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    Caterpillar Product Information

    Comparative BulletinApril 2010

    Cat797F and 797BMining Trucks

    For Dealer Sales Personnel

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    2 April 2010Cat797F and 797B Mining Trucks

    Table of Contents

    Overview ...............................................................................................................................................................................3

    Engine ....................................................................................................................................................................................5

    Power Train ..........................................................................................................................................................................7

    Brake System .......................................................................................................................................................................9

    Truck Body Systems ..........................................................................................................................................................10

    Operator Environment .......................................................................................................................................................12

    Machine Intelligence .......................................................................................................................................................14

    Safety ...................................................................................................................................................................................15

    Technical Specifications .................................................................................................................................................16

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    3April 2010 Cat797F and 797B Mining Trucks

    Overview

    Overview. The Cat797 is the ultra-class, industry leader and now the 797F continues this tradition withadvancements to safety, productivity, serviceability and comfort.

    Cat 797F and 797B Mining TrucksThe 797F Mining Truck is the largest model in the Cat Mining Truck product line with a nominal payload

    capacity of 363 metric tons (400 tons) and an operating weight of 623 690 kg (1,375,000 lb). The 797F has

    signicant updates which increase performance and lower operating costs.The CatC175-20 engine is U.S. EPA Tier 2 compliant, meeting stringent environmental regulations

    without sacricing fuel efciency while providing 10 percent more power.

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    4 April 2010Cat797F and 797B Mining Trucks

    Overview

    Other 797F improvements include:

    Higher capacity lock-up clutch to accommodate increased horsepower

    New cab mounts with increased ROPS capacity

    Straight rails replace Z rails to radiator mount

    New ergonomically designed cab to reduce operator fatigue, enhance operator performance and promote

    safe operation with exceptional all-around visibility

    New VIMS 3G monitoring system provides more information to the operator on machine status

    Improved serviceability access

    The 797B Mining Truck nominal payload capacity was 345 tonnes (380 tons) with a gross operating

    weight of 623 690 kg (1,375,000 lb). Gross power was 2648 kW (3,550 hp). The 797B met U.S. EPA Tier 1

    emission standards.

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    5April 2010 Cat797F and 797B Mining Trucks

    Engine

    Engine. The CatC175-20 engine is built for power, reliability and efficiency.

    CatC175-20 Engine

    The C175-20 engine used in the 797F is a newly

    developed 20-cylinder diesel engine that utilizes:

    Advanced block, piston, rod, liner and head

    structures

    Cat Common Rail Fuel System

    ADEM A4 electronic controls

    Air-to-Air After Cooling

    These technologies combine to yield the best engine

    performance available in a large mining truck.

    The C175-20 is available in two congurations

    for operation based on the mines altitude:

    Standard Altitude: Up to 2134 m (7,000 ft)

    without derate

    High Altitude: Up to 4877 m (16,000 ft)

    without derate

    Cat3524B High Displacement Engine

    The 3524B engine used in the 797B Mining Truck

    was a tandem unit consisting of two 3512B HD engine

    blocks, coupled to perform as a single engine in terms

    of operation, monitoring and control. The 3524B began

    derating at 2591 m (8,500 ft) altitude. The optional

    High Altitude Arrangement did not derate between

    3048-4572 m (10,000-15,000 ft).

    CatCommon Rail Fuel System (CCRFS)

    A building block of both ACERT Technology andthe C175-20 engine design is the Cat Common Rail

    Fuel System (CCRFS). The key objective of this system

    is the exibility to work over a wide range of loads

    while lowering emissions and fuel consumption.

    The CCRFS also has the capability to deliver multiple

    injections within a single combustion event with

    unprecedented precision and repeatability. This precise

    and exible fuel system also results in faster transient

    response, enhanced cold start capability and reduced

    white smoke. Overall, the CCRFS gives the enginethe ability to meet emissions regulations without

    sacricing performance, reliability or durability.

    CCRFS versus Mechanically Activated EUI Injector

    The higher pressure developed in the CCRFS

    gives better atomization for complete combustion

    and lower combustion temperature, resulting in

    lower emissions.

    CCRFS gives more exibility for multiple injections.

    EUI is restricted to the amount of bumps on thecamshaft lobe, while the CCRFS can inject fuel

    at any point in time.

    EUI can only hold constant maximum pressure for

    a certain amount of time (40 cam angle) since it is

    driven by camshaft rotation. EUI always injects the

    same amount of fuel. CCRFS allows for rate shaping

    at any point in time due to constant fuel pressure in

    the rail. The injector can be opened at any time and

    the amount of fuel can be controlled.

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    7April 2010 Cat797F and 797B Mining Trucks

    Power Train

    Power Train. More power to the ground for greater productivity.

    1 Transmission, 2 Lock-Up Torque Converter, 3 Final Drives

    Power Train

    The 797F has retained the proven design of the

    797B but has additional features to accommodate

    higher horsepower, provide improved powertrain protection and support application specic

    performance enhancements.

    Torque Converter

    The 797F Mining Truckss C175-20 engine is coupled

    with the E7608 ADC torque converter. It utilizes a

    four-disc lockup clutch (LUC), one more than the

    797B. The LUC pressure has been raised to 31.36 bar

    (310 psi) to accommodate higher horsepower and

    maintain durability. The LUC features ElectronicClutch Pressure Controls (ECPC), and LUC

    engagement has been tuned for different shift types.

    Transmission

    Power ows from the torque converter through

    a 20C drive shaft directly into the input yoke and

    input planetary of the transmission. The transmission

    output is directly splined into the differential pinion.

    The transmission is comprised of an input and output

    planetary group, input and output case group, wiringgroup and controls group. Changes have been made

    to all of these groups on the 797F, providing improved

    transmission protection while accommodating higher

    horsepower. This provides durability and reliability

    for long service life.

    Planetary Groups

    Design changes to the input and output planetarygroups were made to improve transmission durability

    and reliability. Improvements were made to address

    the wear often exhibited between the train 1/2 ring

    gear and clutch 2/3 housing by utilizing nylon,

    impregnated plastic thrust buttons. Improvements

    were also made to gear trains 1 and 5 by redesigning

    the gear set for optimal pitting and bending life,

    while maintaining the 797B gear reduction.

    Planetary Clutches and Controls Group

    The 797F control group is redesigned to eliminate

    the latching valves and solenoid, as well as all

    medium ECPC valves. The new control group

    also features an aluminum manifold for decreased

    weight. The number 1 and 4 clutches have been

    improved by eliminating the wave springs and

    utilizing coil springs. The rotating housings have

    also be redesigned for decreased weight.

    Transmission Case

    The input and output transmission cases have been

    redesigned to decrease weight. A new lter group

    has been incorporated for 1,000 hour lter element

    change intervals, while maintaining the 797B

    mounting location and port size.

    Wiring Group and Sensors

    A new internal and external transmission harness

    has been designed for all electrical functions on

    the transmission, including a new transmission

    intermediate sensor.

    To provide consistent protection for the transmission,

    software cross-checks the transmission input and

    dual output speeds. This redundant speed sensor

    system protects the power train in the event of a

    sensor or control system malfunction.

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    8 April 2010Cat797F and 797B Mining Trucks

    Power Train

    Performance

    The C175-20 engine boosts net power from 2647 to

    2983 kW (3,550 to 4,000 hp). The converter drive

    torque limit of 25 760 Nm (19,000 ft-lb) in rst gear

    remains, but this increase in power allows the 797F tooutperform the 797B beyond that point via increased

    speed on grade.

    Final Drives

    The 797F nal drives feature a new cover that allows

    for removal of the axle shaft and thrust button on

    level ground without completely draining the rear

    axle. This reduces downtime during towing operations

    and certain inspections.

    Wheels and Rims

    The front wheels of the 797F now incorporate a new

    sight gauge to check the oil level. The rear wheels

    have plugs for checking oil level and a new center

    access cover that allows for axle removal without

    signicant nal drive oil loss.

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    9April 2010 Cat797F and 797B Mining Trucks

    Brake System

    Brake System. Superior brake control lets operators focus on productivity.

    Integrated Braking System

    The 797F continues use of the Cat oil-cooled braking

    system to deliver reliable performance and control in

    extreme haul road conditions. The integrated system

    combines the service, secondary, parking brake and

    retarding functions in the same robust system for

    optimum braking efciency.

    Brake Discs

    New for the 797F the extended life carbon ber

    friction discs come standard in all congurations.

    These were optional on the 797B. In most operating

    conditions, this new material will provide increased

    wear life over standard paper friction material,

    reducing operating costs. A unique bonding process

    has been developed that adds strength and prevents

    separation failures. This extended life friction material

    is also more resistant to glazing. By resisting glazing,

    the brakes have more consistent braking power with

    less noise. The 797F uses 1067 mm (42 in) diameterfriction discs, employing 10 discs per side in the

    front and 15 discs per side in the rear.

    Brake Cooling System

    The 797F has a new brake/cooling systemincorporating square coolers that are more efcient

    than the round ones on the 797B. This new system

    uses one less cooler. The 797F brake ECM controls

    the solenoid for the brake-cooling pump in order to

    adjust the ow of oil that is used for brake cooling.

    The brake cooling pump has an additional small

    section on the end of the stack to provide ow to the

    brake actuation/park brake circuit, as well as provide

    ow for the rear axle ltration and lube.

    Adjustable Retarding Control

    On the 797B, the rpm was set for all gears and went

    to maximum rpm. On the 797F, adjustable retarding

    control allows the operator to pick the rpm in each

    gear. The operator can also raise and lower actual

    speed within each gear, allowing the operator much

    more control thus improving performance.

    The Automatic Retarder Control (ARC) on the 797B

    runs the engine at a xed top rpm of 1,900 (50)

    and this, in turn, sets the speed for a given gear.For the 797F, the retarding speed in a gear can be

    set to hold a speed below the maximum rpm point.

    Retarding

    The 797F offers two options for retarding. Flat/Uphill

    Haul option is the standard conguration and provides

    a simplied system for less maintenance. For those

    applications requiring downhill loaded operation, an

    optional conguration increases retarding capability.

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    10 April 2010Cat797F and 797B Mining Trucks

    Truck Body Systems

    Truck Body Systems. Cat designed and built for rugged performance and reliability.

    Body Options

    Caterpillar offers four MSD II (Mine Specic Design)

    body options in conjunction with a congurable liner

    system to achieve the most efcient hauling solution

    at the lowest cost-per-ton.

    220 m 3(288 yd3)

    240 m 3(315 yd3)

    251 m 3(330 yd3)

    266 m 3(350 yd3)

    Body Selection

    The Cat truck body program is committed to

    providing the most efcient and highest value body

    solution for every mining customers application.

    The process starts with body application engineers

    understanding the users application. By studying

    the mine site and understanding the overall

    operational requirements and constraints, the body

    can be congured to meet the unique needs of the

    application. The goal of the Cat body specication

    process is to balance payload and structural life

    (durability) within the limitations of the gross

    vehicle weight.

    MSD II Body Design

    Cat truck bodies are designed for optimal strength,

    capacity and durability. The MSD II Body was

    developed using the Caterpillar patented body

    design and analysis system. The internal body shell

    (oor, sidewalls, frontwall and transition plates)

    is 400 Brinell steel for superior impact and wear

    protection. The Mine Specic Design liner options

    deliver impact and wear protection that maximizes

    body life and performance.

    The MSD II bodies are the number one choice in themining industry. Benets of the MSD II bodies are:

    Full length main rail design adds strength

    and rigidity throughout the bed

    Internal and external gussets have been added

    to the main rail and pivot area for additional

    strength

    Two-piece pivot bore bushing reduces pin

    walkout

    New hoist bracket designs terminations wrap

    around the rib and internal gussets in the ribfor better stress transition

    Additional sidewall ribs help reinforce sidewall

    structural integrity

    Rail cap options help manage loading tool

    and material contact damage

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    11April 2010 Cat797F and 797B Mining Trucks

    Truck Body Systems

    Two rear ribs utilize a round design to better

    transmit stress in rear racking conditions

    Lower sidewall lifting lug option is an

    alternative body lifting process

    Heated body option minimizes carry back in cohesive applications

    Truck Body Liners

    A variety of truck body liners are available to save

    weight and extend the body life through impact and

    wear management. The mine specic design system

    used to build an application specic liner conguration

    is called FACLT (Fragmentation, Abrasion, Cohesion

    and Loading Tools). By analyzing each FACLT

    element, the Caterpillar application engineers are

    able to optimize the balance of payload and durability.

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    12 April 2010Cat797F and 797B Mining Trucks

    Operator Environment

    Operator Environment. Ergonomically designed for all-day comfort, control and productivity.

    Operator Station

    Caterpillar is the leader in safe design, using a four-

    post integral ROPS structure that provides superior

    protection when compared with competitors designs.

    The 797F features a completely new spacious cab

    that offers excellent visibility. The controls and layout

    offer operator comfort and convenience, while

    maintaining Caterpillar standards for functionality

    and durability. The cab is resiliently mounted and

    has extra dampening and barrier material in the side

    panels, oor and doors. This provides the operator

    with a smoother ride, due to less vibration.

    Cat Comfort Seat

    The 797F features the new Cat Comfort seat with

    three-point seat belt restraint. Ergonomically-designed

    cushions provide the operator with support where itis needed for all-day comfort. The new shoulder belt

    restraint system offers three height adjustments and

    six vertical adjustment positions for optimal t and

    secure travel.

    The standard trainer seat is a full-size Cat Comfort

    seat with suspension.

    Air Conditioning and Ventilation System

    The 797F has a total of 17 vents to direct airowthroughout the cab. The 797B had 11 vents.

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    13April 2010 Cat797F and 797B Mining Trucks

    Operator Environment

    Operator Controls

    The center-mounted console now features an

    automotive-style shift lever with integrated parking

    brake. The hoist control has been moved from the

    left side of the operators seat to the center console.

    Viewing Area

    Designed for all-around visibility and clear sight

    lines to the haul road, the new cab features a large

    viewing area that enables the operator to maneuver

    with condence for high productivity. The gauge

    cluster has been moved to the center of the cab to

    allow the operator improved visibility in front of

    the machine.

    Storage Compartment

    An overhead storage area has been added to the

    rear between the operator and trainer seat. A bottle

    and lunch box storage area with tie-downs have

    also been added, along with two, variable-sized

    cup holders.

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    14 April 2010Cat797F and 797B Mining Trucks

    Machine Intelligence

    Machine Intelligence. Vital machine health and payload data keeps production at peak levels.

    3rd Generation VIMS Monitoring System

    The 3rd Generation VIMS Monitoring System

    provides critical machine health and payload data

    in real-time to keep the 797F performing at top

    production levels. Sensors located throughout the

    machine enable VIMS to quickly exchange and

    monitor information from all machine systems.

    Users can view up to 10 different machine

    parameters at a time by accessing each VIMS3G-equipped machines unique web address. Service

    technicians or mine personnel can quickly download

    data and generate reports in the ofce, shop or in

    the cab by connecting directly to the system through

    an on-board Ethernet port. On-board the machine,

    various levels of alerts provide the operator with

    notication and severity of abnormal machine

    health conditions. Data can be used to improve

    effectiveness of scheduled maintenance programs,

    maximize component life, improve machine

    availability and lower operating costs.

    External Payload Indicators

    External lights signal loading tool operators when

    to cease loading for optimum payloads without

    overloading. Optional payload displays with digital

    numeric monitor are available.

    VIMSpc

    This off-board software reporting program allowsservice personnel to download a complete record

    of machine health and productivity data. Health and

    payload reports can be generated for more effective

    machine management which helps reduce downtime

    and lowers operating costs.

    Advisor Display

    Standard on the 797F, the Advisor display provides

    real-time machine performance and operating data,

    as well as basic trip, maintenance and diagnosticdata using an LCD display. Various machine

    parameters can be viewed on the display, including

    incline, coolant temperature, oil pressure, current

    gear selection, current payload, etc.

    VIMS Supervisor

    This optional software allows mine personnel to

    easily manage and interpret VIMS data for optimum

    eet management and productivity.

    Reduced Horsepower Mode

    The 797F can be programmed to operate in

    Reduced Horsepower Mode, which uses the reduced

    797B horsepower and lug curve to improve fuel

    consumption, lower noise level and potentially

    lengthen engine life. Reduced Horsepower Mode is

    best used when a customer has extra truck capacity

    and wants to lower his cost-per-ton or wants to

    match his 797F performance to an existing 797B

    eet. A customer who effectively uses Reduced

    Horsepower Mode can reduce operating costswithout sacricing production.

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    15April 2010 Cat797F and 797B Mining Trucks

    Safety

    Safety. Cat Mining Machines/Systems are designed with safety as the first priority.

    Added Safety Features on the 797F

    The following safety features are included on the 797F:

    New Lockout Tagout Box with separate battery

    disconnect, engine start and transmission lockoutsReduced the number of level changes on the

    top deck and hoods to assist in minimizing

    trip points

    Strengthened area on the deck for customer

    attachments (such as re suppression canisters)

    Optional heated mirrors

    Increased ROPS capacity, exceeding

    SAE requirements

    Improved rear service ladder

    Added service platforms to the engine and transmission

    Increased number of ground level accessible

    service points

    Increased number of sight gauges for simple

    and easy maintenance checks

    Reduced cab vibration by using new MARC

    mounts and machined cab mounting pointson the frame

    Removal of hydraulic lines directly above

    the engine

    Added driveline and PTO drive guards

    Engine safety features include:

    High pressure fuel lines on the lower outside

    of the engine in double-walled system

    Hot exhaust tubes located in the center

    of the engine V

    No crossover oil lines above the engineTurbos are up high and forward of the engine

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    17April 2010 Cat797F and 797B Mining Trucks

    Technical Specifications

    Transmission Cat 797F Cat 797B

    Forward 1 km/h (mph) 11.3 (7) 11.3 (7)

    Forward 2 km/h (mph) 15.2 (9.5) 15.2 (9.5)

    Forward 3 km/h (mph) 20.5 (12.7) 20.5 (12.7)

    Forward 4 km/h (mph) 27.7 (17.2) 27.7 (17.2)

    Forward 5 km/h (mph) 37.2 (23.1) 37.2 (23.1)

    Forward 6 km/h (mph) 50.3 (31.2) 50.3 (31.2)

    Forward 7 km/h (mph) 67.6 (42) 67.6 (42)

    Reverse km/h (mph) 11.9 (7.4) 12.9 (8)

    Suspension Cat 797F Cat 797B

    Effective Cylinder Stroke Front mm (in) 313.6 (12.3) 313.6 (12.3)

    Effective Cylinder Stroke Rear mm (in) 165.1 (6.5) 165.1 (6.5)

    Rear Axle Oscillation 4.0 degrees 4.0 degrees

    Body Hoists Cat 797F Cat 797B

    Pump Flow High Idle L/min (gal/min) 1200 (317) 1225 (323)

    Relief Valve Setting Raise kPa (psi) 24 200 (3,510) 23 787 (3,450)

    Body Raise Time High Idle Seconds 25 25

    Body Lower Time Float Seconds 19 18.5

    Body Power Down High Idle Seconds 18 17.3

    Brakes Cat 797F Cat 797B

    Number of Discs Per Side Front 10 10

    Number of Discs Per Side Rear 15 15

    Outside Diameter mm (in) 1067 (42) 1067 (42)

    Brake Surface Front cm2(in2) 132 258 (20,500) 132 258 (20,500.03)

    Brake Surface Rear cm2(in2) 198 387 (30,750) 198 387 (30,750.04)

    Standards J-ISO 3450 JAN88,

    ISO 3450-1996

    J-ISO 3450 JAN88,

    ISO 3450-1996

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    18 April 2010Cat797F and 797B Mining Trucks

    Technical Specifications

    Weight Distributions Approximate Cat 797F Cat 797B

    Front Axle Empty % 47.2 43.5

    Rear Axle Empty % 52.8 56.5

    Front Axle Loaded % 33.3 33.3

    Rear Axle Loaded % 66.7 66.7

    Capacity MSD II 100% fill factor Cat 797F Cat 797B

    Struck m3(yd3) 188-213 (246-290) 188-213 (246-290)

    Heaped (SAE 2:1) m3(yd3) 240-267 (314-350) 240-267 (314-350)

    Service Refill Capacities Cat 797F Cat 797B

    Fuel Tank L (gal) 3785 (1,000) 6814 (1,800)

    Cooling System L (gal) 1160 (306) 1194 (315)

    Crankcase L (gal) 390 (103) 417 (110)

    Front Wheels, Each L (gal) 61 (16) 61 (16)

    Final Drives, Each L (gal) 185 (49) 185 (49)

    Differentials L (gal) 1176 (311) 701 (185)

    Steering Tank L (gal) 254 (67) 235 (62)

    Steering System (Includes Tank) L (gal) 355 (94) 432 (114)

    Brake/Hoist Hydraulic Tank L (gal) 825 (218) 996 (263)

    Brake/Hoist System (Includes Tank) L (gal) 1670 (441) 1842 (486)

    Torque Converter/Transmission Sump L (gal) 190 (50)

    Torque Converter Sump L (gal) 303 (80)

    Torque Converter/Transmission System (Includes Sump) L (gal) 629 (166) 629 (166)

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    19April 2010 Cat797F and 797B Mining Trucks

    Technical Specifications

    Tires Cat 797F Cat 797B

    Standard Tire 59/80R63 59/80R63

    ROPS Cat 797F Cat 797B

    ROPS Standards ISO 3471-1994 SAE J1040 APR88,

    SAE J231 JAN81,

    ISO 3471:1994,

    ISO 3449:1992 Level II

    Sound Cat 797F Cat 797B

    Sound Standards SAE J919:1995,

    ANSI/SAE J166:2008,

    ISO 6394:2008, ISO 6396:2008,

    ISO 6393:2008, ISO 6395:2008,

    SAW J88:2006

    ANSI/SAE J1166 MAY90,

    ANSI/SAE J88 JUN86

    Steering Cat 797F Cat 797B

    Steering Standards SAE J1511 OCT90,

    ISO 5010:1992

    SAE J1511 OCT90,

    ISO 5010-1984

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