Example Cover Photo

Caterpillar ® 797F Off Highway Truck

NPI – Operator Training Materials

Name
Global Mining Division

Month Year
 Safety Reminders

Emergency Contacts Emergency Information

Fire Alarm Description

•Building: <Phone #> • Evacuate
•Municipal: <Phone #> • Take cover
• All clear
Medical
•Building: <Phone #> Unique Hazards
•Municipal: <Phone #> •Room
•Floor/Building
First Responders
•Room <Identify> Emergency Procedures
•Building <Location and name> •Equipment locations
•Evacuation routes
History
 Mining Truck Evolution

Caterpillar’s mining truck experience dates back over 40 years and

includes the world’s largest truck
Year
Cat Model Introuced
769 1963
770 2004
772 1971
773 1970
775 1992
777 1975
785 1984
789 1986
793 1991
797 1998

• Over 50,000 construction and mining trucks (769-797) delivered since 1963
• Over 18,000 large mining trucks (777-797) delivered since 1980
 Field Population

Truck Total Fleet Highest Hour Unit

Model Units Hours (As of Decem ber 2008)

777 10000+ 350 million 150,000

785 2900+ 108 million 139,700
789 2200+ 91 million 116,703
793 2700+ 100 million 106,891
797 350+ 6.6 million 69,755
 Large Mining Truck Worldwide Fleet

Over 18,900 Shipments* (as of Feb. 31st 2009)

38%
North America

28%
Asia Pacific,
Indonesia &
Australia
20%
Latin America 14%
Europe, Africa &
Middle East

*Shipments leaving factory (Percentages reflect 777,785, 789, 793,797, distribution)

 797 Worldwide Fleet

Over 400 Shipments* (as of Feb. 31st 2009)

55%
North America

15%
Asia Pacific,
Indonesia &
Australia
30%
Latin America <1%
Europe, Africa &
Middle East

*Shipments leaving factory (Percentages reflect 797 distribution since 1997)

 Future Mining Truck Market Segmentation
100mt – 390mt

785C 789C 793D 795F-AC 797B

785D 793F 797F

EH3500-ACII EH4500-2 (AC) EH5000ACII

HD 1500-7 730E (DC) 830E-AC 860E (AC) 930E-4 (AC) 960E (AC)

830E (DC) 930E-4SE (AC)

MT3300AC MT3700AC MT4400AC MT5500AC MT6300AC

Unit Rig

TI274 (AC) T282B (AC)

7513 Series (DC) 7530 Series (DC) 75600 (AC)

7514 Electric (DC) 75171 (DC)

SF31904 (DC) SF32601 (DC) SF33900 (AC)

Short Tons 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250 260 270 280 290 300 310 320 330 340 350 360 370 380 390 400 410 420
Metric Tons 100 109 118 127 136 145 154 163 172 181 191 200 209 218 227 236 245 254 263 272 281 290 299 308 318 327 336 345 354 363 372 381
 797 History

The 797 has evolved to remain the leader in 360 – 400 ton size class

• Cat® 797
– 1998 to 2002
– Over 80 Units Sold
• B-Series
– 2002 to 2008
– Over 320 Units Sold
• F-Series
– Multiple Field Follow locations
in various applications
– Over 35,000 hours of field
testing and development
– Over 200,000 hours on the
C175 engines series
 F Series Development

The F-Series has evolved to offer increasing safety performance and service

• Enhanced Safety
• Increasing performance
– Lower cost per ton
– Lower maintenance costs
– Increases operator efficiency
– Streamlined operator station
• C175
– Tier 2 compliant
– Common rail fuel system
– ATAAC
• Improved Serviceability
– Ground level service
– New engine designed for serviceability
Specifications
 797B and 797F Specifications

797B 797F

Engine 3524B HD C175-20

Gross HP (2648 kW) 3,550 hp (2983 kW) 4,000 hp

GMOW (623 690 kg) 1,375,000 lb (623 690 kg) 1,375,000 lb

Gross Machine
Operating Weight

Top Speed (67.6 km/h) 42 mph (std.) (67.6 km/h) 42 mph (std.)
Loaded

Payload (345 tonnes) 380 ton (363 tonnes) 400 ton

797F Dimensions
 797F Specifications

Metric Standard Metric Standard

Maximum GMW 623 689 kg 1,375,000 lbs Fuel Tank Capacity 7570 L 2,000 gal
Avg Chasis Weight 214 888 kg 476,746 lbs Brake Discs per Side - Front 10
Engine Model C175-20 Brake Area - Front 132 238cm2 20,497 in2
3
Displacement 106 L 6469 in Brake Discs per Side - Rear 15
Gross Power 2983 kW 4000 hp Brake Area - Rear 198 354 in2 30745 in2
Flywheel Power 2829 kW 3795 hp Brake Disc Outisde Diameter 1006 mm 42 in
Rated Engine Speed 1750 rpm Total Brake Area 330 559 cm2 51,243in2
Derate Altitude 4877 m 16000 ft
Transmission Speeds 7 Forward - 1 Reverse
 Competitive Comparison

Caterpillar Komatsu Liebherre Terex

Specifications 797B 797F 960E T282 B MT6300
Engine 3524 C175-20 QSK 78 MTU 20V 4000 QSK 78
Power 2647 Kw 2982 Kw 2610 Kw 2796 kW 2609 kW
3550 hp 4000 hp 3500 (est) 3750 hp 3500 hp
Low Altitude Cap. 2590 m 2133 m 4877
8500 ft 7,000 ft 16,000 ft
High Altitude Cap. 4572 m 4877 m
15,000 ft 16,000 ft
Payload 345 tonnes 362 tonnes 326 tonnes 362 tonnes 362 tonnes
380 tons 400 tons 360 tons 400 tons 400 tons
GMW 623 690 kg 624 690 kg 572 062 kg 598 741 kg 591 938 kg
1,375,000 lbs 1,375,000 lbs 1,270,000 lbs 1,320,000 lbs 1,305,000 lbs
Tires 59/80R63 59/80R63 59/80R63 59/80R63 59/80R63
56/80R63 56/80R63 56/80R63
Speed on Grade 12% EG 10.6 kph 12.9 kph 11.1 kph
6.6 mph 8.0 mph 6.9 mph
Retarding on -9% EG 15.2 - 37 kph 15.2 - 37 kph 31.7 kph 31 kph
9.5 - 23 mph 9.5 - 23 mph 19.7 mph (est) 19.3 mph (est)
Top Speed 68 kph 68 kph 64 kph 64 kph 64 kph
42 mph 42 mph 40 mph 40 mph 40 mph
F Series Design for maximum production
 797F

The 797F is the next step in mining trucks, designed and built by Caterpillar
using components and systems that have evolved through years of rugged
mining applications
• Frame & structures
• C175-20 Tier 2 Engine
• Suspension
• Hydraulic system
• Power train
• Cooling system
• Brakes & retarding
• Operator station
• System integration
• Bodies & liners
• Tires & rims
 Operator Differences between 797B and 797F

• Walk around inspection points

• Cab – Your new office (Ergonomics)
• Cat Comfort Seat
• Brake systems
• Technology
 Performance

Preliminary data indicates the 797F with C175-20 Technology provides

improved performance over the previous 797B with 3524B engine

• 3-6% Cost per ton improvement

• All hydraulic, oil-cooled brakes
and Automatic Retarder Control
enable faster downhill hauls
• High altitude operation –
zero derrate to 4573 m (15,000 ft)
• Meets Tier 2/Stage II emissions
regulations without EGR
• 1000-hour hyd. service interval
keeps the 797F on the job longer
• New cab improves operator
comfort and efficiency
 797F Reduces Cost per Ton

Safety Maintenance Cost per Hour

• Key safety features you are used to on Cat • Continuous improvements throughout the
trucks truck target higher up-time and lower cost
(oil cooled brakes, ROPS/FOPS, 10/10/20) per hour
• Plus new enhanced safety features • VIMS System capability allows diagnostics
contribute to further lowering your costs and prognostics to extend service life of
Production components

• Optimized payload (with MSD bodies) Tire Cost per Hour

Utilization • Weight distribution and low Empty Machine

Weight (EMW)
• Traction control allows continued operation
in poor underfoot conditions • Steering geometry

Mechanical Availability • VIMS System TKPH (TMPH) Speed

Manager
• Improved reliability, higher uptime
Operator Efficiency
• C175-20 engine has lowest BMEP in its
class for added durability and reliability • Operator station comfort and ergonomics
Owning Cost • Operator confidence in braking and
retarding optimizes downhill speed
• Long economic life
Fuel Cost per Ton
• Higher resale value than competition. Even
though • Mechanical power train efficiency
a customer may not resell their truck, the • High displacement engine
high resale is indicative of the remaining • Zero fuel consumption while retarding
value in older Cat trucks
 Main Frame Castings

Caterpillar frames are designed to deliver long service life in rugged mining
applications; the 797F frame relies far more on steel castings than other
models
Fabrications
Castings

797F 797B
 Integrated Steering & Suspension

Designed for excellent maneuverability, safe operation, low maintenance

cost, lower operating costs, and a comfortable ride

• Four-corner independent, nitrogen-

over-oil cylinders offer superior
performance and
ease of service
• Front & rear struts have built-in
rebound control to improve ride
• Front cylinders act as axle mounting
group
• Turning radius designed to minimize
tire wear
• Payload sensors integrated into
suspension cylinders
• All coating on the struts rod are
Advanced Surface Technology (AST)
• AST eliminates environmental
hazards, improve wear and corrosion
resistance (compared to chrome).
 Retarding Arrangement

Improved Cost and Serviceability for Machines that don’t need extreme
retarding capacity
Downhill Haul
Two Retarding Options:
• Downhill Haul Option Equivalent
Performance to Today’s Machine
(Minimum 10% advantage)
• Flat/Uphill Haul Option which
Offers Simpler and More Cost
Effective System

Differences between the Systems:

• Hydraulic Tank Flat/Uphill Haul
• Number of Brake Oil Coolers
• Hydraulic Pump Drive Stack
• Line Sizes (Higher flow brake
cooling)
• Engine Fan Hyd. Drive
(Higher capacity cooling
system)
 Front Axle Steering Components

The 797F front suspension is a field proven design with dual tie-
rods for optimum steering geometry to help extend tire life
• Separate steering hydraulic
system prevents cross
contamination
• Secondary steering meets ISO
5010 up to120% of target payload
• Steering arm pin retention plate
provides redundant pin retention
• Front suspension cylinders serve
as kingpins
• Serviceable bracket assembly on
steering box casting saves time at
rebuild
• Two tie-rods allow optimum
steering geometry
 C 175-20

This powerful single engine block offers enhanced performance, reliability, and
serviceability.
• Gross output of 2,893 kW (4,000
hp) from 105.8 L (6,456 in 3)
• Cat Common Rail Fuel System
• Turbocharged and aftercooled
• Electronic monitoring of key
functions and logging critical
indicators
• High altitude arrangement available
• US EPA Tier 2 Compliant
• (1) ADEM IV ECM
• Retrofit available for 797B
 Tier Certification

This powerful single engine block offers performance, reliability, and

serviceability.

• Produces less NOx, HC, CO 2 and

particulate emission levels in order to
meet US EPA Tier 2 off road
requirements.
• 40% lower NOx and HC than Tier 1
requirements w/ 60% less
particulates
• Thanks to engine technology C-175
is capable of meeting these
requirements, to improve fuel
efficiency up to 5%
 Engine Specifications

C175-20 Engine Specifications

Metric English
Operating Altitude 0- 2133 m 0 - 7000 ft
Ratings @ 1750 rpm
Gross 2982 kW 4000 hp
Net 2777 kW 3724 hp
Dimensions
Bore 175 mm 6.88 in
Stroke 220 mm 8.66 in
Displacement 106 L 6469 in3
C175-20 HAA Engine Specifications
Metric English
Operating Altitude 2133 - 4877 m 7000 - 16000 ft
Ratings @ 1750 rpm
Gross 2982 kW 4000 hp
Net 2777 kW 3724 hp
Dimensions
Bore 175 mm 6.88 in
Stroke 220 mm 8.66 in
3
Displacement 106L 6469 in
 Engine Comparisons

797B797B 797F 797F HAA

Engine 2 3524B C175-20 C175-20
6 2648 kW 2983 kW 2983 kW
Gross Power
4 3550 hp 4000 hp 4000 hp

Displacement 117.1 L 106 L 106 L

7143 in3 6469 in3 6469 in3
BSFC g/kWhr 213 205 205
lbs/HpHr 0.346 0.334 0.334
1551.5 kPa 1930 kPa 1930 kPa
BMEP
225 psi 280 psi 280 psi
 Block

New engine block boosts durability and reliability of the engine

• Manufactured in Mapleton Foundry

• Single engine block
• High tensile strength ductile cast iron
• Single centrally located camshaft
• Hydraulically tightened main bearing
caps and cross bolts
 Common Rail Fuel System

Revolutionizing fuel technology to take the engine to the next level

• Gear driven high pressure fuel pump

• Achieves Tier 2 certification by
eliminating cam actuated injectors
• Optimized fuel atomization for efficient
and effective fuel burn
• Injection maximizes efficiency and cold
weather performance
 Cross Flow Cylinder Head

The head has been redesigned to improve service and performance

• Cross flow head design C175 3500B

– Increases thermal efficiency
compared to 3500
• Self rotating and water cooled valves
• Sealed with single head gasket
• Fire ring design seals eliminates need
for head gasket to carry combustion
load
 Cooling System

The 797F Cooling System new features will provide long life, higher durability,
easier serviceability and reduce downtime
• ATAAC vs. B-Series JWAC Tube
– Reduces internal combustion
Seal
temperature and emissions
– Achieves Tier 2
– Mid-Support Liner allows for better
cooling of cylinders
• On demand variable speed
hydraulic cooling fan
Hydraulic
– Reduces parasitic loss
Cooling Fan
– 5% reduction of fuel consumption
• Mesabi Radiator (Standard)
– Designed to withstand harsh
conditions and operating
environments
– Individual folded cores for
serviceability and maintenance
– Seals allow tube to be replaced
individually
 Brake Mean Effective Pressure (BMEP)

Cat engines have high power with low BMEP, which means the C175-20
works easier and lasts longer
• BMEP measures how hard
an engine is working
• Lower BMEP = longer life
• Cat engines’ low BMEP
improves availability,
extends service life and
reduces overall costs
• C175-20 works harder and
lasts longer
 VIMS ™ System & Powertrain Integration

Power train integration is designed to allow the various sensors throughout the machine to
communicate information on the performance of the machine via Cat Electronic Technician and
VIMS ™ Systems 3rd Party PL CANip Ethernet
Radio Radio Radio Truck Payload Radio
GEN 2.5 Scoreboard
Cluster
• VIMS Monitoring System
– Critical machine health and
payload information VIMS-3G Main VIMS-3G Application Smart Signal

– Real time display for Advisor CAN 1

RS232 #1
Module (A4-N4) Module (A4-N4) Module (A4-N4)

CAN 2
operator Action Lamp
RS232 #2 RS485
Data Link
RS232 #2

CAN 2

– Advanced diagnostics Action Horn

RS232 #3
Ethernet Port
RS232 #3
Ethernet Port
CAN 2
– Abnormal conditions Service Tool
Connector
CAN 1 Service Tool
Connector

identified before damage @ Cab @ Bumper

External Service Strut

occurs Lamp (300mA
Sinking Driver)
Press
Frequency

– Simplifies trouble shooting

Sensors

• Data Access ET
Service Next-Gen
Tool Off-Board
– Data stored on-board for Tool

download Cat Data Link

CAN/J1939
– Message center in cab
– Optional wireless
transmission Engine
Control
Transmission
Control
Integrated
Brake Control
Chassis
Control

– Lower overall operating cost

– Greater machine availability
 Lock-up Torque Converter

Combines the advantages of direct drive and converter drive to achieve

high component reliability and maximum output performance

• Increased power train efficiency

• High reliability from proven design
components
• 28% stall torque
• Broad converter performance
band
• Lock-up clutch engages at 7.3
km/h (4.5 mph)
 Controlled Throttle Shift

Reduces driveline torque stress for smoother shifts, extended component

life and improved operator comfort
Controlled Throttle Shift (CTS)
• Regulates engine rpm during shifts

Transmission Output Torque

• Reduces torque spikes and extends Shift without CTS
transmission life
• Smoother ride and less spillage
• Lowers operator fatigue Shift with CTS

• Possible only through electronic

integration of components
Clutch Power
Shift without CTS

Shift with CTS

Time
 Seven-Speed Planetary Transmission

Large diameter clutch packs are controlled to provide smooth shifting and
to limit clutch energy input for extended component life

• Torque converter lock-up in first Electrical Filter harness

hookup
gear Transmission
lube
• Smart shifting eliminates gear
hunting
• Downshift inhibitor prevents
engine over-speed
• Clutch packs mounted outside
of gear sets for ease of service
• Directional shift management Input Output
Lube scavenge
automatically reduces engine
throttle before shifting
 Rear Wheel Group & Differential

Heavy duty components and continuous filtration contribute to proven

durability in the most rugged conditions
• Laser-hardened spindle
• One-piece cast wheel
• Large bearings
• Continuous rear axle filtration
• Oil cleanliness to ISO 16/13
 4 Bar Link Suspension

• Lighter than traditional A-Frame

design.

• Transfers and supports loads to the

frame more efficiently than the A-
Frame design.
 AST- Advanced Surface Technology

Increasing availability, reliability, and durability AST lowers operating costs

on the machine
• No Risk to Environment
• Resurfacing Method
• Thermal Spray
• Gases combined with fine metal powder and sprayed three times the
speed of sound onto rod surface. Ground to like new polish.
• Extends life 3 times longer
• Better Wear Resistance
• Reduces Repair time
• Increases quality with life
• Reduced Seal Leakage
 AST Cylinders

• Advance Service Technology provides

improved wear resistance and repair time

• Available on front/rear struts and hoist

cylinders

• Replaces chroming
 Benefits of Continuous Filtration

Caterpillar's success with kidney looping resulted in the continuous

filtration system on the original 797 and later adapted to the rear axle of the
793D

Bearings with kidney looping and Bearings with oil changes at

4,000-hour oil changes showed 1,200-hour intervals, but without
little wear after 18,000 hours kidney looping, showed pitting at
13,000 hours
Images magnified 50x
Component and % $ Value
Improvement
10% Improvement in $26,400
Cost/Hour @ 60,000
hours
15% Improvement in $38,790
Cost/Hour @ 60,000
hours
20% Improvement in $48,840
Cost/Hour @ 60,000
hours
 Braking System

The braking systems have been designed with the operator’s safety,
product performance, and operating costs in mind.
• Four corner braking system
• Wet brake system vs. Competitive dry brake system
• Hydraulic retarding system
– Saves on brake wear
– Used on all speeds over 7 mph
• Proper operator training available through Cat dealer and certified operator
trainers
• Optional brake wear indicator
 797F Brakes and Retarding

Oil-cooled multiple disc brakes on all four wheels provide exceptional

braking and retarding
• Integrated systems deliver 2
optimum performance
• Non-fade oil cooled design 1
offers reliable performance
and long life
• Spring applied secondary
parking brake systems
7
enhance safety 3
1. Parking/secondary piston
• Four wheel braking 2. Service/retarding piston
4
improves control 3. Friction discs
• Sealed system prevents 4. Steel plates
contamination 5 6 5. Actuating springs
• Brake wear measurements 6. Cooling oil in
7. Cooling oil out
completed quickly
• Purpose Built Integrated
System
 Integrated Braking Control

Integrates the Hydraulic Automatic Retarding Control and the Traction

Control System into one electronically controlled braking system

Hydraulic Automatic Retarding Control: Traction Control System:

• Increases production due to faster • Improved traction in poor underfoot
downhill speeds conditions
• Adjustable by operator • Less slippage means less tire wear
• Less operator fatigue
• Engine overspeed protection
 797B Tires & Rims

• Tires are available from the two Tire Rim

leading manufactures to ensure
Bridgestone 59/80R63 1118 mm
competitive pricing
44 in
and ongoing development
Michelin 59/80R63 1118 mm
• Rims are available in three options
44 in
– Standard
– Wedge-lock
– Heavy Duty Quick Change
• Designed to minimize
maintenance and maximize
durability
• Quick Change Rims reduce the
time it takes for changing tires,
and improve serviceability
 Quick Change Rims

• Reduces time required to perform tire maintenance up to 70%

• Design ensures longer life
• First inspection at 15,000 hrs
• Rim removal synchronized with final drive removal
• No tensioning of nuts required after tire change
 Tire Change Time Comparison

D
O
W
N
T
I
M
E

H
O
U
R
S

Pos 3 or 6 Pos 4 or 5 Pos 3&4 or 5&6 Pos

3,4,5&6
Standard Rim Quick Change Rim
 Extended Tire Life

The Cat 797F is designed specifically to extend tire life and reduce costs

• Gross weight distribution is ideally 33.3 /

66.7 front-to-rear axle
• Traction Control System reduces tire
slippage and wear
• Integrated VIMS System Speed Manager
reduces heat separation failures by
monitoring tonne kilometers per hour (ton
miles per hour)
• Steering geometry and turning radius are
designed to minimize tire scrub
 Operator Station

The integral, sound-suppressed ROPS/FOPS cab gives the operator a

comfortable and safe working environment
• Common cab from 793 - 797
• Ergonomically designed, air
suspension seat
• Integrated Parking Brake and
gear selector
• VIMS™ System displays and
operator keypad
• Tilt and telescoping steering
wheel
• Centralized Controls
• Full sized Trainer seat
• Powered operator window
• Passenger Power Window
(Optional)
• Fixed
(Standard)
 Cab Visibility

Keeping the operator in mind we have changed the cab to enhance

operator efficiency and comfort.

797B 797 F

• 40% more window area than 797B

• 15% improvement in operator visibility

 Safety

Design features target to help reduce haulage injures

*
Fire Prevention
• Turbo – raised off the engine and to the front with
no hydraulic lines above
• Starters- air standard
• Brushless alternator reduces sparks
Slip and Fall Prevention
• One level right hand platform
• Service platforms
• 600 mm access / egress
Haulage Specific Prevention
• Four-corner wet oil-cooled brakes
• Four post ROPS
• Wide operator visibility
• Quiet cab
• Guarding for moving part

* Historical data provided to Cat from an international mining company

Serviceability
 Ground Level Service

Easily accessible drain plugs are installed in components to provide an

environmentally safe and effective method to drain fluids
• Ecology Drains
• Filters serviceable from ground
level (excluding air filters)
• Power 3-way lockout box
• Oil level sight gauges
• Fast fuel system
• Grouped service points

1800 mm
1798 mm
 Environmental

Producing product responsibly to work better today for a safer tomorrow.

• EPA US Tier 2 compliant

– Reduced emissions into environment
• Ecology Drains
• 1000hr hydraulic system filter life
• Extended PM intervals
• Cat Reman
Equipping Your Truck
 797F Standard Equipment

Operator Environment • Hoist, body control (electric) • Braking system:

• ROPS cab-insulated/sound – Integrated park brake and
• Air conditioner suppressed directional selector
• 12 V DC Power Supply • Seat, air suspension – Brake release motor
• Coat hook • Seat, passenger – air (towing)
suspension – Oil-cooled, multi-disc (front
• Diagnostic connection port • Seat belt, 75 mm (3 in) wide & rear) (service, retarding,
retractable parking, secondary)
• Dome courtesy light • Steering wheel, tilt, padded, – Automatic Retarder
• Gauges/Indicators: telescopic Control
• Storage compartment – Engine overspeed
– Transmission fluid • Tinted glass
temp protection
• Window, electric powered, – Extended life brake disc
– Brake oil temp operator material
– Engine coolant temp • Windshield wiper, intermittent • Transmission:
– Fuel level control, washer – 7-speed, auto power shift
Power Train w/ECPC
– Torque converter • C175-20 Tier 2 Diesel Engine – Body-up reverse
temp • Turbocharging (4) / Aftercooled neutralizer
– Body-up shift inhibitor
– Hour meter • Air cleaner w/precleaner (5)
• – Controlled throttle shifting
– Speedometer Automatic starter protection
– Directional shift
• Ground level engine shutdown
– Tachometer • Ether starting aid (automatic)
management
– Neutral coast inhibitor
– Transmission gear • Elevated low idle control – Neutral start switch
indicator • Crankcase protection – Programmable top gear
– VIMS message • Multi-point oil pressure sensing
center w/ advisor
 797F Other Standard Equipment

Electrical • Ground level VIMS System data port

• Alarm, backup • Ground level battery disconnect
• Brushless Alternator 150 ampere
• Batteries (2), 12V, 93 amp-hour • Hi-speed crankcase oil change
• Converters (2), 12V electrical • Reservoirs (4):
• Electrical system, 24V, 10, 20 & 25 amp – Brake
• Directional signals (front & rear LED)
• Front stair access/Service deck – Hoist
• Stop/taillights (LED) – Steering/Engine Hyd. Fan
• Engine compartment light – Torque Converter/Transmission
• Headlights w/ lo-hi beam selector
• Backup and hazard lights • Rock ejectors
General • Supplemental steering (automatic)
• Traction Control System • Traction control system
• Auto lubrication system
• Aux "buddy" dumping quick connect • Tie down eyes
• Aux steering quick connect (towing) • Vandalism protection locks
• Driveline operator safety guard VIMS System
• Fast fill fuel system
• Fuel filter w/ water separator • Includes VIMS System Payload Monitor w/MAX Payload
& Speed Manager
• Recommended using download cable 127-9797
and PC based software JERD 2175
• Supplemental software "VIMS System Supervisor" YERA
1403
Order separately (Computer not provided)
Antifreeze
• Extended Life Coolant to -35C (-30F)
 797F Optional Equipment

• WAVS Camera System

• Oil Renewal System with or
without 3 day makeup tank
• Fire Extinguisher
• Torque converter guards
• Brake wear gauge
• Fuel Heater
• Cold weather starting
• Wiggins service center
• Brake wear indicator
• Rims
– Standard
– Wedgeblock
– Quick Change
Caterpillar Truck Bodies
 797F MSDII Body

Available in 3 sizes:
• 241 m 3 (315 yd 3 )
• 252 m 3 (330 yd 3 )
• 268 m 3 (350 yd 3 )
Enhanced design versus smaller trucks
• Floor, sidewall, & frontwall plate
thickness increased
• Heavier floor structure
Why?
• Wide application range
• Green field vs. mature mine
• Larger loading tools
 Front to Rear Body Flare

• 1 ° flare – front interior body

6982 mm width to rear interior body width
• Improved material flow / release
• Reduces wear on rear sidewalls
(less material contact)

Front to
Rear
Flare

7265 mm
 Body Exhaust Heat

Exhaust
Outlets

• Highly cohesive applications

• Carry back reduction system
• Hot surface improves material flow
• Targets problem areas
 Floor & Ribs

• Rib seam offset from floor seam

• Maximize berm clearance

• Enhanced impact resistance
• Reduces stress under racking conditions
 Attached Hardware

Lifting Options
• Lower sidewall lifting lugs
• Upper sidewall lifting lugs
• Loading target Pivot Area and Hoist Brackets
• Factory pre-assembled and
installed
• Internal and external gussets
provide full support
• Solid piece pivot bracket
 Understructure Gussets & Rib Coverage

• Internal and external gussets optimize stress distribution

• Minimizes impact damage to floor
• Analyzed and tested for optimal floor rib coverage
 Body – Chassis Guards

• Complete forward machine coverage

• Canopy rock shedders
• Rear tire rock shedders
 Mine Specific Design (F.A.C.LT)

Impact & wear protection that maximizes body life & performance

F ragmentation
A brasion
C ohesion
L oading
T ool
 FACLT & Body Liner Segmentation

L1 L1

L2 L1 L2

L4 L3 L4

L5 L3 L5

L8 L8
L7 L 11 L 13 L 11 L7

L9 L6 L6 L9
L 12 L 14 L 12

L 10 L 10

L 15
L 15
L 15
 Caterpillar Body Liner Options - Types

Smooth Plate
for cohesive
materials
Zipper Grid
For semi-cohesive
materials

Rock Box
for dry and non-cohesive
materials

Mechanically Attached Wear

Plate System (MAWPS)
semi-cohesive to non-
cohesive materials
Productivity
 10/10/20 Overload Policy

90% of loads should fall into this

• No more than 10% of loads above 110% range
No more than 10% of loads
• No loads above 120% should exceed 110% of the target
• The average payload shall not exceed the payload
No loads should be above
target 120% of the target payload

90
%
 MineStar™ System – Integrated Mine Information

GPS Infrastructure: Satellites, Repeaters, Base Station

Radio Network

MineStar… Assignment Production Machine Material Machine

Health
Monitoring Tracking Tracking Guidance

KPIs/
Graphing
Data Flow
Reporting

Business
Intelligence Engineering Administration
Production
and / Management
Geology
Reports

Processing Maintenance Safety

 Road Analysis Control (RAC)

RAC monitors and logs haul road severity to increase truck life and reduce
cost/ton
• Existing suspension cylinder
pressure sensors measure pitch &
bias of truck, and frame rack (twist)
• System identifies haul road problem
areas to avoid and correct
• Transmits real time data and GPS
locations to haul road maintenance
via radio, if equipped
• Improved haul roads help optimize
truck component life, fuel
consumption, and safety
 VIMS™ System Speed Manager

Fully integrated with VIMS System, Speed Manager consists of three

features that help optimize truck safety and performance, lower costs, and
extend service life
• VIMS System MAX Speed
Manager
• VIMS System TKPH (TMPH)
Speed Manager
• VIMS System MAX Payload
Speed Manager
New Features
 New Features

• Safety (Standard)
– 600 mm (23.6 in) wide access from ground to cab
– Improved secondary egress ladder
– Ground level access service points
– Ground level access to filters
– Three-way lock-out/tag-out box at ground level
– Engine bay designed without any hydraulic routings above the
turbos.
– Spring assist struts on hood providing less effort to open.
 New Features (Cont.)

• Safety (cont…)
- Fully enclosed driveshaft
- Increased ROPS capacity
- Low operator sound and vibration
- Toe kicks
- Reverse neutralizer when dumping
- Body raise indicator
- Dual body retaining cables
• Optional
- Optional WAVS (Work Area Vision System)
- Slow Object Detection System
 New Features (Cont.)

• Engine
– C175 – 20 ACERT Technology Engine EPA Tier II compliant.
• Provides 13% more power.
• Common rail fuel system.
• Power Train
– Increased speed on grade (12% effective) to 12.5 km/h (7.8 mph)
 New Features (Cont.)

• Improved main frame

– 4 Post cab mounts with increased ROPS capacity
– Straight front frame rail design (simpler and allows for better load
transfer for towing)
– Battery Box integrated into front bumper design for better serviceability
• Hydraulic Brakes
– Extended Life Brakes (XLP) are standard in all configurations
• Serviceability
– All Service Points accessible from ground level
 New Features (Cont.)

• Cab and Operator Environment

– Increased ROPS capacity
– 15% improved visibility
– New cab mounts reducing vibration and noise levels
– New cab/controls
• Adjustable retarding control
• Transmission and Hoist controls
• Monitoring System
– VIMS 3G with Advisor monitoring system
Machine Inspections
 Right Side Inspection

Inspect the following:

- Tires/rims
- Front wheel oil sight gauge
- Steering system components
- Suspension cylinder
- Steering Accumulators (3)
- Filters
- Transmission/Torque converter
- Hydraulic tank sight gauges
- Hoist cylinder
- Frame and body
 Front wheel oil level - check

• Check the front wheel oil level using the sight gauges and maintain the oil
level to the bottom of filler plug.
 Hydraulic Tank

1) Brake actuation reservoir

2) Hoist and brake cooling

reservoir

3) Steering/Hyd. Fan reservoir

 Hydraulic Tank

Brake/Hoist Fill

Brake sight gauge

Hoist sight gauges

Steering/Fan Fill

Steering/Engine Hydraulic
Fan sight gauges
 Brake and Hoist sight gauges

(1) Hoist reservoir sight gauge (2) Brake reservoir sight gauge
 Hoist sight gauge (body raised)

(1) Hoist reservoir sight gauge (body raised)

 Steering and Eng. hyd. fan reservoir sight gauges

Engine “stopped” check

1

Engine “running” check

Steering and Engine hydraulic fan

reservoir sight gauges 2
 Rear Inspection

Inspect the following:

- Lights
- Suspension cylinders
- Leaks
- Oil level sight gauge
- Grease fittings and lines
- Rock ejectors
- Tire tread
- Body pins
- Body cables
 Differential and Final Drive Oil Check

A
B
1

Differential and Final Drive Oil Sight Gauge

 Left Side Inspection

Inspect the following:

- Handrails
- Engine Oil level sight gauge
- Auto Lube Reservoir
- Air Tank
- Tires/rims
- Front wheel oil sight gauge
- Steering system components
- Suspension cylinder
- Torque convertor/Trans. oil level
sight gauge
- Fuel tank
- Hoist cylinder
- Frame and body
 Engine Oil Level Sight Gauge location

Engine Oil Level Sight Gauge

 Engine Oil Level Sight Gauge

If the engine is stopped and the

oil is cold, maintain the oil level in
the upper green range. A

If the engine is running at low idle

and the oil is at operating
Tempture, maintain the oil level in
the lower green range.

B
 Air tanks

Air Tank Drain

 Auto Lubrication System

Auto Lube System (Air Motor)

 Front wheel oil level - check

• Check the front wheel oil level using the sight gauges and maintain the oil
level to the bottom of filler plug.
 Torque Converter/Trans. oil level check

Check oil level in Torque Converter

sump with engine at an idle.

Oil at operating temp. (hot) in upper sight gauge (1)

Oil at ambient temp. (cold) in lower sight gauge (2)

 Front Inspection

Inspect the following:

• Ground level controls
• Lights
• Auto Lube Reservoir
• Air filters
• Radiator
• Battery compartment
• Fast Fill Service Center (Optional)
• Ladders and platforms
• Engine compartment
• Coolant level
• Windows/Mirrors
 797F Ground Level Energy Isolation Box (standard)

VIMS Event
Light
VIMS Data Port

Battery Charge
Battery Receptacle
(mounted beside box, not
Lockout (1) pictured)

Machine/
Engine Service Transmission
Lights Switch (2) Lockout (6) &
Indicator Lamp

Ladder Lamp Engine/Starter

Engine Shutdown
Switch (3) Lockout (5) &
Switch (4)
Indicator Lamp
*NOTE: This is a standard feature on the F series. Please continue to refer to site specific “lock out/tag out” policies.
 Battery compartment

• Battery Box
integrated into front
bumper design for
better serviceability
 797F Fast fill service center (optional)

Level indicator for Torq. Conv./Trans. oil (cold) (1) Level indicator for hoist/brake oil (cold) (3)
Level indicator for Torq. Conv./Trans. oil (hot) (2) Level indicator for hoist/brake oil (hot) (4)

Level indicator
for Engine oil
(Full engine on)
(5)
Level
3 4
indicator for
coolant
1 2
(Full) (6)

Level indicator Power switch

for Steering oil for Fast Fill
(Full engine off) service
(15) center (7)

Torque Engine Oil

Conv./Trans Level Port (8)
Oil Port (14) indicator for
Engine
Diesel Fuel Coolant Port Auto Lube Steering system Oil Hoist and Brake Oil
Port (13) Reservoir Port (10)
(12) (Full) (11) Port (9)
Cab Features
 Operator Comfort and Efficiency

Cat 797BD Cat 797F

 Operator Environment - Pedals

Service
brake
Foot rest

Secondary
brake Accelerator
 Steering Wheel and controls

Steering Wheel Control

Multi Function Manual Retarder

Control Lever Control Lever

Steering Wheel Tilt/Telescope Control Lever

(Below Multi function control lever)
 Cat Comfort Seat

The Caterpillar Comfort Seat with three-point operator restraint is the

most durable and supportive seat available for Cat Mining Trucks

• High-back seat supports head and neck Three-point restraint

• Ride zone indicator adjusts seat suspension to
operator’s weight
• Adjustable rake lower cushion
• Washable seat cover
• Dual retractor lap and shoulder belt system
• Adjustable shoulder belt has six vertical
height settings for optimum fit
Note: Refer to “Operations and Maint. Manual”
SEBU8406-00 for more detailed explanation of
adjustments. *

* Additional resources listed below in speaker notes for seat and adjustments to ensure operator comfort.
 Seat control adjustments

Seat cushion
Back cushion tilt
angle lever
Fore/Aft
adjustment
lever

Ride indicator
Ride
adjustment
lever

Height
adjustment
lever
NOTE: There are additional adjustments not shown in this photo, please see below and refer to OMM.
 Instrumentation Panel
Instrument Cluster

Hazard Flasher Switch VIMS Advisor Screen

Access Light Switch

Headlight, Parking Lights, Heated Mirror Switch

and Taillights Switch (If equipped)

Fog Light Switch Panel Light Switch

Air Conditioner Switch

Engine Start Switch

Cigarette Lighter

12 volt receptacle
Fan Speed Switch Temp. Variable Control
 Electric Start System

New machine starting option will allow the elimination of an air system.
 ATC - Automatic Temp. Control

Heating and Air Conditioning System

Air Conditioner Switch –

- Pushing the “top” of the switch “manually”
turns on the AC.

- If the switch is in the “middle” position the

AC system is off.

- Pushing the “bottom” of the switch will turn

on the Automatic Temperature Control.
Instrument Cluster
VIMS™ 3G with Advisor
 Console Controls

Transmission Control

Hoist Control

Automatic Retarder
Control(ARC)

Throttle backup and

Throttle Lock Switch
Automatic Retarder
Adjustment

WAVS Camera Switch (If

Equipped)

Left Power window switch Right Power Window

Switch
 Console Controls – Transmission Control Lever

Increment button (on front of control handle)

Shift control release button

Decrement button
 Console Controls – Hoist Control Lever

Body Lower

Body “Float”

Body “Hold”

Body Raise
 Console Switches

Automatic Retarder
Control(ARC) Throttle backup and
Throttle Lock Switch

WAVS Camera Switch

Automatic Retarder
(If Equipped)
Adjustment

Right Power Window

Left Power window switch
Switch (If equipped)
 Overhead console switches

Brake Release Switch

Idle Shutdown Timer Switch (If

equipped) See speaker notes.

Traction Control System Test switch

 WAVS Camera System

Display Front Camera Right-hand Camera Rear Camera

Optional system to enhance the operators vision

Rear view automatically displayed when machine

is placed in reverse
 Caterpillar Integrated Object Detection System TM

The system consists of:

• An interactive touch screen display in
the cab
• Medium Range Radars front & rear
(~ 20 metre range)
• Short Range Radar front, rear & sides
(~ 7 metre range)
• Cameras on all 4 sides of the machine

Alerts the operator during startup

and initial machine movement of
objects within the machine’s
immediate surroundings,
particularly “blind spots.”
 Cat Integrated Object Detection System Benefits

• Improves site safety by enhancing

operator’s situational awareness

• Stand alone machine system - does not

require any off-board infrastructure

• Easy to learn user interface

• Minimizes nuisance audible alarms

• Scalable solution allows user to start with

camera system and later add radars
Cat Integrated Object Detection System

• Available January 2010 on Large Mining Trucks

– 785, 789, 793 & 797
– Additional models expected later 2010

• Can be ordered with new truck or retrofitted to

existing
– Listed as optional attachment on truck
price pages

• Marketing materials being completed and

uploaded to Cat Electronic Sales Library

• Dealers start targeting customers for system

now
 VIMS™ 3G with Advisor

Scroll up/left button

Scroll
down/right
button

Preset Buttons Back

button

Main
“Home”
menu
button
OK
Digital display area button
 Warning Levels

Category Message Display Action Lamp Action alarm

Level 1 Displayed on Advisor screen Solid Amber N/A

Level 2 Displayed on Advisor screen Flash Red N/A

Level 2S Displayed on Advisor screen Flash Red Continuous

Level 3 Displayed on Advisor screen Flash Red Pulse

 Advisor “Home” Screen

Actual Gear Transmission control position Top drive Gear

Status of
ARC *

Date/Time

“More options” indicator

Menu items
Advisor “Home” Menu Selections
Advisor “Operator” Menu Selections
Advisor “Operator” Menu Selection Map
Advisor “Monitor” Menu Selection
Advisor “Monitor” Menu Selection Parameters
Advisor “Payload” Menu Selection
Advisor “Payload” Menu Selection View
Advisor “Service” Menu Selection
Advisor “Service” Menu Selection Map
Advisor “Service - Diagnostics” Menu Map
Advisor “Diagnostics – Active Events” Menu

Active Events List

Advisor “Diagnostics – Logged Events” Menu

Logged Events List

Advisor “Diagnostics – Triggered Snapshot” Menu
Advisor “Diagnostics – Data-logger Start” Menu
Advisor “Diagnostics – Data-logger Stop” Menu
Advisor “Diagnostics – Data-logger Reset” Menu
Advisor “Service - Submenus” Menu
Advisor “Service - Calibration” Menu
Advisor “Settings” Menu
Advisor “Service Mode” Menu
 797F Operation

Secondary Steering Test

1. When the engine is stopped, check level of steering oil is in proper range in upper
sight gauge.
2. After engine is started, check level of steering oil is in the proper range in the lower
sight gauge.
3. With engine running and engine start switch in “on” position, shut engine down with
the ground level shut down switch (front bumper).
4. Return to cab and turn steering wheel to the left and to the right.
5. If steering wheel does not turn or there are problems turning the wheel, consult
your local Cat dealer.
 797F Operation

Brake System Tests

• Service
• Secondary
• Parking
 797F Operation

Service and Secondary Brake System Test

1. Fasten the seat belt before you test the brakes.
2. Check the area around the machine. Make sure that the machine and area is clear
of personnel and clear of obstacles.
3. Test the brakes on a dry, level surface.
4. Start the engine.
5. Depress respective brake control in order to apply the respective brake system.
6. Move the transmission control to the “D” position.
7. Gradually increase the engine speed to 1300 rpm. The machine should not move.
8. Reduce the engine speed to an idle. Move the transmission control to the P
position. Stop the engine.

NOTICE
If the machine moved while testing the brakes, contact your Caterpillar dealer.
Have the dealer inspect and, if necessary, repair the service brake before returning the
machine to operation.
 797F Operation

Parking Brake System Test

1. Fasten the seat belt before you test the brakes.
2. Check the area around the machine. Make sure that the machine and area is clear
of personnel and clear of obstacles.
3. Test the brakes on a dry, level surface.
4. Start the engine.
5. When the transmission control is in the P position, depress the “increment” button
(front of control lever) and depress the “decrement” button (left side of the control
lever) at the same time.
6. While both buttons are depressed, Move the transmission control to the D
position.
Note: The buttons can now be released and the parking brake will remain on.
7. Gradually increase the engine speed to 1300 rpm. The machine should not move.
8. Reduce the engine speed to an idle. Move the transmission control to the P
position. Stop the engine.

NOTICE
If the machine moved while testing the brakes, contact your Caterpillar dealer.
Have the dealer inspect and, if necessary, repair the service brake before returning the
machine to operation.
Questions?
Caterpillar® 797F Off Highway Truck
 797B to 797F Retrofit

797 B vs 797F Component Interchangeability

797 B 797 F Comments
Retrofit Package
Engine 3,550 hp 3524B 4,000 hp C175-20
Available w/ 1st Production
19,000 ft lbs, Additional Disc Backwards Retrofittable Package Available
Torque Converter 19,000 ft lbs
& Plate w/ 1st Production
Backwards Retrofittable with Software
Transmission 7 speed FWD 7 speed FWD, non-latching
Availability not confirmed yet
Differential Rear Mounted Rear Mounted, Gen 3 Interchangeable
Front Wheel Stations Interchangeable with a spindle change
10 Discs/Brake, 42", 5 Pitch 10 Discs/Brake, 42", 4 Pitch
Interchangeable with Complete Wheel
PB Spring Applied PB Spring Applied
Front Brakes Group.
SB Hydraulic Applied SB Hydraulic Applied
Available w/ 1st Production
Oil Cooled Oil Cooled
Rear Wheel Stations Interchangeable
15 Discs/Brake, 42", 5 Pitch 15 Discs/Brake, 42", 4 Pitch
PB Spring Applied PB Spring Applied Interchangeable with Spindle Change
Rear Brakes
SB Hydraulic Applied SB Hydraulic Applied Available w/ 1st Production
Oil Cooled Oil Cooled
Fan Hydraulically Driven 106" Hydraulically Driven 106" Interchangeable
Pump Drive Box HD HD Interchangeable
 Media Support
www.cat.com
www.safety.cat.com
www.catreman.cat.com
www.catminer.cat.com
C175 Engines
Mining Truck Bodies
Body Maintenance
Ground Rules
Product Development Video
Specalog XXXXX-XXXX
Show Spec Sheet AEHQ5946-01
VIMS AEXC0681
WAVS TEKQ0647-03
Virtual Operator Training TERV0101
Mining Safety Brochure AEXQ0370
Minestar AEHQ6017-01
CPI AERV5715
RAC TELQ4461
 Reference Materials

• 797F OMM #SEBU8417-00

• 797F Specalog #AEHQ6039 (Spanish – ASHQ6039)
• 797F Marketing Bulletin #TEJB9480-01
• 797F Product Bulletin #TEJB9521
• Cat Comfort Seat Salesgram #TEKQ0239
• “Cat Comfort Seat with three point operator restraint” video
#AEVN5717 (Avail. in Spanish and Portuguese)
• Integrated Object Detection System Salesgram #TEKQ0747-02
• Integrated Object Detection System Specalog #AEHQ6054 (Avail.
In Spanish, Portuguese, Indonesia and French)
• F Series Supporting documents; https://catminer.cat.com/trucks
• STMG media #SERV1872