Global Manpower Development

795F AC Off-Highway Truck

INTRODUCTION
TEXT REFERENCE

SERV1882

795F AC Off-Highway Truck

Introduction
Text Reference

© 2010 Caterpillar Inc.

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SERV1882 - 07/10 -2- Introduction

2_1

TRUCK FEATURES

• Electric drive train The 795F AC truck features an electric drive train in place of a mechanical power
train. Electric drive relies on a diesel engine to turn a generator, which provides
electric power for wheel traction motors that propel the truck.

•C
 175 16 cylinder engine Power is supplied to the new 795F AC truck by the C175 16 cylinder engine. The
engine will supply increased horsepower with more accurate fuel injection control.
The fuel system will consist of a low pressure transfer pump and a high pressure fuel
pump supplying fuel to a common rail. The fuel system delivery will be controlled by
a fuel control valve which receives its signal from a A4:E4 Electronic Control
Module.

• Brake hydraulic system The service and parking brakes are controlled hydraulically. The hydraulic system
is equipped with a new brake/chassis control valve which controls service and
parking (secondary) braking, and accumulator purging.

• VIMS™ 3G with Advisor The monitoring system in the 795F AC truck is the new VIMS™ 3G with Advisor.
VIMS 3G will be a messenger from each of the individual ECMs on the truck.

• New cab The 795F AC truck will be equipped with a new cab. The cab changes include
improvements made for operator comfort and improved access for the technician.
The cab also has more interior air movement, with additional louvers for increased
air flow.

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(2) Mechanical Power Train (1) Electric Drive Train

(3) (3)
Engine Engine
(5) Torque
Converter
(4) Generator

(6) Inverter
(7)
Transmission
(9) Final (9) Final (9) Final (8) (8) (9) Final
(10) Differential Electric Electric Drive
Drive Drive Drive
Motor Motor

3_1

ELECTRIC DRIVE TRAIN VS. MECHANICAL POWER TRAIN

• Drive system components: This illustration shows the basic components of an electric drive train (1) compared
to the basic components of a conventional mechanical power train (2).
1. Electric drive train
2. Mechanical drive train The electric drive train arrangement uses mechanical energy from the engine (3)
to rotate a generator (4), whereas the engine rotates a torque converter (5) on
3. Engine mechanical drive trucks. The generator transmits power through high voltage cables
4. Generator to the inverter (6) which controls the rimpull, direction, and speed of the truck. On
5. Torque converter trucks with a mechanical power train, the rimpull, direction, and speed of the truck is
controlled by the transmission (7).
6. Inverter
7. Transmission On electric drive trucks, the inverter changes and controls the incoming power, then
8. Electric motor drives an electric traction motor (8) coupled to a final drive (9) at each rear wheel
9. Final drive station. The rear traction motors convert this electrical energy to mechanical energy
to propel the truck.
10. Differential
Trucks with mechanical power trains transfer power to the rear wheels through the
differential (10) and final drives.

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4_1
POWER TRAIN ANIMATION

• Play animation This animation shows the power flow through a mechanical power train and an
electric drive train.

Note: The generator is not connected directly to the engine as depicted in this
illustration. On the 795F AC truck, the generator is coupled to the engine by a
torsional rubber coupling and driveshaft. Refer to Module 10 “Drive Train” for
more information on the electric drive system.

Power flows though the following mechanical power train components:

-- engine (1)
-- torque converter (2)
-- drive shaft (3)
-- transmission (4)
-- differential (5)
-- final drive (6)
-- differential power transfer (7)

Inside the differential, power flows through the pinion gear (8) and the ring gear (9).

Power flows though the following electric drive train components:

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SERV1882 - 07/10
•F
 ast fill panel ports and
indicators:
1. Cold hoist oil full indicator
2. Hot hoist oil full indicator
3. Engine oil full indicator
4. Steering oil tank section full
indicator
5. Engine coolant full indicator
6. Grease tank full indicator
7. Indicator test switch
8. Fuel tank fast fill port
9. Engine oil fast fill port
10. Engine coolant fast fill port
11. Steering oil tank section fast
fill port
12. Hoist and brake oil tank
section fast fill port
-6- Introduction
6_1
CATERPILLAR FAST FILL PANEL
The Caterpillar Fast Fill panel is located to the left of the front bumper.
The fast fill panel allows individual fluid levels to be filled directly from the front of the
truck. Also displayed on the panel are the fluid level indicators.
The fill ports and indicators are:
-- cold hoist oil full indicator (1)
-- hot hoist oil full indicator (2)
-- engine oil full indicator (3)
-- steering oil tank section full indicator (4)
-- engine coolant full indicator (5)
-- grease tank full indicator (6)
-- indicator test switch (7)
-- fuel tank fast fill port (8)
-- engine oil fast fill port (9)
-- engine coolant fast fill port (10)
-- steering oil tank section fast fill port (11)
-- hoist and brake oil tank section fast fill port (12)
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• Front bumper:
1. Blue light
2. Engine shutdown switch
3. Battery disconnect switch
4. Machine lockout switch
5. Machine lockout lamp
6. Starter lockout switch
7. Starter lockout lamp
8. VIMS™ 3G download service
connector
9. Engine work lamp switch
10. Ladder lamp switch
11. Optional powered stairway
switch
-7- Introduction
7_1
REMOTE SWITCH PANEL
The remote switch panel is located on the front bumper.
Above the remote switch panel is a blue light (1) that is illuminated whenever an
active diagnostic code or an active event (Warning Level 2 or higher) is recognized
by the VIMS™ 3G module.
The engine shutdown switch (2) is used to stop the engine from ground level. The
battery disconnect switch (3) in the OFF position disconnects power to the truck.
The machine lockout switch (4) initiates NEUTRAL through the Drive Train Electronic
Control Module (ECM). The Drive Train ECM disables the generator excitation field
regulator which allows the technician to service the machine with a running engine.
The machine lockout switch also disables the hoist function. When the machine
lockout switch is ON, the parking brake is ON, and the ground speed is zero. The
machine lockout lamp (5) will be ON solid and the machine will be locked out (not
able to move). The machine lockout lamp will flash when the machine lockout switch
is activated but either the parking brake is OFF or the ground speed indication is not
zero.
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• Powered stairway switches:
1. Upper stairway switch
2. Remote switch panel
3. Manual valve
-9- Introduction
9_1
POWERED STAIRWAY
The 795F AC Truck may be equipped with a powered stairway. The stairway can be
mounted to face the left or right side of the truck.
The stairway is raised and lowered with a switch (1) located at the top of the ladder
and a switch located in the remote switch panel (2). A manual valve (3) can be used
to lower the ladder if truck electrical power is lost.
If the manual valve is activated, the control valve linkage will need to be reset before
the control switches can be used to move the powered stairway.
NOTE: Refer to the Operation and Maintenance Manual for the procedure to
reset the control valve linkage.
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10_1
• Remote switch panel (arrow) This illustration shows the stairway facing the left side of the truck.

When the stairway faces the left side of the truck, the remote switch panel (arrow) is
located on the left side of the front bumper.

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11_1 11_2

11_3 11_4
• Powered stairway switches: These illustrations show a closer view of the upper stairway switch (1), the lower
stairway switch (2), and the manual valve (3).
1. Upper stairway switch
2. Lower stairway switch
3. Manual valve

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12_1
• Below stairway platform: The hydraulic pump (1) sends oil to the hydraulic cylinder (2) to raise and lower the
ladder. The pump is driven by an electric motor (3) via the motor relay (4).
1. Hydraulic pump
2. Hydraulic cylinder The ladder can be activated when the parking brake is ON and the shift lever is in
3. Electric motor PARK or NEUTRAL. If the parking brake is not ON or the shift lever in not in PARK
or NEUTRAL, the Brake ECM will send a signal to the ladder enable relay and the
4. Motor relay relay will disable the system.
5. Ladder sensor
When the ladder is fully raised, the ladder sensor (5) notifies the Chassis ECM.

The VIMS™ 3G will initiate a Level 2S Warning if the ladder is not fully raised and all
of the following conditions are present:

-- engine speed is above 500 rpm

-- truck is not locked out
-- shift lever is not in the PARK position

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13_1 13_2

13_3
STARTING SYSTEM OPTIONS

Starting system components: The 795F AC trucks can be equipped with an air starting system or an optional
1. Air start motor electric starting system. The top left illustration shows the location of the air start
2. Electric start motors motor (1). The air start motor is located at the rear of the engine on the left side.
3. Start relays
The top right illustration shows the two electric start motors (2), the start relays (3),
4. Start solenoids
and the start solenoids (4).

On trucks with an air starting system, the air system also controls the autolube
system and the air horn. On trucks with an electric starting system, there is no air
system. The autolube system and the horn are electrically controlled.

When the truck is equipped with an air system, two 12 volt batteries connected in
series supply 24 volts to the machine and engine systems.

When the truck is equipped with an electric starting system, dual sets of two 12 volt
batteries (bottom illustration) are connected in series to supply 24 volts . Each set of
batteries supplying 24 volts is connected in parallel for additional current for engine
starting.

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