POWER STEP

Operator & Maintenance Access Systems

POWER STEP MANUALS

CONTENTS:
INSTALLATION MANUAL
INSPECTION & OPERATING INSTRUCTIONS
PARTS MANUAL
APPLICATION: Cat 793B/793C/793D
Model No. TS793C2

READ CAREFULLY BEFORE INSTALLATION AND OPERATION

OF THE POWER STEP

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5/01/10
Powered Truck Step
INSPECTION & OPERATING INSTRUCTIONS

INSPECTION:

OBSERVE AND CHECK THE FOLLOWING PRIOR TO USE AND DURING

MAINTENANCE -
1. Stair pivot and cylinder pins securely in place.
2. Hydraulic system for leakage.
3. Handrails in working order.
4. Step latch functional.
5. Mounting bolts in place and tight.
6. Stair treads in place and tight.
7. Other physical damage to components.

OPERATING PROCEDURES:

To Lower Step -

1. Release latch by depressing lever with hand or foot.

2. Move switch to the “down” position. Hold until step has fully descended to the
stop position.
3. If the step has settled into the latch, raise step to upper stop before releasing
latch.

To Raise Step -

Move switch to the “up” position. Hold until step contacts the upper stop. The
step will latch automatically. Leave pressure on stop.

Loss of Battery Power -

Back-up Bleed-down Valve Use

If electrical power has been lost to the step, it can be lowered by using the manual
bleed-down valve located on the end of the power unit enclosure.

1. To lower, pull valve release knob, then release latch.

2. If step has settled on latch, manually pull step towards you, then release latch.
Step will bleed down under gravity.
3. Power must be restored and valve must be reset to the closed position (push in
knob) prior to raising the step.
PRECAUTIONS:

1. Communicate with truck operator prior to boarding a running

machine.
2. When operating, make sure area of step motion is clear of personnel
and obstructions.
3. Keep step and deck clear of debris and other tripping hazards.
4. Keep clear of moving parts during operation.
5. Always run step to the down stop before using.
6. Never attempt to operate while someone is on the step.
7. Use handrails at all times.
8. Secure step in latched position
prior to moving truck.
POWER STEP
INSTALLATION MANUAL
Cat 793B/793C/793D
Model No. TS793C2

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855.787.3477 or 780.481.4057

5/01/10
POWER STEP INSTALLATION – CAT 793B/C/D
Model No. TS793C2

INSTALLATION NEEDS

1. Fork truck - 2000 lb. capacity.

2. Welding truck with air arc equipment.

3. Two personnel - welder and mechanic.

4. 3 1/2 quarts of Dexron II or equivalent hydraulic oil. For cold weather environments,
a broad range synthetic oil is recommended (use Mobil Aero HFA or equivalent).

PREPARATION

1. Remove mud flap bracket from the rear of the lower bumper deck at the bottom of
the diagonal stairway. Leave hanging for later. Remove the existing bottom deck and
lower flexible step assembly from the truck. Remove existing deck mounting blocks on
side of bumper. Clean area where new blocks will be installed

2. Refer to Mounting Location Section to determine the exact location of the new deck
and stair.

3. Review Figures 1, 2, and 3 to see where power step components will be mounted.

1
MOUNTING LOCATION

Mount Deck 1 ½” Forward (2” on

the 793B) and Level With Bumper
Top

Cat 793 Power Step

Completed Installation

Figure 1

2
3
Figure 2
4
Figure 3
MOUNTING & ASSEMBLY
Refer to Figure 3 for item numbers.

1. Using (10) 5/8-11 x 1 ½” bolts and lock washers (1), install mounting blocks (2) on
back of new deck back plate (3). Use proper blocks as shown.

2. Lift step deck assembly into place, with the mounting blocks against the side of
the bumper. Make sure top of stair assembly is level and even with the bumper
top in the previously measured location. Tack all four blocks in place. Use 3/8”
spacer legs behind blocks if necessary.

3. Remove bolts from blocks and remove deck. Complete welding around blocks.
Clean and paint welded areas.

4. Reinstall new deck. Tighten all mounting bolts.

5. Install stair assembly (4) on deck using ½-13 x 2” bolts, and locknuts. Use flat
washers under nuts.

6. With stair assembly in horizontal position, install cylinder (5), cylinder pins (6), and
cotter pins (7). Lower stair assembly.

7. Install front and back rails (8 & 9) on deck using ½-13 x 1” bolts and lock washers.
Also install left stair rail using similar fasteners.

8. Mount switch brackets (10 & 11) in locations approximately as shown in figure 2.
Mount where they will be accessible form the ground and deck but not be
inadvertently actuated and where they will be protected from possible damage.

9. Mount two stair rail extension plates (12) to stair using ½-13 x 1 ¼” bolts and lock
washers. Mount Stair rail (13) using ½-13 x 1 ½ bolts, and locknuts. Use ½” flat
washers under nuts.

10. Mount power unit (14) using 3/8-16 x 1” bolts lock washers and flat washers (15)
to deck mounting blocks.

11. Open motor enclosure. Route the two three wire harness connectors (switch
wires) (16) below the enclosure and connect to control box connectors in the
power unit. Route the other end of the wires through the holes in the deck
support plates and over the cylinder to the hole at the front of the deck. Install
wire loom around wires where possible to prevent abrasion. Tighten and clamp
wires, then cut to length at switch brackets. Install switches as shown in Figure
5. Tie control wires to rail upright.
5
12. Route hydraulic hoses (17) between the power unit and cylinder also using holes
in deck plates. Connect hoses. For proper operation, the rod end cylinder hose
is connected to the rear fitting on the power unit (Figure 4).

13. Reinstall truck mud flap bracket on back of new deck using (4) 3/8 x 1 1/4 bolts,
locknuts and washers.

Hydraulic Connections
Rod End

Cylinder End

Control & Limit Switch

Wire Connectors

Figure 4

6
 Switch Bracket

Toggle Boot

Switch

Terminals

Switch Boot

Switch Wire Connections

White Wire - UP

Black Wire – Common 24VDC

Green Wire - DOWN

Figure 5

14. Route the positive +24VDC battery cable (18) from the power unit (Figure 6) to the
truck battery. Install the flexible conduit connector in the battery box opening if
necessary. Install the fuse holder (19) inside the battery box (Figure 7). Use the short
cable (20) to connect the fuse to the battery. Fill power unit with hydraulic fluid.

15. Mount limit switch (23) and limit switch bracket, as shown in Figure 8. Run limit
switch wire under side of power unit box to the 4-wire connector at the control box and
make connection. The limit switch should be within ¼” (6 mm) of the step when in the
“UP” position for proper sensing. Close and bolt power unit enclosure cover.

+24VDC Motor Connection

Figure 6

7
 Fuse Figure 7

Battery

Figure 8

Limit Switch

Weld

8
RUNNING AND ADJUSTMENT

1. Using one of the control switches, run step into the “up” position. Cycle several times
to remove any possible air from the system.

2. Run step to the upper stop. Connect the latch release rod to the latch bar using the
3/8 – 24 x 1 ½ bolt and locknut (21). Position the latch release lever assembly away
from the step latch. Pull away until the latch bar is in full contact with the latch bolt.
Tack release lever assembly in place on the deck surface. Test latch release lever to
make sure the latch bar will pivot freely with the step in the fully “up” position. Adjust
if necessary. Finish welding latch release assembly to deck.

OPERATOR ALARM BOX

Locate the operator alarm box (22) in the truck cab. Route the 16/2 alarm box wire
from the power unit to alarm box. Connect one of the wires to the No. 1 terminal
on the power unit control box as shown in Figure 8. Connect the cab end to the
light and sonic alarm in the alarm box (white wires). This wire provides a switched
ground to the alarm devices. Connect the other (red) alarm wires as shown in the
wiring diagram. The alarm is designed to provide a warning light when the step is
down and the vehicle is operating and a combined visual and audio warning when
the brake is released. If desired, it can be wired to provide both warnings whenever
the step is not fully up.

No. 1 Terminal

Figure 9

9
POWER STEP
PARTS MANUAL
Cat 793B/793C/793D
Model No. TS793C2

Distributed by

www.internationalserviceandsupplies.com
info@internationalserviceandsupplies.com
855.787.3477 or 780.481.4057

5/01/10
 POWER STEP
PARTS LIST
Powered Truck Step - Cat 793B/C/D
Model No. TS793C2

FIGURE 1
Master Parts List
ITEM NO. DESCRIPTION QUANTITY PART NO.
1 Stairway Frame 1 11301
2 Power Unit Module 1 80105
3 Deck 1 11302
4 Stair Pivot 1 11303
5 Stair Pivot, Latch Side 1 11304
6 Tread, Stair 20" 5 41001
7 Rail, Stair 2 41003
8 Pin, Stair Pivot 2 24020
9 Bolt, 3/8 - 24 x 1 Grd. 8 6 90005
10 Nut, Lock 3/8 - 24 Grd. 8 10 91003
11 Snap Ring 1" 2 93015
12 Grease Zerk, 1/8 NPT 2 61006
13 Plate, Rail Spacer 2 41004
14 Bolt, 3/8-16 x 3/4, Grd. 8 24 90025
15 Washer, 3/8 Lock 28 92006
16 Bolt, 1/2 - 20 x 2, Grd. 8 8 90026
17 Washer, 1/2 Flat 12 92003
18 Nut, Lock, 1/2 - 20, Grd. 8 8 91019
19 Bearing, Journal 1 inch 2 29005
20 Latch Bar 1 33202
21 Bolt, Latch Bar 1 93101
22 Washer, 3/8 Flat 1 92002
23 Bearing, 1/2 1 85002
24 Nut, 3/8 Nylock 1 91002
25 Bracket, Latch Release 1 33206
26 Rod End 2 39025
27 Bolt, 3/8 - 24 x 1 1/2 Grd. 8 1 90049
28 Rod, Latch Release 1 33203
29 Nut, Jam, 3/8 - 24 2 91035
30 Bolt, 3/8 - 24 x 1 1/4 Grd. 8 1 90006
31 Spring 1 39002
32 Base, Latch Release 1 33207
33 Lever, Latch Release 1 33214
34 Bolt, 1/2 -13 x 1, Grd. 8 10 90030
35 Washer, 1/2 Lock 14 92015
36 Bearing, 3/8 1 85001
37 Washer, 5/16 Flat 1 92016
38 Nut, 5/16 Nylock 1 91038
39 Pin, Cylinder 2 93021
40 Pin, Cotter 3/16 x 2 2 93012
41 Cylinder 1 63007
42 Zerk, Grease, 1/4-28 2 61025
43 Union Adapter 90 deg. 1/4, .078" Orifice 1 61023
44 Reducer, 3/8 x 1/4 1 61053
45 Union Adapter 90 deg. 1/4, .094" Orifice 1 61064
46 Rail, Deck Front 1 41005
47 Switch, Limit, Proximity 1 73026
48 Bracket, Limit Switch 1 73029
49 Hose, Cylinder End 1 60017
50 Hose, Rod End 1 60017
51 Wire, Lower Switch 1 70101
52 Wire, Upper Switch 1 70102
53 Switch 2 73001
54 Decal, Switch 2 96001
55 Boot, Toggle 2 73005
56 Switch Bracket 2 32016
57 Connector, Fork 6 74002
58 Boot, Switch 2 73003
59 Bolt, 1/2 - 13 x 1 1/4, Grd. 8 4 90050
60 Bolt, 1/2 - 13 x 1 1/2, Grd. 8 4 90021
61 Nut, Lock, 1/2 -13, Grd. 8 4 91039
62 Bolt, Latch, 1/2 x 3 1/2 1 90047
63 Nut, Lock, 1/2 -13, Grd. 8 1 91039
64 Decal, Caution 1 96004
65 Reflector Strip 1 96007
66 Wire, Limit Switch 1 70103
67 Fuse Holder 1 75018
68 Fuse, 250 A 1 75014
69 Cable, Battery 25' 1 71014
70 Cable, Battery 30" 1 71013
71 Block, Mounting 1 41006
72 Block, Mounting 1 41007
73 Block, Mounting 1 41008
74 Block, Mounting 1 41009
75 Rail, Rear Deck 1 41039
76 Bolt, 3/8 - 16 x 1, Grd. 8 6 90002
77 Washer, 3/8 Flat 8 92002
78 Bolt, 5/8 - 11 x 1 1/2, Grd. 8 10 90014
79 Washer, Lock 5/8 10 92017
80 Tread, Stair 17" 1 41002
81 Conduit, 1/2", 24' 1 74044
82 Wire Tie - 6 inch 10 74008
83 Wire Tie - 12 inch 5 74009
84 Wire, Cab Alarm, 16/2, 50' 1 74045
85 Strain Relief, 1/2 x 1/4 1 73007
86 Bolt, 3/8-24 x 1, Grd 8 4 90011
87 Wire Loom, 30' 1 76004
88 Alarm Box 1 75017
89 Spacer Plate 4" 2 12075
90 Spacer Plate 10" 2 12076
 FIGURE 2
Power Unit Module
Part No. 80105
ITEM NO. DESCRIPTION QUANTITY PART NO.
1 Power Unit Assy. 1 80012
2 Enclosure 1 84004
3 Control Box Assy. 1 75021
4 Valve Package 1 65006
5 Adapter, Female Swivel 1/4, 90 Deg. 2 61050
6 Bolt, 3/8-16 x 1, Grd. 8 2 90002
7 Washer, 3/8 Lock 4 92006
8 Washer, 3/8 Flat 2 92002
9 Bolt, 3/8-16 x 3/4, Grd. 8 2 90025
10 Bolt, 1/4-20 x 3/4, Grd. 8 2 90051
11 Nut, Nylock, 1/4 - 20 4 91041
12 Washer, 1/4 Flat 2 92005
13 Cable, Ground 1 71015
14 Clamp, Wire, 3/4 1 74046
15 Clamp, Wire, 3/8 1 74020
16 Nut, Nylock 3/8 - 16, Low Profile 2 91036
17 Knob, 1/4 1 89012
18 Rod, Valve Release 1 65008
19 Slide, Valve Release 1 65009
20 Grommet 1 92101
21 Pin, Cotter 1 93106
22 Label 1 96008
23 Label 1 96011
 FIGURE 3
Power Unit Components
Part No. 80012
ITEM NO. DESCRIPTION QUANTITY PART NO.
1 Motor Solenoid Assy. 1 82406
2 Motor 24V 1 82405
3 Plug 1 81041
4 Check Valve 1 81023
5 O-Ring 1 81024
6 Coupling 1 81025
7 Pump O-Ring Kit 1 81026
8 Inlet Plumbing Kit 1 81027
9 Filter 1 81028
10 Pump Assy. 1 81021
11 Pump Housing Bolt 2 81029
12 Reservoir 1 81019
13 Reservoir Screw 4 81030
14 Breather 1 81020
15 Relief Valve Assy. 1 81036
16 Plug 1 81032
17 Center Plate 1 81035

FIGURE 4
Valve Package Components
Assembly Part No. 65006
1 Valve Body 1 65101
2 Cartridge Valve 1 65102
3 Relief Valve (Set at 600 PSI) 1 65103
4 Release Valve 1 65104
5 Bolt, 1/4 - 20 x 3 3 90056
6 Washer, Lock 1/4 3 92010
7 O-Ring 2 65105
8 Dual Pilot Op. Check Valve 1 65106
9 Check Valve 1 65108
10 Relief Valve (Set at 1200 PSI) 1 65109
 FIGURE 5
Control Box Components
Assembly Part No. 75021
ITEM NO. DESCRIPTION QUANTITY PART NO.
1 Box, Cover & Screws 1 76001
2 Alarm 1 74023
3 Relay 1 75019
4 Breaker, 10A 1 75016
5 Strain Relief 2 74048
6 Terminal Strip 1 74047
7 Screw & Nut 2 90053
8 Nut 3 91042
9 Screw & Nut 1 90054
10 Din Connector 2 74049

FIGURE 6
Alarm Box Components
Part No. 75017
ITEM NO. DESCRIPTION QUANTITY PART NO.
1 Box 1 74027
2 Strain Relief 1 73007
3 Alarm 1 74023
4 Lamp Socket 1 74025
5 Lens 1 74026
6 Bulb 1 74024
7 Label 1 96009
8 Connector 3 74040
9 Screw, 1/4 x 1 Self Tap 2 90055