by

Head Office Branches New South Wales

11 Burns Road Unit 3/93 Kyle Street

Armadale WA 6112
Tel: +61 8 9399 8844
Fax: +61 8 9463 6338
email@aeeng.com.au
www.safeboarder.com.au
Rutherford NSW 2320
Tel: +61 0 448 778 445
Fax: +61 2 4006 3061

ST01 Operation &

Parts Guide
For Caterpillar
785 & 789 Dump Trucks

Release 2.6
 CONTENTS

Page

1.0 Introduction ............................................................................ 1

3.0 Hydraulic System ................................................................... 1

2.1 Solenoid Valve and Filter location........................................................ 1
2.2 Circuit Operation .................................................................................. 3
2.3 Pressure Switch Location .................................................................... 4

3.0 Electrical System .................................................................... 5

3.1 Component Location ............................................................................ 8
3.2 Circuit Operation .................................................................................. 9

4.0 Testing & Adjusting ................................................................ 8

4.1 Pressure Adjustment............................................................................ 8
4.2 Proximity Switch Adjustment................................................................ 8

5.0 Parts & Technical Information ............................................... 9

5.1 Mechanical Parts ................................................................................. 9
5.2 Hydraulic Circuit & Parts ...................................................................... 10
5.3 Electrical Parts ..................................................................................... 11
5.4 Electrical Circuit ................................................................................... 12

Release 2.6
1.0 Introduction

The Australian Equipment Engineering ST01 Stair Access System utilizes the
vehicle’s hoist pilot oil pressure for its operation. No additional external power
supplies are required to be added to the machine.

CAUTION: Ensure you have fully read and understood this guide
before operating the machine and Access System. Failure to do so may
result in equipment damage and personal harm.

CAUTION: Ensure the machine is parked on firm flat ground, wheels

securely chocked, key removed or the machine is suitably isolated, before
beginning work on the machine.

2.0 Hydraulic System

2.1 Solenoid & Filter Location

The hydraulic components for the stair circuit are to be assembled onto the Valve
Mount Plate. For the 785 Truck the arrangement is as shown in Figure 1. The Valve
Mount Plate is installed on the front side of the engine cross member bumper using
the factory weld buttons and supplied fixings, as shown in Figure 2.

90° Elbow Filter Filter Hose

Filter Clamp 45° Elbow Solenoid Valve

Figure 1

ST01 Operational & Parts Guide. Release 2.6 1

 Return
Hose

Supply
Hose

Cross Member Valve Mount Plate

Figure 2

For the 789 Truck, the components are arranged as shown in Figure 3. The Valve
Mount Plate is installed on the rear, left side of the engine cross member bumper
using the factory weld buttons and supplied fixings, as shown in Figure 4.

Filter Clamp Filter Hose Valve Mount Plate

Filter 45° Elbow Supply Hose Stair Hose Solenoid Valve

Figure 3

ST01 Operational & Parts Guide. Release 2.6 2

 Return
Hose

Supply
Hose

Stair
Hose

Cross Member Valve Mount Plate

Figure 4

2.2 Circuit Operation

Releasing the park brake sends a signal to the Solenoid Valve which allows the
pressurised oil from the hoist pilot system to pass from the inlet port through the
outlet port of the Solenoid Valve to the Stair Cylinder, causing the cylinder to extend
and raise the Stairs.

Due to the patented design of the Access System, the stair’s upward motion can be
halted or forced back down easily through the majority of its upward travel. When the
stairs have reached the raised position the hydraulic pressure, acting with the
patented mechanism design, ensures the ladder is held firmly in place.

When the Park Brake is engaged and the Ladder Switch is operated, the Solenoid
Valve de-energises and directs the oil from the outlet port to the return port. This
allows the oil to return back to machine’s drain line, after passing through the inline
filter, and so back to tank.

The Pressure Regulator on the Solenoid Control Valve controls the incoming system
pressure. See Section 4.1 (page 8) for instruction on how to adjust the Stair Circuit
Pressure. The Pressure Regulator is located on the Solenoid Valve next to the
Solenoid, shown in Figure 5.

ST01 Operational & Parts Guide. Release 2.6 3

 Lock Nut
Solenoid

Pressure
Regulator
Cylinder Port

Return Port

Pressure Port

Figure 5

ANY LOSS OF THE MACHINE’S SYSTEM PRESSURE WILL RESULT IN

THE STAIRS LOWERING AUTOMATICALLY

2.3 Pressure Switch Location

CAUTION: Ensure there is no system pressure in the circuit when

removing any hydraulic or pneumatic fittings from the machine.

The components for the Stair Pressure Switch tee in between the machine’s Park
Brake Valve and the O.E.M air pressure switch at the back of the Operator’s Cabin,
as shown in Figure 16.

Operator’s Cabin Stair Pressure Switch O.E.M Park Brake Switch

Figure 6

ST01 Operational & Parts Guide. Release 2.6 4

3.0 Electrical System

3.1 Component Location

The main Electrical Connector Board, shown in Figure 7 is located in the cavity in the
back of the Operator’s Compartment as shown in Figure 8.

Figure 7

Operator’s Cabin Cavity Connector Board

Figure 8

ST01 Operational & Parts Guide. Release 2.6 5

The Proximity Switch is located above the inner Stair Pivot of the Stairs, as shown in
Figure 9.

Proximity Switch

Stair Pivot

Figure 9

The Release Button is located in the dash panel as shown in Figure 10.

Stair
Release
Button

Vacant
Switch
Cover

Figure 10

ST01 Operational & Parts Guide. Release 2.6 6

 3.2 Circuit Operation

With the machine running (air-pressure built up), park brake applied and Stairs
lowered, moving the park brake switch to the release position will cause the park
brake air pressure to close the Pressure Switch contacts. This closes the contacts of
Relay 1, powering the circuit, allowing the Stairs to rise. The buzzer will sound until
the Proximity Switch detects the Stairs when they are almost in the fully raised
position.

With the Stairs in the fully raised position, and the machine still running, operating the
Park Brake Switch to engage the Park Brake will function as usual. The power
supplied through the Latching Relay ensures the Solenoid Control Valve remains
energised and the Stairs will remain raised.

To manually lower the Stairs with the machine running, the Park Brake must be in the
applied position and the Ladder Release button switch be depressed. In this situation
power is cut from both the Park Brake Circuit and the Latching Relay, as pressing the
switch interrupts power to the Latching Relay windings and the contacts open.
Cutting power to the Solenoid Control valve de-energises the solenoid enabling the
Stairs to lower.

Turning off the key or any loss of ignition circuit power will cause the stairs to lower.

ANY LOSS OF THE MACHINE’S ELECTRICAL POWER – PARK

BRAKE APPLIED, EMERGENCY STOP ACTIVATED, OR THE
MACHINE SWITCHED OFF - WILL RESULT IN THE STAIRS
LOWERING AUTOMATICALLY.

ST01 Operational & Parts Guide. Release 2.6 7

4.0 Testing and Adjusting

CAUTION: Ensure that you have read and understood all of the
instructions before making adjustments to the Stair’s systems.
Incorrect adjustment could cause the ladder to operate incorrectly
and result in component failure, injury or death.

4.1 Pressure Adjustment

Ensure the machine is parked on level ground and securely chocked so it can
not move with the park brake released. Back off the pressure regulator on the
solenoid valve by winding it anti-clockwise. Start the machine if it is safe to do
so. Release the park brake.

Note: If the access system begins to raise active the park brake
immediately, switch off the engine and back the pressure regulator valve off
more. Start the machine again if it is safe to do so. Release the park brake.

With a person standing near the access system release the park brake. Adjust
the pressure regulator in until the Stairs begins to rise. The person standing
near the access system should be able to stop it from rising with about 5
kilograms of force. Once the pressure is adjusted correctly lock the lock nut on
the regulator.

4.2 Proximity Switch Adjustment

As illustrated in Figure 12 (page 8), the proximity switch must be suitably

adjusted as not to foul on the Stairs when in the fully upright position, though
close enough for the sensor to detect the Stairs when in the fully upright
position. The gap should be 3-5mm. Incorrect adjustment could cause damage
to the sensor or cause the buzzer to sound while the machine is operating with
the Stairs in the fully upright position.

ST01 Operational & Parts Guide. Release 2.6 8

5.0 Parts & Technical Information

5.1 Mechanical Parts

ST01 Operational & Parts Guide. Release 2.6 9

5.2 Hydraulic Circuit & Parts

ST01 Operational & Parts Guide. Release 2.6 10

5.3 Electrical Parts

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5.5 Electrical Circuit

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