Power Step 773D Series Manual Download Page 2

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FOLDING STAIRWAY

Caterpillar 773D Truck

Hydraulic Operation

Pg2

CAT 773D 19-12-12

CONTENTS

Page 3

Section 1 Installation and Mounting instructions

Installation Drawings

Section 2 Recommended Maintenance Procedure

Section 3 Operating Procedure

Section 4 Drawings and Repair Parts lists

4 Assembly Complete

4-1 Platform Assembly

Parts List

4-2 Fixed Stair Assembly

Parts List

4-3 Lower Stair Assembly

Parts List

4-4 Hydraulic Cylinder & Plumbing

Parts List
Valve Diagram

4-5 Power Pack Assembly

4-6 Electrical Controls

Parts List

Wiring Diagrams

Summary of Contents for 773D Series

Page 1: ...FOLDING STAIRWAY Manual for Cat 773D Truck Hydraulic Operation CAT 773D 19 12 12 Model No PSA 773D FS Serial No 773D Date Manufactured August 2012 ...

Page 2: ...ecommended Maintenance Procedure 13 Section 3 Operating Procedure Section 4 Drawings and Repair Parts lists 14 4 Assembly Complete 15 4 1 Platform Assembly Parts List 16 4 2 Fixed Stair Assembly Parts List 19 4 3 Lower Stair Assembly Parts List 21 4 4 Hydraulic Cylinder Plumbing Parts List Valve Diagram 23 4 5 Power Pack Assembly 26 4 6 Electrical Controls Parts List Wiring Diagrams ...

Page 3: ...w all on site Mine lifting and safety procedures when installing Power Step Landings to Truck PROCEDURE See Drawing PS 22683 1 Remove existing cabin landing and cabin side ladder 2 Fit Mounting Bars per View 1 Do not tighten bolts 3 Fit Top Landing bolting to the tapped holes in the Mounting Bars 4 Tighten all the bolts VIEW 1 VIEW 2 ...

Page 4: ... is required to temporarily support the stair during early stages of the installation procedure The welding must be upgraded to its final specification later in the installation 2 Check that the dimension shown in Views 1 1 1 3 the distance between the alignments of the Return Edge of the cabin landing and the face of the Front Bolting Pad is measures 130 10 on the truck If it does not measure 130...

Page 5: ...FOLDING STAIRWAY Caterpillar 773D Truck Section 1 Installation Instruction Drawings PS 24802 Front Bolting Pad VIE W 1 2 VIE W 3 VIE W 2 VIE W 1 3 VIEW 1 1 Welding All Cat SP to AS1554 unless specifically directed otherwise ...

Page 6: ...Pg6 CAT 773D 19 12 12 FOLDING STAIRWAY Caterpillar 773D Truck Section 1 Installation Instruction Drawings Landing PS 24803 See Procedure notes Page 4 VIEW 3 0 DETAIL 3 1 DETAIL 2 1 VIEW 4 VIEW 1 ...

Page 7: ...7 CAT 773D 19 12 12 FOLDING STAIRWAY Caterpillar 773D Truck Section 1 Installation Instruction Drawings PS 24389 Welding of Bolting Pads Welding All Cat SP to AS1554 unless specifically directed otherwise ...

Page 8: ...73D Truck Section 1 Installation Instruction Drawings PS 24804 Raised Walkway NOTE Follow all on site Mine lifting and safety procedures when installing Power Step Landings to Truck See Procedure notes Page 4 VIEW 4 VIEW 3 VIEW 2 DET AIL 1 1 DET AIL 1 2 ...

Page 9: ...Unit per View 1 3 Fit the Landing Shield to the front of the Raised Walkway per View 1 4 Fit the Buffer Socket and Mounting s to the truck bumper per drg 24 390 5 Adjust the handrail vibration buffers Views 2 3 and Detail 4 The stair set is fitted with rubber bumpers to reduce vibration in the handrails Adjust the bumpers so they bear firmly on their adjacent handrails Trim the fingers of the bump...

Page 10: ...Pg10 CAT 773D 19 12 12 FOLDING STAIRWAY Caterpillar 773D Truck Section 1 Installation Instruction Drawings Handrails PS 24805 VIEW 1 HANDRAILS DETAIL 4 VIEW 3 VIEW 3 See Procedure notes Page 9 ...

Page 11: ... bumper bolt Socket Bracket to Pad with bolts in slots so Bracket is as high as possible relative to Pad that is with adjustment available in slot to allow lowering of bracket on Pad when required to accommodate future wear in the buffer hinges and cylinder pins bushes etc The Pad and Bracket can then be hung on the buffer with the lower stair in it is fully raised vertical stowed position to esta...

Page 12: ... damage replace as necessary Grease all nipples and moving parts Repeat daily check as above 5000 Hours Check and inspect all main bolts on stairway system Re torque if required Repeat daily check as above Drain and refill Hydraulic tanks hoses Bleed system before use Check for wear and replace damaged or worn parts Check wiring and electrical components for damage Grease all nipples and moving pa...

Page 13: ...handrails and ladder raises into operate the air switch to the raise position up The ladder 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 r...

Page 14: ...Pg14 CAT 773D 19 12 12 FOLDING STAIRWAY Caterpillar 773D Truck Section 4 Assembly Complete PSA 773D FS ...

Page 15: ...Pg15 CAT 773D 19 12 12 FOLDING STAIRWAY Caterpillar 773D Truck Section 4 1 Platform Assembly PS 22671A See Parts List Page 16 ...

Page 16: ...0ZP CPS M10X30ZP CPS M16NZP CPS M12NZP CPS M10NN CPS M16WH CPS M12WH CPS M10WH PS 24396 TOP LANDING RAISED PLATFORM HANDRAIL TOP LANDING HANDRAIL RAISED WALKWAY HANDRAIL BONNET BONNET TOEBOARD supplied loose MIRROR POST SPACER MIRROR POST SIDE MOUNTING BAR FRONT MOUNTING BAR LANDING ISOLATOR PLATE LANDING ISOLATOR BRACKET BUSH RUBBER Mackay M169 BUFFER Insul 840 99725 LANDING SHIELD BOLTING PAD BO...

Page 17: ...Pg17 CAT 773D 19 12 12 FOLDING STAIRWAY Caterpillar 773D Truck Section 4 2 Fixed Stair Assembly PS 23253A See Parts List Page 18 ...

Page 18: ...ZP CPS M16NZP CPS M12NZP CPS M24WH CPS M20WH CPS M16WH CPS M12WH LANDING FIXED STAIR FABRICATION STAIR ATTACHMENT BRACKET POWER UNIT BRACKET OUTER HANDRAIL FIXED STAIR INNER HANDRAIL FIXED STAIR STAIR SUPPORT PLATE TREAD STAIR MOUNTING ARM BOLTING PAD STAIR MOUNTING ARM BOLTING PAD BRACKET GO SWITCH HANDRAIL BUMPER BRACKET HANDRAIL BUMPER long BRACKET HANDRAIL BUMPER ISOLATOR MOUNTING ASSEMBLY ACT...

Page 19: ...Pg19 CAT 773D 19 12 12 FOLDING STAIRWAY Caterpillar 773D Truck Section 4 3 Lower Stair Assembly PS 24373A See Parts List Page 20 ...

Page 20: ... M16WH CPS M12WH CPS M8WH PS 24384 01 PS 24384 02 PS 23263 PS 24371 01 BOTTOM STAIR FABRICATION LADDER EXTENSION OUTER HANDRAIL LOWER STAIR INNER HANDRAIL LOWER STAIR TREAD Inc one on Extension HINGE PLATE SPACER HINGE CHEEK PLATE SWITCH TARGET BUFFER ARM BUFFER BUFFER SOCKET MOUNTING HINGED STAIR ACTUATOR ATTACHMENT HINGE PIN HINGE BUSH BOLT M16 x 25 BOLT M12 x 70 BOLT M12 x 50 BOLT M12 x 30 BOLT...

Page 21: ...4 PS 61157 PS 61158 1MM PS61163 PS 61160 PS 61147 PS 61145 PS 60051 1 65 PS 60050 1 8 HYDRAULIC CYL with hard plumbing HARD PLUMBING KIT HYDRAULIC CYLINDER 2 1 2 PIN CYLINDER SPLIT PIN M4 CLEVIS PIN BOTTOM TOP SEAL KIT Not shown VALVE PILOT OPERATED LOCKING FITTING ELBOW 9 16 JIC FITTING ELBOW O RING 1 4BSPPx7 16 JIC FITTING O RING 1 4BSPPx 9 16 JIC FITTING 1 mm RESTRICTION 90 DEG REDUCER JIC x BS...

Page 22: ...Pg22 CAT 773D 19 12 12 FOLDING STAIRWAY Caterpillar 773D Truck Section 4 4 Hydraulic Cylinder Valve Diagram See Drawing Pg 21 ...

Page 23: ...T 773D 19 12 12 FOLDING STAIR Caterpillar 773D Truck Section 4 5 Power Pack PS 80103A SLD See Parts List Pg 25 8 4 13 27 26 6 5 25 6 2 7 10 29 11 16 14 3 30 24 3A Hoses shown dotted View B View A 7A 9 9A 8A 12 ...

Page 24: ...F THE POWERPACK IS TO BE SET TO 2800SI IF THE POWERPACK IS REPLACED THIS RELIEF PRESSURE WILL NEED TO BE RESET USING INLINE GAUGES FAILURE TO DO SO MAY RESULT IN ACCIDENT OR INJURY Pg24 CAT 773D 19 12 12 FOLDING STAIR Caterpillar 773D Truck Section 4 5 Power Pack PS 80103A SLD See Parts List Pg 25 ...

Page 25: ... ENCLOSURE SEALED POWER PACK CLAMP ELECTRIC MOTOR AUDIBLE ALARM BRIDGE RECTIFIER SOLENOID 24V START MOTOR HYDR HOSES 9 16 JIC STRAIGHT SWIVEL HYDR HOSES 7 16 JIC STRAIGHT SWIVEL HYDRAULIC FITTING 9 16 HYDRAULIC FITTING 7 16 HYDRAULIC FITTING 9 16 HYDRAULIC FITTING 7 16 135A CIRCUIT BREAKER 5A CIRCUIT BREAKER ISOLATION SWITCH INCLUDING BRACKET SEALED WIRING BOX TOGGLE SWITCH KIT BATTERY FEED STUDS ...

Page 26: ...Y Caterpillar 773D Truck Section 4 6 Electrical Controls See Parts List Pg 27 6 7 Cab Harness Equipment Refer Wiring Harness Drawings Proximity Switch Assembly Mounted on Fixed Landing Control Pendant Switch Mounted on Handrail 3 4 2 5 6 1 ...

Page 27: ...ALL ELECTRICAL SWITCHES AND COMPONENTS Item Part No Part Name Qty 1 2 3 4 5 6 7 8 PS 73013 PS 73013 B PS 77005 PS 77009AR PS 77004 PS 75430 PS 77002 PS 77003 CONTROL PENDANT SWITCH CONTROL PENDANT BRACKET HAND RAIL SWITCH HARNESS AUTO RAISE HARNESS CABIN TO SWITCH HARNESS PROXIMITY SWITCH CABIN BOX LED LIGHT INDICATOR WIRING HARNESS IN CABIN 1 1 1 1 1 2 1 1 Optional only 1 x Optional ...

Page 28: ...Pg28 CAT 773D 19 12 12 FOLDING STAIR Caterpillar 773D Truck Section 4 6 Electrical Controls Wiring Diagram Pg 1 ...

Page 29: ...Pg29 CAT 773D 19 12 12 FOLDING STAIR Caterpillar 773D Truck Section 4 6 Electrical Controls Wiring Diagram Pge 2 ...

Page 30: ...Pg30 CAT 773D 19 12 12 FOLDING STAIR Caterpillar 773D Truck Section 4 6 Electrical Controls Wiring Diagram Pge 3 WIRING HARNESS 1 ...

Page 31: ...Pg31 CAT 773D 19 12 12 FOLDING STAIR Caterpillar 773D Truck Section 4 6 Electrical Controls Wiring Diagram Pge 4 WIRING HARNESS 2 ...

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