GLOBAL DEALER LEARNING

794 AC OFF-HIGHWAY TRUCK

OPERATOR STATION
MODULE 1 - TEXT REFERENCE

SERV2131

CAT, CATERPILLAR, their respective logos, ACERT, “Caterpillar Yellow” and the POWER EDGE
trade dress, as well as corporate and product identity used herein, are trademarks of Caterpillar
and may not be used without permission. © 2018 Caterpillar Inc. All Rights Reserved.
Caterpillar: Confidential Yellow
SERV2131 - 09/18 -2- Module 1 - Operator Station

TABLE OF CONTENTS
SAFETY BRIEFING..................................................................................................................... 3
PURPOSE ................................................................................................................................... 4
REASON ..................................................................................................................................... 5
COMPETENCY STATEMENT ..................................................................................................... 6
LEARNING OUTCOMES ............................................................................................................ 7
INTRODUCTION ......................................................................................................................... 8
OPERATOR’S STATION ............................................................................................................. 9
FRONT DASH ........................................................................................................................... 10
INDICATOR LIGHTS ..................................................................................................................11
LEFT SIDE DASH SWITCHES ................................................................................................. 13
GAUGES ................................................................................................................................... 15
INDICATOR LIGHTS ................................................................................................................. 16
RIGHT SIDE OF DASH ............................................................................................................. 17
COMPUTER DATA PORTS ....................................................................................................... 18
CENTER CONSOLE ................................................................................................................. 19
HOIST CONTROL SWITCH ...................................................................................................... 20
FLOOR PEDALS ....................................................................................................................... 21
OVERHEAD CONSOLE ............................................................................................................ 23
CIRCUIT BREAKERS ............................................................................................................... 24
CAB AIR FILTER ....................................................................................................................... 25
PURPOSE REVIEW .................................................................................................................. 26
REASON REVIEW .................................................................................................................... 27
COMPETENCY STATEMENT ................................................................................................... 28
LEARNING OUTCOMES REVIEW ........................................................................................... 29
MODULE CONCLUSION .......................................................................................................... 30

Caterpillar: Confidential Yellow

SERV2131 - 09/18 -3- Module 1 - Operator Station

SAFETY BRIEFING
• Emergency Phone Numbers
• First Aid Responders
• Location of Exits
• Location of Fire Extinguisher
• Room Alerts or Hazards
• Designated Location for Evacuation
• Storm Shelter
• Hazardous Material

Safely Home. Everyone. Every Day.™

3
SAFETY BRIEFING

Before beginning this module, the following topics will be reviewed:

• Emergency Phone Numbers
• First Aid Responders
• Location of Exits
• Location of Fire Extinguisher
• Room Alerts or Hazards
• Designated Location for Evacuation
• Storm Shelter
• Hazardous Material

Safely Home. Everyone. Every Day.™

NOTE: Any system or component specifications stated in this training

module are used only for training purposes. Components and specifications
may change as the product evolves. Always refer to Caterpillar Service
information to obtain the most current specifications when servicing Cat
products.

Caterpillar: Confidential Yellow

SERV2131 - 09/18 -4- Module 1 - Operator Station

PURPOSE

This module is designed to ensure you can identify and

describe the function of all components and machine
operation controls in the operator’s station.

4
• Course purpose PURPOSE

Caterpillar: Confidential Yellow

SERV2131 - 09/18 -5- Module 1 - Operator Station

REASON

This training is necessary to properly locate, identify,

and describe the function of all components and
machine operation controls in the operator’s station in
order to test all machine functions for proper use.

5
• Course reason REASON

Caterpillar: Confidential Yellow

SERV2131 - 09/18 -6- Module 1 - Operator Station

COMPETENCY STATEMENT

At the completion of this module, you will be able

to locate, identify, and describe the function of all
components and machine operation controls during a
lab exercise for this module.

6
• Course competency statement COMPETENCY STATEMENT

Caterpillar: Confidential Yellow

SERV2131 - 09/18 -7- Module 1 - Operator Station

LEARNING OUTCOMES

You will meet the following learning outcomes

during this Operator Station module of the 794 AC
Off-Highway Truck course:
• Locate, identify, and describe the function of all
components and machine operation controls, switches,
and buttons in the operator’s station.
• Use all machine operation controls in the operator’s
station to test all machine functions for proper operation.

7
• Learning outcomes LEARNING OUTCOMES

Caterpillar: Confidential Yellow

SERV2131 - 09/18 -8- Module 1 - Operator Station

8
INTRODUCTION

• Introduction The operator’s station accommodates two full size reclining seats and has storage
space behind them. The front windshield is designed with curved glass to provide
a 191 degree view. The support pillars have been moved back to provide an
unobstructed front view.

Features of the cab include:

• Adjustable steering column
• Turn signals
• Gauge cluster
• Advisor display
• 191 degree viewing
• Right gauge panel
• Indicator light panel
• Circuit breakers
• Air suspension seat
• Automatic retarding control
• 3-point seat belt (driver) 2-point seat belt (companion)
• Storage compartment

Caterpillar: Confidential Yellow

SERV2131 - 09/18 -9- Module 1 - Operator Station

9
OPERATOR’S STATION

• Operator’s Station. The operator’s station is a climate-controlled, metal-shelled structure that provides
a large, comfortable environment equipped with the controls necessary to operate
the truck. Large windows provide good visibility (191 degree viewing area) in all
directions. Doors on both sides provide easy operator access. Removable panels
ease maintenance by improving access to cab mounted components.

Caterpillar: Confidential Yellow

SERV2131 - 09/18 -10- Module 1 - Operator Station

10
FRONT DASH

• Front dash. This image shows the front dash in the cab.

Caterpillar: Confidential Yellow

SERV2131 - 09/18
1 2
3 4
5 6
• Identify the indicator lights.
-11- Module 1 - Operator Station
7 8
9 10
11 12
13 14
15 16
11
INDICATOR LIGHTS
The indicator lights on the left side of the dash are:
• Front brakes drag (1) and rear brakes drag (2): Illuminate when residual
pressure exists in the brake system that will not allow the brakes to completely
release. Operation with the brakes partially applied will generate excessive
heat. This will result in reduced braking effectiveness during normal service,
and will reduce brake component life.
• Brake Oil Hot (3): The brake oil hot symbol illuminates when the brake oil
temperatures is too high.
• Traction Control System (4): This indicator is illuminated when the torque to
the traction motors is adjusted by the Traction Control System (TCS).
• Powered Stairway Down (5): The powered stairway down indicator will
illuminate when the powered stairway is in the lowered position. Do not
operate the machine when the powered stairway is in the lowered position.
• Autolube alarm (6): Illuminates when the autolube system is not functioning.
• Stop engine (7): Illuminates when an engine condition requires stopping the
engine immediately. If the stop engine indicator illuminates, the truck will lose
propulsion power and dynamic retarding. If continued movement of the truck is
desired (e.g. to find a safe parking location), depress and hold the stop engine
or override button.
Caterpillar: Confidential Yellow
SERV2131 - 09/18 -12- Module 1 - Operator Station

• Check engine (8): Illuminates when engine operating conditions exceed

parameters. The operator should get the truck to a service area as soon as
possible.
• Brake oil pressure (9): Illuminates when the brake oil pressure is too low. If
the brake pressure continues to decrease, the rear brakes will apply and stop
the truck.
• Hydraulic oil temperature (10): Illuminates when the hydraulic oil
temperature is too high.
• Low steering pressure (11): Illuminates when the steering oil pressure is too
low.
• Low hydraulic fluid (12): Illuminates when the hydraulic oil level is low.
• Fuel level (13): Illuminates when the fuel level is low.
• Hot retarder temperature warning (14): Illuminates when the retarding grid
temperature exceeds parameters. This is a calculated temperature using
ambient temperature, voltage and current going into the grid.
• Level 3 fault (15): Illuminates when parameters exceed safe operating
conditions. The operator should stop the truck and shut down the engine when
safe to do so.
• Level 2 or 2S system fault (16): Illuminates when operating conditions
exceed parameters. The operator should get the truck to a service area as
soon as possible.

Caterpillar: Confidential Yellow

SERV2131 - 09/18 -13- Module 1 - Operator Station

1 2 3

4 5 6

13
LEFT SIDE DASH SWITCHES

• Identify the left side dash
switches.
The switches shown in this image are located on the left side of the dash.
The head lights/tail lights switch (1) activates the head lights and tail lights. In the
down position, all lights are OFF; in the center position, the optional marker and tail
lights are illuminated; in the up position, the head, tail, and marker lights are all ON.

The stairway light switch (2) activates the light on the superstructure access ladder.

The throttle back-up and lock switch (3) is used for two purposes:
• If there is a malfunction of the throttle PWM sensor, the operator can hold the
switch to raise the engine rpm above low idle to move the machine off the haul
road or to a service area.
• Throttle lock will maintain the engine rpm at full throttle without depressing the
throttle pedal. When the truck is at the desired speed, fully depress the throttle
pedal and depress the switch. The throttle lock indicator on the dash panel
will illuminate indicating the function is activated. This feature is to help the
operator on long, flat haul roads. To deactivate throttle lock, press the bottom
of the switch, apply either brake pedal, or move the drive train control lever. If
there is a failure of any critical component, throttle lock will be deactivated.

Caterpillar: Confidential Yellow

SERV2131 - 09/18 -14- Module 1 - Operator Station

NOTE: The throttle lock function is deactivated from the factory. Cat ET
must be used to activate the throttle lock function.

The delayed engine shutdown switch (4) activates the engine off timer. The engine
off timer switch allows the engine to shut down after a specific time period once
the key start switch has been turned OFF. The amount of idle time is set at five
minutes.

The manual lube switch (5) is used to activate the manual lube system.

The autolube alarm test switch (6) switch allows for manual testing of the truck’s
automatic lubrication system.

Caterpillar: Confidential Yellow

SERV2131 - 09/18 -15- Module 1 - Operator Station

1 5

3 4

2
6

15
GAUGES

• Identify the gauges. This image show the gauges in the center of the dash.

The engine oil pressure gauge (1) indicates the engine oil pressure.

The coolant temperature gauge (2) indicates the engine coolant temperature.

The tachometer (3) indicates the engine speed in rpm.

The speedometer (4) indicates the ground speed in miles per hour (mph) and
kilometers per hour (km/h).

The voltmeter (5) indicates, in volts, the amount of charge in the 24 volt electrical
system. Normal system voltage is 24 to 27 volts when the engine is at normal
operating speed.

The fuel level gauge (6) indicates the fuel level.

Caterpillar: Confidential Yellow

SERV2131 - 09/18 -16- Module 1 - Operator Station

2 5 6
1 3 4

16
INDICATOR LIGHTS

• Identify the indicator lights.
This image shows the indicator lights in the center of the dash, above the gauges:
• Left turn (1)
• Hand/load brake (2)
• High beam (3)
• RSC/ARC (Retard Speed Control/Automatic Retard Control) (4)
• Dump body raised (5)
• Right turn (6)

Caterpillar: Confidential Yellow

SERV2131 - 09/18 -17- Module 1 - Operator Station

2
3

7 8 5

17
RIGHT SIDE OF DASH

• Identify the right side of dash. The HVAC controls (1) regulate the heating and air conditioning temperature and
the fan speed.

The key start switch (2) is used to start and stop the engine.

The parking brake indicator lamp (3) illuminates when the parking brakes are
engaged and the shift lever is out of PARK.

The test switch (4) tests the indicator lights.

The load brake switch (5) activates the load brake. The load brake is only applied
when the truck is being loaded or dumped. This switch applies only the rear wet
service brakes. It is not a parking brake and the operator should not leave the truck
with only this brake applied.

The 12 volt DC power receptacle (6) is available for providing power for external
devices such as computers.

The window lights switch (7) controls the window lights (if equipped).

The fog lights switch (8) activates the fog lights at the front of the truck.

Caterpillar: Confidential Yellow

SERV2131 - 09/18 -18- Module 1 - Operator Station

3
2
1

18
COMPUTER DATA PORTS

• Identify the computer data ports.
This image shows the data ports, located in the cab on the passenger side center
console, which allow access to the following for downloading information:
• Cat Electronic Technician (Cat ET) connector (1)
• VIMS 3G connector (2)
• Additional 12 volt DC power receptacle (3)

Caterpillar: Confidential Yellow

SERV2131 - 09/18 -19- Module 1 - Operator Station

1 4

5
2

19
CENTER CONSOLE

• Identify the center console.
The drive train shift lever (1) is located on the center console. The parking brakes
are automatically engaged when the shift lever is in PARK. To select REVERSE,
NEUTRAL, or FORWARD (DRIVE or LOW), depress the shift control release
button (2) and pull the lever into the desired selection. The DRIVE position allows
the machine to propel forward in all speeds. The LOW position allows the machine
to travel in forward at a maximum of 13 km/h (8 mph).

The Auto Retarding Control (ARC) on/off button (3) activates the ARC feature. The
retard speed increment/decrement switch (4) controls the dynamic retarding effort
provided by the system when activated.

Buttons (5 and 6) are used to test the parking brake.

Caterpillar: Confidential Yellow

SERV2131 - 09/18 -20- Module 1 - Operator Station

20
HOIST CONTROL SWITCH

• Identify the hoist control switch. The hoist control switch (1) activates the four positions of the hoist control valve.
The four positions are: RAISE, HOLD, FLOAT, and LOWER. The hoist control lever
returns to the FLOAT position when released from the LOWER (power down)
position.

NOTE: To keep the hydraulic system from overheating, ensure that the
hoist switch is in the FLOAT position when hauling.

To the left of the operator’s seat is the proximity switch (2) for the operator’s door.
Both doors have this switch. If either door is open and the operator moves the shift
lever out of PARK, the warning alarm will sound.

Caterpillar: Confidential Yellow

SERV2131 - 09/18
1
5 4
• Identify the floor pedals.
-21- Module 1 - Operator Station
3
21
FLOOR PEDALS
The service brake pedal (1) applies the front and rear wet service brakes. The
service brake pedal has a pressure reducing valve (4) attached to the bottom of the
pedal below the floor of the cab. As the pedal is depressed, brake oil pressure is
directed to the front and rear service brakes. The farther the pedal is depressed,
the more the brakes are applied. The service brake pedal position sensor (5) sends
a PWM signal to the Brake ECM, which uses this signal to neutralize the
transmission.
NOTE: These brakes are intended for stopping in emergencies at any
speed, and can be used when starting movement on hills to prevent
unintended movement.
The dynamic retarder pedal (2) regulates the amount of dynamic retarding
applied by the electric drive train. The retard/brake control pedal controls the
truck’s retarding and friction brake systems. The more the pedal is depressed the
stronger the retarding effort. When the pedal is depressed, the wheel motors act
as generators and the truck’s rolling energy is dissipated as heat through a grid of
air-cooled resistors. The farther the pedal is depressed, the greater the retarding
action applied, as long as the truck speed remains within the limits of the truck’s
retarding system. When the dynamic retarder pedal reaches approximately 80% of
travel, the front and rear service brakes are hydraulically applied.
NOTE: The friction brakes are intended for stopping in emergencies at any
speed.
Caterpillar: Confidential Yellow
SERV2131 - 09/18 -22- Module 1 - Operator Station

This combination function pedal uses a PWM sensor attached to the bottom side of
the pedal. This signal is directed to the Drive Train ECM.

The Throttle Position Sensor (TPS) (3) is the input from the operator to the Drive
Train ECM. At engine startup in PARK, the engine rpm goes to 800 rpm, which
is low idle. When the operator moves the electric drive shifter to FORWARD or
REVERSE, engine rpm goes to 1800 and remains until the operator starts to
depress the throttle pedal. The operator controls the machine ground speed with
this pedal.

Another feature of this truck is anti-rollback protection. If the operator stops the
truck with either brake pedal on an incline (uphill or downhill), then removes their
foot from the pedal, and doesn’t place their foot on the throttle pedal, the truck will
start to roll and the service brakes will automatically come on. The anti-rollback
feature protects the truck from unintended movement. To begin movement, the
operator steps on either pedal to reset the feature, removes their foot from the
pedal, and steps on the throttle pedal which will allow the machine to move in the
direction selected by the operator.

The service brakes will be automatically applied when the machine speed passes
through zero and exceeds 2 km/h (1 mph) in the opposite direction as the setting
on the shift control lever. After the anti-rollback function is engaged, the
anti-rollback function must be disengaged before propelling the machine.

Any of the following actions will disengage the anti-rollback function:

• Apply 90% of the service brake
• Move the shift lever into the P position

Caterpillar: Confidential Yellow

SERV2131 - 09/18 -23- Module 1 - Operator Station

2 3
1

5
4

23
OVERHEAD CONSOLE

• Identify the overhead console. The windshield wiper/washer switch (1) controls the windshield wipers and washer.

The Advisor display panel (2) shows the various parameters of the truck and
engine, and will be discussed in detail in Module 2 “794 AC Off-Highway Truck
Advisor Monitoring System.”

The air filter restriction gauges (3) indicate the amount of restriction in the air filter
and induction system in inches of water.

A radio (4) can be installed in the overhead console.

The warning lamp (5) warns the operator if either cab door is open.

Caterpillar: Confidential Yellow

SERV2131 - 09/18 -24- Module 1 - Operator Station

24
CIRCUIT BREAKERS

• Identify the circuit breakers. This image shows the circuit breakers, accessible beneath the front right side dash
cover.

Caterpillar: Confidential Yellow

SERV2131 - 09/18 -25- Module 1 - Operator Station

25
CAB AIR FILTER

• Identify the cab air filter. The cab is pressurized and the air is filtered by an air filter element, located behind
a cover (arrow) at the rear of the operator’s station. The air filter is 99.5% efficient
in filtering coarse dust.

Caterpillar: Confidential Yellow

SERV2131 - 09/18 -26- Module 1 - Operator Station

PURPOSE

This module was designed to ensure you can identify

and describe the function of all components and
machine operation controls in the operator’s station.

26
• Course purpose review PURPOSE REVIEW

Caterpillar: Confidential Yellow

SERV2131 - 09/18 -27- Module 1 - Operator Station

REASON

This training was necessary to properly locate, identify,

and describe the function of all components and
machine operation controls in the operator’s station in
order to test all machine functions for proper use.

27
• Course reason review REASON REVIEW

Caterpillar: Confidential Yellow

SERV2131 - 09/18 -28- Module 1 - Operator Station

COMPETENCY STATEMENT

You are now able to locate, identify, and describe the

function of all components and machine operation
controls during a lab exercise for this module.

28
• Course competency review COMPETENCY STATEMENT

Caterpillar: Confidential Yellow

SERV2131 - 09/18 -29- Module 1 - Operator Station

LEARNING OUTCOMES

You have met the following learning outcomes

during this Operator Station module of the 794 AC
Off-Highway Truck course:
• Located, identified, and described the function of all
components and machine operation controls, switches,
and buttons in the operator’s station.
• Used all machine operation controls in the operator’s
station to test all machine functions for proper operation.

29
• Learning outcomes review LEARNING OUTCOMES REVIEW

Caterpillar: Confidential Yellow

SERV2131 - 09/18 -30- Module 1 - Operator Station

30
• Conclusion MODULE CONCLUSION

This concludes the Operator Station module for the 794 AC Off-Highway Truck.

When used in conjunction with the service manuals, the information in this module
will aid the service technician in troubleshooting, testing, adjusting, and correcting
problems with the machine.

For service repairs, adjustments, and maintenance, always refer to the Operation
and Maintenance Manual (OMM), service manuals, and other related service
publications.

Caterpillar: Confidential Yellow