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

• 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
 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
 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
Competitive Comparison
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 emissions
regulations without EGR
• 1000-hour hyd. service interval
keeps the 797F on the job longer
• New cab improves operator
comfort and efficiency

Safety
• Key safety features you are used to on Cat
trucks
(oil cooled brakes, ROPS/FOPS, 10/10/20)
• Plus new enhanced safety features
contribute to further lowering your costs
Production
• Optimized payload (with MSD bodies)
Utilization
• Traction control allows continued operation
in poor underfoot conditions
Mechanical Availability
• Improved reliability, higher uptime
• C175-20 engine has lowest BMEP in its
class for added durability and reliability
Owning Cost
• Long economic life
• Higher resale value than competition. Even
though
a customer may not resell their truck, the
high resale is indicative of the remaining
value in older Cat trucks
797F Reduces Cost per Ton
Maintenance Cost per Hour
• Continuous improvements throughout the
truck target higher up-time and lower cost
per hour
• VIMS System capability allows diagnostics
and prognostics to extend service life of
components
Tire Cost per Hour
• Weight distribution and low Empty Machine
Weight (EMW)
• Steering geometry
• VIMS System TKPH (TMPH) Speed
Manager
Operator Efficiency
• Operator station comfort and ergonomics
• Operator confidence in braking and
retarding optimizes downhill speed
Fuel Cost per Ton
• Mechanical power train efficiency
• High displacement engine
• Zero fuel consumption while retarding
 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
• Steering system 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 in3)
• 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, CO2 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
Engine Comparisons
 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
• VIMS Monitoring System
– Critical machine health and
payload information
– Real time display for
operator
– Advanced diagnostics
– Abnormal conditions
identified before damage
occurs
– Simplifies trouble shooting
• Data Access
– Data stored on-board for
download
– Message center in cab
– Optional wireless
transmission
– 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 Transmission
gear
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
 Continuous Rear Axle Filtration

• Standard feature
• Cleaner components
equal 10 to 20% longer
component life.
• Continuously circulates
axle lubricant through Component and % $ Value
6 micron filter to Improvement
maintain ISO 18/15 10% Improvement in $26,400
cleanliness. Cost/Hour @ 60,000
hours
• Reduces kidney loop
maintenance times. 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
downhill speeds
• Adjustable by operator
• Less operator fatigue
• Engine overspeed protection
• Improved traction in poor underfoot
conditions
• Less slippage means less tire wear
 797B Tires & Rims

• Tires are available from the two

leading manufactures to ensure
competitive pricing
and ongoing development
• Rims are available in three options
– 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

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)
• ROPS cab-insulated/sound
• Air conditioner suppressed
• 12 V DC Power Supply • Seat, air suspension
• Seat, passenger – air
• Coat hook suspension
• Diagnostic connection port • Seat belt, 75 mm (3 in) wide
retractable
• Dome courtesy light • Steering wheel, tilt, padded,
• Gauges/Indicators: telescopic
• Storage compartment
– Transmission fluid • Tinted glass
temp
• Window, electric powered,
– Brake oil temp operator
– Engine coolant temp • Windshield wiper, intermittent
– Fuel level control, washer
Power Train
– Torque converter • C175-20 Tier 2 Diesel Engine
temp • Turbocharging (4) / Aftercooled
– Hour meter • Air cleaner w/precleaner (5)
• – Controlled throttle shifting
– Speedometer Automatic starter protection
• Ground level engine shutdown
– Tachometer • Ether starting aid (automatic)
– Transmission gear • Elevated low idle control
indicator • Crankcase protection
– VIMS message • Multi-point oil pressure sensing
center w/ advisor
• Braking system:
– Integrated park brake and
directional selector
– Brake release motor
(towing)
– Oil-cooled, multi-disc (front
& rear) (service, retarding,
parking, secondary)
– Automatic Retarder
Control
– Engine overspeed
protection
– Extended life brake disc
material
• Transmission:
– 7-speed, auto power shift
w/ECPC
– Body-up reverse
neutralizer
– Body-up shift inhibitor
– Directional shift
management
– Neutral coast inhibitor
– Neutral start switch
– Programmable top gear

Electrical
• Alarm, backup
• Brushless Alternator 150 ampere
• Batteries (2), 12V, 93 amp-hour
• Converters (2), 12V electrical
• Electrical system, 24V, 10, 20 & 25 amp
• Directional signals (front & rear LED)
• Front stair access/Service deck
• Stop/taillights (LED)
• Engine compartment light
• Headlights w/ lo-hi beam selector
• Backup and hazard lights
General
• Traction Control System
• Auto lubrication system
• Aux "buddy" dumping quick connect
• Aux steering quick connect (towing)
• Driveline operator safety guard
• Fast fill fuel system
• Fuel filter w/ water separator
797F Other Standard Equipment
• Ground level VIMS System data port
• Ground level battery disconnect
• Hi-speed crankcase oil change
• Reservoirs (4):
– Brake
– Hoist
– Steering/Engine Hyd. Fan
– Torque Converter/Transmission
• Rock ejectors
• Supplemental steering (automatic)
• Traction control system
• Tie down eyes
• Vandalism protection locks
VIMS System
• 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

Lifting Options
• Lower sidewall lifting lugs
• Upper sidewall lifting lugs
• Loading target
Attached Hardware
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%
• No loads above 120%
• The average payload shall not exceed the
target
range
No more than 10% of loads
should exceed 110% of the target
payload
No loads should be above
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

Note: MineStar systems availability for specific markets depends on applicable radio licenses.
 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

• 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.)

• Standard (cont…)
- Fully enclosed driveshaft
- Reduced operator sound and vibration
- Toe kicks
- Dual body retaining cables
• Optional
- Optional WAVS (Work Area Vision System)
- 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
 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