truck Section 4. 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 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.

  • Page 15: Section 5. Recommended Maintaintence Procedure

    FOLDING STAIRWAY Caterpillar 789C Haul Truck Section 5. 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 4 grease nipples on pivot &...
  • Page 16 FOLDING STAIRWAY Caterpillar 789C Haul Truck Section 6. Assembly Complete PSA-789C-FS Pg16 PSA789C-ASSY 12-3-10...
  • Page 17 FOLDING STAIRWAY Caterpillar 789C Haul Truck Section 6-1. Top Stair & Landing Assembly PS-23456-A Pg17 PSA789C-ASSY 12-3-10...

  • Page 18: 17 6-1 Top Stair & Landing Assembly

    FOLDING STAIRWAY Caterpillar 789C Haul Truck Section 6-1. Top Stair & Landing Assembly PS-23456-A See Pg 17 Item Part No. Part Name PS-23456 TOP STAIR FABRICATION PS-22457 TOP LANDING EXTENSION PS-22266-A STAIR TREADS PS-23461-A HANDRAIL-TOP-OUTER PS-23463 HANDRAIL-TOP-INNER PS-23458 LANDING POST FRAME PS-23459-98 ISOLATOR MOUNTING PS-23459-99...
  • Page 19 FOLDING STAIRWAY Caterpillar 789C Haul Truck Section 6-2. Middle Stair Assembly PS-23453-A Pg19 PSA789C-ASSY 12-3-10...
  • Page 20 FOLDING STAIRWAY Caterpillar 789C Haul Truck Section 6-2. Middle Stair Assembly PS-23453-A See Pg 19 Item Part No. Part Name PS-23453 STAIR STILE FABRICATION PS-23462-A HANDRAIL-OUTER- RH PS-23460 HANDRAIL-INNER - LH PS-22266 STAIR TREADS PS-23452-99-A LEFT SIDE MOUNTING PS-23452-98-A RIGHT SIDE MOUNTING PS-22233-05-C FIXED STAIR ACTUATOR ATTACHMENT PS-21107METAL...
  • Page 21 FOLDING STAIRWAY Caterpillar 789C Haul Truck Section 6-3. Lower Stair Assembly PS-22709A Pg21 PSA789C-ASSY 12-3-10...
  • Page 22 FOLDING STAIRWAY Caterpillar 789C Haul Truck Section 6-3. Lower Stair Assembly PS-22709A Parts List See Page 21 Item Part No. Part Name PS-22709 STILE ASSEMBLY PS-22465 STAIR EXTENSION PS-22717-01 HANDRAIL-INNER (LH) PS-22717-02 HANDRAIL-OUTER (RH) PS-22266 STAIR TREADS PS-23464 BUFFER ARM PS-40001 RUBBER STOP PS-22233-04C...
  • Page 23 FOLDING STAIRWAY Caterpillar 789C Haul Truck Section 6-4. Emergency Exit Ladder PS-23467A Item Part No. Part Name PS-23467 EMERGENCY EXIT LANDING PS-23466 EMERGENCY EXIT HANDRAIL PS-23467 08 LADDER BRACKET PS-23466-04 BOLTING PAD PS-M12X30ZP BOLT-M12x 30 CPS-M12WH WASHER-HARDENED-M12 Pg23 PSA789C-ASSY 12-3-10...
  • Page 24 FOLDING STAIRWAY Caterpillar 789C Haul Truck Section 6-5. Hydraulic Cylinder Assembly P/No. PS- 62996-AH NOTE: P/No. PS- 62996-AH includes Part No.s 1 to 14 Item Part No. Part Name PS-62996-HPK HARD PLUMBING KIT PS-62996A HYDRAULIC CYLINDER 2 1/2” PS-22246 PIN - CYLINDER CPS-M8X50ZP SOCKET HEAD BOLT - M8 x 50 CPS-M8NL...
  • Page 25 FOLDING STAIRWAY Caterpillar 789C Haul Truck Section 6-5. Hydraulic Cylinder (Valve Diagram) See Drawing Pg. 24 Pg25 PSA789C-ASSY 12-3-10...
  • Page 26 FOLDING STAIRWAY Caterpillar 789C Haul Truck Section 6-6 Power Pack PS-80103A-SLD See Parts List Pg 28 View B View A Hoses shown dotted Pg26 PSA789C-ASSY 12-3-10...
  • Page 27 FOLDING STAIRWAY Caterpillar 789C Haul Truck Section 6-6 Power Pack PS-80103A-SLD See Parts List Pg 28 View A View B Pg27 PSA789C-ASSY 12-3-10...

  • Page 28: 26 6-6 Power Pack

    FOLDING STAIRWAY Caterpillar 789C Haul Truck Section 6-6. Power Pack PS-80103A See Photos Page 26 Item Part No. Part Name PS-80103A-SLD POWER PACK ASSEMBLY PS-21107-METAL MOTOR ENCLOSURE- SEALED ST/ST PS-80103A POWER PACK PS-80103-B MOUNTING PLATE-POWER PACK PS-80103-CLAMP CLAMP ELECTRIC MOTOR-POWER PACK PS-82415 AUDIBLE ALARM PS-84214...

  • Page 29: Electrical System/Controls Parts List

    FOLDING STAIRWAY Caterpillar 789C Haul Truck Section 6-7. Electrical System See Wiring and Harness diagrams pgs. 10 & 11 Proximity Switch Assembly Mounted on Fixed Landing PS-75430 Proximity Switch PS-77004 Harness for Proximity Switch Control Pendant Switch Mounted on Handrail PS-73013 Control Pendant Switch PS-73013B-OKT...
  • Page 30 FOLDING STAIRWAY Caterpillar 789C Haul Truck Section 6-7. Electrical Controls Proximity Switch Assembly Hand Control Switch Assembly Install Drawings Manual 23471 Cat 789C Haul Truck 23473 23474 Pg30 PSA789C-ASSY 12-3-10...
  • Page 31 FOLDING STAIRWAY Caterpillar 789C Haul Truck Section 6-7. Electrical Controls See Photos Page 29 Item Part No. Part Name PS-73013 HAND CONTROL SWITCH ASSEMBLY PS-73013B-OKT BRACKET PS-77005 HARNESS PS-75430 PROXIMITY SWITCH ASSEMBLY PS-77004 HARNESS MANUALS INSTALLATION DRAWINGS PS-41011 DECAL FOR 135A CIRCUIT BREAKER PS-84213 135A CIRCUIT BREAKER ELSB905...