Field Procedure to Install the Power Stairway on the 793F Off-Highway Truck {1408, 7253, 7254, 7960} Caterpillar

Off-Highway Truck/Tractor

793F (S/N: SSP1-UP)

Introduction

This Special Instruction provides the installation of the power stairway.

Important Safety Information

Do not perform any procedure in this special instruction until you have read this special instruction and you understand this information. Use only proper tools and observe all precautions that pertain to the use of those tools. Failure to follow these procedures can result in personal injury. The following procedures should also be observed.

Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs.

A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools in order to perform these functions properly.

Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.

Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. Ensure your safety and safety of others if a tool, a procedure, a work method, or operating technique that is not recommended by Caterpillar is used.

Ensure that the product will not be damaged or the product will be made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.

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Personal injury or death can result from machine movement. Place blocks in front of and behind the wheels to make sure the machine does not move while the parking brakes are disengaged.

1. Permit only one operator on the machine. Either keep other personnel away from the machine, or keep other personnel in the sight of the operator.

2. Move the machine to a smooth horizontal location. Move away from any machines that are working and any personnel.

3. Move the transmission control to the PARK position.

4. Activate the parking brakes. Stop the engine and remove the ignition key.

5. Turn the battery disconnect switch to OFF position.

6. Place blocks in front of the wheels and behind the wheels.

Required Parts List

Install the 328-1140 Stairway Gp

Illustration 1	g02320819
Front view

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Illustration 2	g02320875

1. Use a suitable lifting device to install platform group (1). Secure platform group (1) with eight bolts (2) and eight washers (3). The approximate weight for the platform group (1) is 220 kg (485 lb).
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   Illustration 3	g02322413

2. Install plate assembly (4) with 12 bolts (5) and 12 washers (6).
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   Illustration 4	g02321033

3. Use a suitable lifting device to install stairway assembly (7) to platform group (1). Secure stairway assembly (7) with two hubs (8), 16 bolts (9) and 16 washers (10). The approximate weight of stairway assembly (7) is 110 kg (243 lb).
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   Illustration 5	g02409000

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   Illustration 6	g06303594
   View of area (A)

4. Install pipe assembly (11) and pipe assembly (12) with 16 bolts (13), 16 washers (14), and four plates (14A).
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   Illustration 7	g06303613

5. Assemble block (16A) to pipe assembly (16) with two quad ring seals (16B), two bearings (16C), bushing (16D), and bolt (16E). Repeat the process for pipe assembly (15).

6. Install pipe assembly (15) and pipe assembly (16) with eight bolts (17) and eight washers (14).
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   Illustration 8	g06303631

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   Illustration 9	g06303636
   View of area (A)

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   Illustration 10	g06303638
   View of area (B)

7. Attach the bottom position on tube assembly (12) to pipe assembly (23) with two bushings (21), two quad ring seals (20A), one plated washer (20) and one screw (19).

8. Repeat Step 7 to attach the bottom position of pipe assembly (11) to pipe assembly (22).

9. Attach pipe assembly (23) to the bottom position on pipe assembly (16) with two bushings (21), two quad ring seals (20A), one plated washer (20) and one screw (19).

10. Repeat Step 9 to attach pipe assembly (22) to the bottom position on pipe assembly (15).
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    Illustration 11	g06303646

11. Attach pipe assembly (22) to top position on pipe assembly (11) with two bushings (21), two quad ring seals (20A), one washer (20) and one screw (19).

12. Attach pipe assembly (22) to pipe assembly (15) with two bushings (21), two quad ring seals (20A), one washer (20) and one screw (19).

13. Repeat Step 11 and Step 12 to install pipe assembly (23).

Install the Platform Wiring Group

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Illustration 12	g02327399

1. Install plate (1) to the handrail with two U-bolts (2), four washers (4) and four nuts (3).

2. Install toggle switch (5) to plate (1). Install switch guard (36). Use straps (37) to secure the harness.
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   Illustration 13	g02327840

3. Install wiring harness (6) with one grommet (7), 13 clips (8), 13 bolts (9), and 13 washers (10).
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   Illustration 14	g02328093

4. Install harness (11) with four clips (12), four bolts (9), and four washers (10). Use one clip (13), one stud (17), one nut (18), and spacer (35).

5. Install strap (14) with two bolts (15) and two washers (16).
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   Illustration 15	g02328213

6. Install cable assembly (20) with five clips (19), five grommets (21), five bolts (9), and five washers (10).
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   Illustration 16	g02328838

7. Install plate (22) with two u-bolts (2), four washers (4) and four nuts (23).

8. Install knob (24) with nut (25).

9. Install cable assembly (31) through grommet (34).

10. Install clip (28) and clip (30) on the handrail with grommet (29), bolt (27), washer (16), and nut (26).

11. Attach clip (33) to cable assembly (31).

12. Attach clip (33) to clip (28) and clip (30) with strip (32), bolt (9), washer (10), and nut (18).
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    Illustration 17	g02329673

13. Install film (38).