Global Manpower Development

797F off-highway truck

operator’s station
Module 1 - Text Reference

SERV1872

797F Off-Highway Truck

Module 1 - Operator’s Station
Text Reference

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© 2009 Caterpillar Inc.

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INTRODUCTION

• New cab features The 797F Off-Highway Truck cab is designed for operator comfort and improved
access for the technician. The cab also has excellent interior air movement with
several louvers for increased air flow.

The machine ECMs are accessible through a cover located on the front of the cab.
The fuse and relay panel are easily accessible from behind the buddy seat without
removal of the trim. The air conditioning filter is easily accessible on the left side
exterior panel.

The wiper location has changed to increase the coverage on the windshield, and a
removable wiper motor mount has increased the serviceability for the technician.

© 2009 Caterpillar Inc.

SERV1872 - 11/09 -3- Module 1 - Operator’s Station

• Cab components (front of cab): This view from the rear of the cab shows the location of the major components inside
the cab:
1. Steering wheel
2. Instrument cluster -- steering wheel (1)
3. Advisor panel -- instrument cluster (2)
4. Overhead switch panel -- Advisor panel (3)
5. Interior lights -- overhead switch panel (4)
6. WAVS monitor -- interior lights (5)
7. Accelerator and brake pedals -- Work Area Vision System (WAVS) monitor (6)
8. Transmission and hoist levers -- accelerator and brake pedals (7)
9. Switch panel -- transmission and hoist levers (8)
-- switch panel (9)

© 2009 Caterpillar Inc.

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• Cab components (rear of cab): The operator’s station includes a full size trainer seat (1) next to the operator’s
seat (2).
1. Full size trainer seat
2. Operator’s seat The fuse-relay panel (3) is located behind the trainer seat and the cab fresh air
3. Fuse-relay panel filter (4) is located behind the operator’s seat. Clean or replace the cab fresh air filter
when necessary.
4. Cab fresh air filter
5. Three-point shoulder belt The diagnostic service connectors (not visible) are located between the fuse-relay
panel and the cab fresh air filter.

The seat is equipped with a bright orange three-point shoulder belt (5) for improved
operator restraint.

NOTE: For additional information about the seat and how to properly use it, go
to safety.cat.com.

Additional reference materials are:

The Cat Comfort Seat with Three-Point Operator Restraint: Video (2004). This
video highlights features, including safety features of Caterpillar’s Comfort Seat with
Three-Point Operator Restraint. (6 minutes)

Safety Basics--Seat Belts: Video (2007). Volume 2 in Caterpillar’s Safety Basics

video series. (3 minutes)

© 2009 Caterpillar Inc.

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• Overhead switch panel: Three switches are contained in the overhead switch panel. The traction control test
switch (1) is used to test the Traction Control System (TCS) by pushing the top of the
1. Traction control test switch test switch. When the switch is pressed, the right and left parking brakes are
2. Brake retract switch tested.
3. Engine idle shutdown switch
The brake release switch (2) activates the brake release pump.

The optional engine idle shutdown switch (3) allows the engine to conveniently
cool down after operation. The cool down period is intended to extend the life of
components operating at elevated temperatures. The timer feature allows the
operator to exit the truck with the engine running. The operator must activate the
engine idle shutdown switch and then turn the key start switch to the OFF position.
After a five minute period, the engine will automatically shut off.

© 2009 Caterpillar Inc.

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• Inside front of cab: The mounting bar (1) across the top of the cab is used to support optional monitors
that can be installed.
1. Mounting bar
2. WAVS camera The WAVS camera (2) and the Object Detection Monitor (3) are shown in the bottom
3. Object Detection Monitor illustration.

© 2009 Caterpillar Inc.

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• Floor of cab: The service brake pedal (1) is used to modulate the hydraulic engagement of the
service brakes on all four wheels.
1. Service brake pedal
2. Accelerator pedal The accelerator pedal (2) controls the engine rpm. The throttle position sensor (not
3. Secondary brake pedal visible; behind accelerator pedal) provides the pedal position input signal to the
Engine ECM.
4. Secondary brake pedal
position sensor
The secondary brake pedal (3) is used to quickly stop the machine if the service
5. Foot rest brake does not function properly. When the operator depresses the secondary brake
pedal, the secondary brake pedal position sensor (4) sends a PWM signal to the
Brake ECM. The Brake ECM sends a current to the parking brake solenoid which
drains the parking brake oil in all four wheels; the machine will stop very quickly.

The foot rest (5) is installed for the comfort of the operator.

© 2009 Caterpillar Inc.

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• Steering column components: Located on the right side of the steering column is the manual retarder control
lever (1). This lever is used to regulate the machine speed as the truck is traveling
1. Manual retarder control lever down a grade. The speed is regulated by controlling the amount of brake oil pressure
2. Multifunction lever directed to the front and rear wheel service brakes. The retarder will not apply full
braking capacity.

Moving the lever down increases truck retarding and slows the machine. When the
lever is in the full upward position the manual retarder is OFF.

The multifunction lever (2) on the left side of the steering column controls the window
wipers, the window washer, the headlight brightness, and the turn signals.

© 2009 Caterpillar Inc.

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• Front dash panel: The instrument cluster (1) contains numerous indicator lights and gauges. The
Advisor display (2) is used to access the data from the VIMS Modules, the Engine
1. Instrument cluster ECM, and the Machine ECMs.
2. Advisor display
3. Hazard flasher switch The upper half of the hazard flasher switch (3) turns ON the hazard lights and the
lower half turns the lights OFF.
4. Running lights switch
5. Fog lamps switch The running lights switch (4) controls the headlights, parking lights, and taillights.
6. Three-way access lights The switch has three positions:
switch
7. Optional heated mirror switch -- OFF
8. Panel dimmer switch -- parking lights and taillights (first detent)
9. Key start switch -- headlights, parking lights, and taillights (second detent)
10. Cigar lighter
The upper half of the fog lamps switch (5) turns the lamp in the front bumper ON and
11. 12 volt DC power receptacle the lower half turns the lamp OFF.
12. Fan speed switch
13. Temperature variable control The three-way access lights switch (6) activates the stairway lights. A second
switch three-way access lights switch is located on the ground level switch panel on the
14. HVAC Mode switch front bumper.

The optional heated mirror switch (7) controls the heated mirrors.

© 2009 Caterpillar Inc.

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The panel dimmer switch (8) changes the intensity of the panel lights. Pushing the
top of the switch increases the intensity and pushing the lower half of the switch
decreases the intensity.

The key start switch (9) controls engine starting. In the ON position, the dash panel
and Advisor display are powered. The instrument cluster gauges will sweep and the
indicators will flash. Advisor will automatically perform an electronic calibration and
an audible alarm will sound. In the ON position, the electronic thermostat (E-Stat)
will also self calibrate.

The E-Stat is an electro-mechanical valve that meters coolant between the engine
and radiator. The stepper motor that controls the valve will self calibrate for up to 30
seconds. This is a new, distinct sound coming from the engine compartment.

Engine Prelube is activated in the start position. The prelube pump will run for 45
seconds or 48 kPa (7 psi), whichever occurs first. The prelube pump will stop just
before the engine starts cranking. There is short delay in the logic before cranking is
initiated. The prelube pump does not run while the engine is cranking.

When the engine starts cranking, the fuel priming pump will start running and does
not run while the prelube pump is running. Also, the priming pump assists the fuel
transfer pump during cranking, so both pumps are running when the engine starts
cranking. The priming pump will stop 100 rpm below the low idle speed.

The cigar lighter (10) and 12 volt DC power receptacle (11) are located next to the
key start switch.

The fan speed switch (12) controls the fan speed with an OFF position and three fan
speed positions. The temperature variable switch (13) sends an input to the Brake
ECM which sends an output to the water valve attached to the HVAC unit located
behind the back cover of the cab.

The HVAC Mode switch (14) is a rocker switch with three positions. When the top
section of the switch is pushed, the cab air will be cooled. When the switch is in the
center position, the cab air will be heated. When the lower section of the switch is
pressed, the cab air temperature is controlled automatically. The temperature in the
cab should be between 10° C (50° F) and 32° C (90° F). This variable temperature
is controlled by the temperature control switch.

© 2009 Caterpillar Inc.

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• Behind trainer seat: The fuse / relay panel is located behind the trainer seat. A decal (not visible) is
located above the fuse / relay panel to identify the fuse and relay locations. The 15
1. H igh speed blower circuit Amp high speed blower circuit breaker (1) and the 15 Amp brake retract motor circuit
breaker breaker (2) are located next to the fuses.
2. Brake retract motor circuit
breaker

© 2009 Caterpillar Inc.

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• Rear panel: Located on the rear panel between the operator seat and the trainer seat are the:

1. 12 VDC power port -- 12 VDC power port (1)

2. VIMS service connector -- VIMS service connector (2)
3. Cat ET service connector -- Cat ET service connector (3)

© 2009 Caterpillar Inc.

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• Center console components: The transmission shift lever (1) is located on the center control stand in the cab. The
transmission has six speeds forward and one reverse speed. The parking brakes
1. Transmission shift lever are automatically engaged when the shift lever is in PARK. To select REVERSE,
2. Shift control release button NEUTRAL, or FORWARD, depress the shift control release button (2) and pull the
lever into the desired position.
3. Decrement button
4. Hoist control lever In the DRIVE position, the transmission will shift between FIRST gear and any
selected gear higher than SECOND (THIRD through SIXTH). In the SECOND
position, the transmission will only shift between FIRST and SECOND gear. In the
FIRST position, the transmission will remain in FIRST gear.

The increment button (not visible) on the front of the transmission shift lever is used
to raise the selected high gear limit. SIXTH gear is the maximum high gear limit. The
decrement button (3) on the left side of the shift lever is used to lower the selected
high gear limit. THIRD gear is the minimum high gear limit in the D position.

Each time the truck is started, the Transmission ECM defaults to the highest
gear available. If the operator decides to limit the highest gear to FOURTH, the
decrement button is used while watching the Advisor panel to visually confirm the
new selection.

The increment and decrement buttons are also used to test the parking brake.

NOTE: Refer to the 797F Operation and Maintenance Manual (SEBU8417) to

perform the parking brake test.

© 2009 Caterpillar Inc.

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The hoist control lever (4) raises and lowers the truck body. The four positions of the
hoist lever are RAISE, HOLD, FLOAT, and LOWER. The truck should normally be
operated with the hoist lever in the FLOAT position. Traveling with the hoist in the
FLOAT position will make sure the weight of the body is on the frame and body pads
and not on the hoist cylinders.

© 2009 Caterpillar Inc.

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•C
 enter console stand The Auto Retarder Control (ARC) UP / DOWN switch (1) is used after the proper
components: machine speed is selected during an ARC operation. Pressing the top or the bottom
of the switch for three seconds will maintain the desired ground speed. If the speed
1. ARC UP / DOWN switch needs to be increased, momentarily press the top of the switch again. If the speed
2. ARC ON / OFF switch needs to be decreased, momentarily press the bottom of the switch.
3. Throttle back up and lock
switch The ARC ON / OFF switch (2) activates the ARC feature. Pressing the top of the
switch turns the ARC ON and pressing the bottom of the switch turns the ARC OFF.
4. Left window switch
5. Right window switch The throttle back up and lock switch (3) is used for two purposes:
6. WAVS switch
-- 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 transmission
shift lever. If there is a failure of any critical component, throttle lock will be
deactivated.

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

© 2009 Caterpillar Inc.

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The left window switch (4) and the right window switch (5) raise and lower the door
windows.

The WAVS switch (6) overrides the front and rear WAVS cameras, which causes the
WAVS to use only the right side camera. The WAVS system is discussed later in
this module.

© 2009 Caterpillar Inc.

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• WAVS components: The 793F Truck can be equipped with the Work Area Vision System (WAVS). WAVS
is a closed circuit video monitoring system used to view areas around the truck
1. LCD display where there is no clear line of sight.
2. Front camera
3. Right camera The WAVS on the 793F Truck includes a 178 mm (7 inch) LCD display (1) and
three cameras. The cameras are mounted at the front, rear, and right side of the
4. Rear camera machine.

The front camera (2) views the front of the truck, the right camera (3) views the right
side of the truck, and the rear camera (4) views the rear of the truck.

NOTE: For more information about the WAVS system, refer to the WAVS
Operation and Maintenance Manual (SEBU8157) and the WAVS Systems
Operation Testing and Adjusting Manual (RENR9833).

© 2009 Caterpillar Inc.

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• Comfort seat: The operator’s seat is a self-contained unit which uses 24 VDC to power the seat
heater and the seat air compressor.
1. Seat heater control switch
2. Seat back control lever The seat heater control switch (1) is a round, two position rocker switch. The top
3. Fore and aft seat control lever of the switch has a LED which illuminates when the seat temperature is increased.
Pressing the bottom of the switch lowers the seat temperature.
4. Air compressor knob
5. Ride zone indicator The seat back control lever (2) allows the operator to move the seat back cushion
6. Seat cushion tilt forward or backward approximately 0 to 30 degrees.
7. Shock absorber adjustment
lever The fore and aft seat control lever (3) allows the operator to move the seat back and
forth.

The knob (4) on the lower left side of the seat controls the electrically driven air
compressor. The compressor supplies the air to raise the seat (increase the load
on the seat). Pushing the knob IN will cause the air compressor to increase the air
supply to the seat. Pulling the knob OUT will relieve the air pressure in the seat. A
small hissing sound will occur when the switch is pulled out. Adjust the seat until the
white line is in the green for the ride zone indicator (5).

The seat cushion tilt (6) can change the angle of the cushion approximately eight
degrees with the two position slots.

© 2009 Caterpillar Inc.

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The shock absorber adjustment lever (7) allows the operator to set the firmness of
the seat. Pushing the lever down will increase the seat firmness.

The seat is equipped with a bright orange three-point shoulder belt for improved
operator restraint.

NOTE: For additional information about the seat and how to properly use it, go
to safety.cat.com.

Additional reference materials are:

The Cat Comfort Seat with Three-Point Operator Restraint: Six minute video
(2004)

Safety Basics--Seat Belts: Video (2007). Volume 2 in Caterpillar’s Safety Basics

(three minutes)

© 2009 Caterpillar Inc.

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• Rear of cab: The top illustration shows the back cover with a lifting device attached. Remove the
large bolt in the center and install a swivel for the lifting device. Remove the four
1. Blower motor and fan bolts to remove the cover and allow access to the components in the back of the
2. Windshield washer cab.
reservoir / pump
3. Heat / air conditioning control The bottom illustration shows the following components:
valve
-- blower motor and fan (1)
4. HVAC fan blower motor
connector -- windshield washer reservoir (2)
-- heat / air conditioning control valve (3)
-- HVAC fan blower motor connector (4).

This connection goes through the plate and is connected to the blower motor (not
shown) under the HVAC unit.

© 2009 Caterpillar Inc.

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• HVAC components: The optional recirculating fan and motor (1) removes large air particles before the air
enters the cab filter.
1. R ecirculating fan and motor
(optional) The HVAC recirculating air temperature sensor (2) sends a signal to the Brake ECM
2. HVAC recirculating air indicating recirculating air temperature.
temperature sensor
3. Electronic actuator The lower illustration shows the location of the electronic actuator (3). This actuator
uses a PWM signal between 5% and 95% to control the amount of warm engine
coolant into the cab HVAC unit.

This electronic actuator is being used along with the A/C compressor to maintain
an operator desired temperature. The automatic temperature control will maintain
the operator’s desired temperature. The cab will be cooled down or heated up
depending on operator’s demand.

Without an automatic temperature control configuration (open loop), the position of

the water valve actuator is based on the position of the temperature control switch
on the front dash panel.

© 2009 Caterpillar Inc.

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• Cab air temperature sensors: The cab has a louver temperature sensor (1). The louver temperature sensor, along
with the recirculating air temperature sensor (2), ensures that the temperature within
1. Louver temperature sensor the cab is at the temperature desired by the operator.
2. Recirculating air temperature
sensor If there is a problem with either temperature sensor, the HVAC electronic control
system will default to the manual system and the temperature will be controlled
manually by the air temperature switch.

© 2009 Caterpillar Inc.

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• Electric window control The electric window control is new on the 793F trucks. The system relies on a switch
to control the current to the motor to raise and lower the window as required.

NOTE: The regulator assembly is equipped with a thermal protection circuit to

protect the motor from damage. Depending on air temperature, window load,
and usage, the motor may trip after several cycles. Consider this normal and
not to be a defective regulator. Allow to cool for 10 minutes to reset the thermal
protection between testing.

© 2009 Caterpillar Inc.

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• Machine ECMs: The illustration above shows the location of the ECMs. To access the ECMs, loosen
the thumb screws and lower the door (not shown) at the front of the cab.
1. Transmission ECM
2. Chassis ECM The Transmission ECM (1), the Chassis ECM (2), and the Brake ECM (3) are A4:M1
ECMs equipped with two 70 pin connectors.
3. Brake ECM
4. VIMS Main ECM The A4:M1 ECMs receives three different types of input signals:
5. VIMS Application ECM
1. Switch input: Provides the signal line to battery, ground, or open.
2. PWM input: Provides the signal line with a square wave of a specific frequency
and a varying positive duty cycle.
3. Speed signal: Provides the signal line with either a repeating, fixed voltage
level pattern signal, or a sine wave of varying level and frequency.

The A4:M1 ECMs have three types of output drivers:

1. ON / OFF driver: Provides the output device with a +Battery voltage (ON) or
less than one Volt (OFF).
2. PWM driver: Provides the output device with a square wave of fixed frequency
and a varying positive duty cycle.
3. Controlled current output driver: The ECM will energize the solenoid with
pull-in current for a specific duration and then decrease the level to hold-in
current for a specific duration of the ON time. The initial higher amperage
gives the actuator rapid response and the decreased level is sufficient to hold
the solenoid in the correct position. An added benefit is an increase in the life
of the solenoid.
© 2009 Caterpillar Inc.
SERV1872 - 11/09 -25- Module 1 - Operator’s Station

The A4:M1 ECM has built-in diagnostic capabilities. When a fault is detected, the
ECM logs events in memory and diagnostic codes for troubleshooting. The events
and codes can be displayed on the VIMS Advisor panel or through Cat ET.

The VIMS Main ECM (4) and the VIMS Application ECM (5) are each equipped with
one 70 pin connector. The VIMS Main ECM provides diagnostic features through the
advisor panel. The VIMS Application ECM controls truck features such as the Truck
Payload Measurement System (TPMS).

© 2009 Caterpillar Inc.

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• Left side of cab: The air conditioning filter (1) is accessible by removing the thumb screw on the left
side exterior panel (2). No tools are required for service.
1. Air conditioning filter
2. Left side exterior panel The cab has a 9.5 L (2.5 Gal) washer fluid bottle with a 25.4 mm (1 inch) diameter
3. Fill spout fill spout (3).

© 2009 Caterpillar Inc.