Caterpillar Product Information

Product Bulletin
December 2009

Cat® 797F
Mining Trucks

For Dealer Sales Personnel

This document supplements information in the Specalog. Marketing content will
be available only on secured dealer extranets and by accessing the PDF in the
Electronic Sales Library.
Table of Contents

Overview..................................................................................................................................................................................................... 3
Power Train................................................................................................................................................................................................ 4
Cat® Brake System.................................................................................................................................................................................... 8
Hydraulic System...................................................................................................................................................................................... 9
Structures: Frame and Truck Body....................................................................................................................................................... 11
Operator Environment............................................................................................................................................................................. 13
Monitoring System.................................................................................................................................................................................. 16
Machine Intelligence............................................................................................................................................................................. 17
Safety......................................................................................................................................................................................................... 19
Serviceability........................................................................................................................................................................................... 21
Technical Specifications....................................................................................................................................................................... 22

2 TEJB9521 Cat 797F Mining Trucks December 2009

 Overview

Caterpillar is pleased to announce the availability of the new 797F Mining Truck. This is the largest
model in the Cat® Mining Truck product line with a payload capacity of up to 363 metric tons (400 tons)
and an operating weight of 623 690 kg (1,375,000 lb).
The 797F is a significant update to the 797B with increased performance and lower operating costs.
Major improvements include:
• Cat® C175-20 single block engine that meets U.S. EPA Tier 2 emission standards
• Improved power train and upgraded torque converter
• New cab ergonomically designed for operator comfort with an automotive-feel, functionality
and durability
• Enhanced design for improved serviceability
The 797F is the most cost effective machine in its class.

December 2009 TEJB9521 Cat 797F Mining Trucks 3

Power Train

Power Train. The Cat ® C175-20 engine is built for power, reliability and efficiency.

Cat Common Rail Fuel System. The key objective

of this system is the flexibility to work over a
wide range of loads while lowering emissions and
increasing fuel efficiency. It gives the C175‑20
engine the ability to:

• Meter the quantity of fuel required by each

cylinder from cycle-to-cycle very precisely

• Inject fuel at the correct point in the cycle

at all engine speeds and loads

• Begin and end injection very quickly and

Engine. The Cat® C175-20 is a newly developed
inject multiple times in a cycle if necessary
diesel engine with advanced technology that
yields the best engine performance available • Inject fuel at a very precise rate necessary
in a large mining truck. to control combustion for lower emissions
and to control the rate of pressure rise during
Design. The C175-20 is a 20 cylinder diesel
combustion
engine that combines the following new technology
for best performance: • Improve atomization of fuel using higher
pressure for efficient combustion that
• Advanced block, piston, rod, liner and head
improves fuel efficiency
structures
• Distribute fuel evenly throughout the
• Cat Common Rail Fuel System
combustion chamber for efficient combustion,
• ADEM™ A4 electronic controls resulting in improved fuel efficiency and
lower emissions
• Air-to-air aftercooling
ADEM™ A4 Electronic Engine Control.
U.S. EPA Compliant. The C175-20 engine is This electronic control module manages engine
compliant with U.S. Environmental Protection control, protection, diagnostics and history along
Agency Tier 2 emission standards (Standard with the electronic jacket water thermostat and
Altitude only). prelube pump.

Altitude Compensation. The C175-20 engine Air System. The exhaust system is located within
is available in two configurations for operation the “V” of the engine and ducts the exhaust to the
based on the mine’s altitude. front of the engine where the four turbochargers
are mounted. The turbochargers compress the
• Standard Altitude for up to 2134 m (7,000 ft) air then it is ducted to the air-to-air aftercoolers
without deration (located in front of the radiator), cooled to an
engine preferred temperature for increased
• High Altitude for up to 4877 m (16,000 ft) density and routed to the engine for efficient
without deration (Availability in mid-2010) combustion.

4 TEJB9521 Cat 797F Mining Trucks December 2009

 Power Train

Serviceability. C175-20 serviceability is Oil Lubrication System. The C175-20 engine’s

enhanced with the cylinder head inlet manifolds lube system contains enough oil for 500 hour
and turbochargers located outside the engine’s oil and filter change periods. Engine oil level,
“V”. The number of tubes and hoses are reduced oil fill, oil drain and filter replacement are all
to minimize leakage potential. Ground level accomplished from ground level which reduces
service is standard for all fluid sample ports. maintenance time.
These all combine to reduce maintenance time
and increase uptime for the mine. Torque Converter. The C175-20 is coupled with
the E7608 ADC torque converter. The output
Engine Block. The C175-20 engine block uses torque of 25 760 N·m (19,000 ft-lb) at stall was
high tensile strength ferrite ductile cast iron alloy. maintained by electronic engine torque limiting.
It offers increased resistance to stress cracking The 797F torque converter utilizes a four-disc
under extreme operating conditions. The block lockup clutch (LUC) with a LUC pressure of
supports the cylinder liners for increased head 21.36 bar (310 psi) to accommodate higher
gasket sealing capability at elevated design horsepower and maintain durability.
cylinder pressures. The liner support method
allows a single part number head gasket to
replace the 12 pieces per cylinder required
on previous models.

Cylinder Head. The C175-20 cylinder head is much

thicker/taller than previous engine to withstand
this engine’s greater pressures.

Head Joint Sealing System. A more robust sealing

system is insensitive to tolerance stack-ups.
If combustion gas should escape at the seal, the
gasket is designed to vent it to the atmosphere.
Combustion pressures are prevented from entering
the cooling system, which prevents coolant loss
and its potential for engine damage by overheating.

Pistons and Connecting Rods. A forged steel,

one-piece piston design has an improved stainless
steel top ring set. The piston skirt is built into the
piston. The top ring reduces ring groove and liner
wear and is resistant to corrosion.The connecting
rod is drilled to provide additional lubrication to
piston wrist pins and minimize the risk of seizing
a piston. It also contributes to an increased safety
margin and improved reliability.

December 2009 TEJB9521 Cat 797F Mining Trucks 5

Power Train

Transmission. The transmission is comprised of Performance. The C175-20 engine boosts net
an input and output planetary group, input and power from 2647 to 2938 kW (3,550 to 4,000 hp).
output case group, wiring group and controls The converter drive torque limit in first gear
group. Changes have been made to all of these remains the same as the 797B, but this increase
groups on the 797F, providing improved in power allows the 797F to outperform the
transmission protection while accommodating previous model beyond that point by increased
higher horsepower. This provides durability and speed on grade.
reliability for long service life.
Final Drives. The 797F final drives feature a new
Planetary Groups. Design changes to the input cover that allows removal of the axle shaft and
and output planetary groups improve transmission thrust button on level ground without completely
durability and reliability. These changes help draining the rear axle. This feature reduces
reduce wear, pitting and bending while maintaining downtime during towing operations and certain
797B gear reductions. inspections.

Planetary Clutches and Control Groups. Differential. Located in the rear axle housing
The control group is redesigned to eliminate behind the transmission, the differential divides
the latching valves and solenoid while utilizing the power to the right and left axle shafts and
all medium Electronic Clutch Pressure Control turns the power 90-degrees so the wheels can
valves. The new control group also features turn. The differential adjusts the speed of the
an aluminum manifold for decreased weight. axle shafts for vehicle cornering and the power
The number one and four clutches are improved delivered to the axle shafts is unequal during
with coils springs rather than wave springs, cornering. An ecology drain plug for oil on the
while the rotating housing is redesigned for rear axle makes servicing easy and a magnet is
decreased weight. located in the differential drain to facilitate easy
removal of metal chips.
Transmission Case. The input and output
transmission cases are redesigned to decrease
weight and a new filter group has been incorporated
for 1,000 hour filter element change intervals.

Wiring Group and Sensors. A new internal and

external transmission harness has been designed
for all electrical functions on the transmission,
including a new intermediate speed 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 sensor or control
system malfunction.

6 TEJB9521 Cat 797F Mining Trucks December 2009

 Power Train

Rear Axle Lubrication and Filtration System. Struts. The front and rear struts have Advanced
The 797F final drives and rear wheel bearings Surface Technology (AST) coatings to eliminate
are lubricated by splash lube where half of the the potential for environmental hazards associated
components are rotating under the oil level while with chrome as well as provide twice the life and
the other half is above the oil. Gears, bearings corrosion resistance when compared with chrome.
and thrust washers receive required lubrication Currently, Caterpillar is the only OEM providing
by dipping in the oil or splash from other parts AST coatings for cylinders. This provides the
that are running through the oil bath. Secondary customer a higher quality component with a
lubrication oil flow and final drive cooling is lower maintenance and repair cost.
achieved by pumping oil from the rear axle
housing reservoir via a filter through the wheel
bearings and into the final drive reservoir.
The filters in this system have 1,000 hour service
intervals. All 797F configurations feature a
continuous rear axle lube and filtration system
to provide a cleaner system, improved component
wear life and lower operating costs.

Wheels and Rims. Cast rear wheels and Cat

center-mount rims are mounted using studs and
nuts to minimize maintenance and maximize
durability. The front wheels 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 significant final drive oil loss.

Steering and Suspension. The 797F steering and

suspension are designed to dissipate haul road
and loading impacts for longer frame life and a
more comfortable ride and handling. Frame life is
extended by using an independent, self-contained,
oil pneumatic suspension cylinder on each
corner to absorb shock loads before they reach
the structure.

December 2009 TEJB9521 Cat 797F Mining Trucks 7

Cat® Brake System

Cat® Brake System. The Cat oil-cooled braking system delivers reliable performance and control in
extreme haul road conditions. The integrated system combines the service, secondary and parking
brakes with retarding functions in the same robust system for optimum braking efficiency.

Integrated Braking Control (IBC). The Automatic

Retarder Control (ARC) and Traction Control
System (TCS) are combined into one integrated
brake control system for optimum efficiency,
performance and reliability.

Automatic Retarding Control. The electronically

managed ARC controls the brakes, maintaining
optimum engine rpm while maintaining a
constant speed on downhill grades.

Brake Cooling System. A new brake cooling

Pistons. Service, secondary and parking brakes system controls the cooling of the brakes.
as well as retarding functions are combined in The brake ECM controls the solenoid for the
the two piston system design. brake-cooling pump in order to adjust the flow of
oil that is used for brake cooling. The 797F brake
Disc Brakes. The four-wheel, forced oil-cooled, cooling pump has an additional small section on
multiple disc brakes are continuously cooled the end of the stack to provide flow to the brake
by water-to-oil heat exchangers for exceptional, actuation/park brake circuit, as well as provide
non‑fade braking and retarding performance. flow for rear axle filtration and lube.
With proper attention to oil temperatures, the
brakes experience virtually no wear and often Traction Control System (TCS). TCS electronically
have service lives well over 10,000 hours. monitors and controls rear wheel slippage for
greater traction and enhanced truck performance
Brake Discs. Extended life carbon fiber friction in poor underfoot conditions. If slippage exceeds
discs are standard in all 797F configurations. a set limit, the oil-cooled disc brakes engage
The extended life friction material provides to slow the spinning wheel. Steering cylinder
increased wear life and reduced operating costs. position is monitored to provide active input
A unique bonding process has been developed to the system to determine if the slippage is a
which adds strength and prevents separation result of turning low traction. Torque is then
failures. The extended life friction material is automatically transferred to the wheel with better
also more resistant to glazing, which occurs traction when necessary.
during periods of high-temperature braking in
both moderate and severe operating conditions,
including downhill braking with full loads.
By resisting glazing, the brakes have more
consistent braking power with less noise.

8 TEJB9521 Cat 797F Mining Trucks December 2009

 Hydraulic System

Hydraulic System. The hydraulic pump drive is driven from the rear of the C175-20 engine by
an auxiliary drive shaft that drives multiple pumps that control steering, fan, hoist, brake cooling,
brake actuation/park brake functions, RAX lubrication and the optional rear axle cooling.

Hydraulic Fan Drive. The 797F hydraulic fan

drive system optimizes engine cooling and helps
reduce parasitic losses normally associated
with conventional fans. The on-demand fan is
much more controllable and speed can be varied
independent of the engine speed. The variable
speed control promotes better engine efficiency
leading to lower power consumption, less fuel
waste and less noise. Eliminating continuous
fan operation also helps maintain proper jacket
water temperatures necessary in extremely cold
temperatures.
Hydraulic System. The hydraulic pump is driven
from the rear of the C175-20 engine by an Hydraulic Brake Cooling System. For trucks
auxiliary (PTO) drive shaft. It drives multiple equipped with the Flat/Uphill Haul retarding
pumps that control steering, fan, hoist, brake system, the hydraulic brake cooling supply gear
cooling, brake actuation/park brake functions, pumps are driven from the primary pump stack
RAX lubrication and the optional rear axle cooling. and the hoist system provides supplemental
brake cooling flow. For trucks equipped with the
Steering Circuit. Operating pressure in the Downhill-Haul retarding package, the hydraulic
steering system is maintained by a pressure brake cooling supply pumps are located in the
compensated piston pump. Three piston-type tank and are driven by a variable displacement
accumulators provide secondary steering support. pump motor. The 797F brake cooling system
An in-line check valve is integrated into the allows a greater reduction of engine speed
accumulator bleed down valve to help simplify without a loss of flow. The system is designed
the circuit. The steering Hand Metering Unit that to operate automatically. The Downhill-Haul
controls the flow to the steering cylinders is the retarding system is also designed to minimize
same as in the 797B. system parasitic power losses under certain
conditions, such as uphill loaded hauling
Hoist System. The 797F hoist valve is the same situations when brakes are not in use at all.
as the 797B and electronically controls the hoist By using variable displacement motors, parasitic
system. The system provides operator control of power consumption can be reduced by up to
the hoist system including automatic body down 10 percent over a gear driven pump system.
snubbing, over-center load control and modulated
control throughout the operating range. The hoist
cylinders have the Advanced Surface Technology
(AST) coating which eliminates the use of
chrome for more durability and more economical
rebuild cost.

December 2009 TEJB9521 Cat 797F Mining Trucks 9

Hydraulic System

Rear Axle (RAX) Filtration and Lubrication.

The hydraulically-driven, continuous flow rear
axle lube and filtration system provides constant
lubrication, filtration and optional cooling
capabilities to ensure cleaner oil and longer
component life. The system provides a constant
flow through the axle whether the truck is
moving or not.

10 TEJB9521 Cat 797F Mining Trucks December 2009

 Structures: Frame and Truck Body

Structures: Frame and Truck Body. Cat ® truck frames are built to optimize torsional load displacement
with flexibility, durability and resistance to impact loads. Caterpillar designed and built truck bodies
ensure optimal performance and reliability in the toughest mining applications.

Rear Axle – Four-Bar Linkage. The four-bar

linkage connects the rear axle to the frame.
Benefits of the four-bar linkage system are:

• Accommodates the seven-speed transmission

• Linkage is lighter than conventional A-frame

• Conserves wheelbase by providing more

articulation in a smaller space

• Transfers and supports loads to the frame

more efficiently than the traditional A-frame

Each link is composed of a casting to increase

structure strength. The four-bar linkage creates
more space between the frame ribs to allow for a
more successful suspension system. The linkage
directs the load into the frame, allowing it to be
absorbed and spread through the all-cast frame
structure. The linkage is connected to the frame
by maintenance-free pins.
Frame. The 797F frame is built on the 40-year
history of the Caterpillar off-highway truck
product line. The frame is well-suited to be
the backbone of the 797F for many years of
trouble-free operation.

Weldings and Castings. The robotically-welded

and ultrasonically checked frame is composed
of nine mild steel castings that account for
80 percent of the frame’s weight and are the key
to providing durability in some of the world’s
toughest conditions. The large radii castings are
resilient to frame flexing and ensure long life.
The lower stress areas at the front of the frame
are made of welded fabrications. The 797F frame Truck Bodies. Caterpillar offers four 797F MSD II
uses mild steel to provide flexibility, durability body options in conjunction with a configurable
and resistance to impact loads, even in cold liner system to achieve the most efficient hauling
climates. Frame repairs can be made without solutions at the lowest cost-per-ton.
preheating in ambient temperatures, avoiding
metallurgical degradation.

December 2009 TEJB9521 Cat 797F Mining Trucks 11

Structures: Frame and Truck Body

Body Selection. The truck body selection

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 configured to meet the unique needs
of the application. The goal of the Caterpillar
body specification process is balancing payload
and structural life (durability) within the
limitations of the gross vehicle weight.

Body/Chassis Integration. Cat truck bodies are

designed using System Structural Analysis.
The body is designed as part of a truck system
rather than a static structure. The Cat system
approach ensures the body works in harmony
with the chassis, power train, suspension,
wheels and tires and the terrain to ensure a
fully integrated truck haulage system.

MSD II Body Design. The MSD II body was

developed using the Caterpillar patented body
design and analysis system. The internal body
shell (floor, sidewalls, frontwall and transition
plates) is 400 Brinell™ steel for superior impact
and wear protection. The mine specific design
liner options deliver impact and wear protection
that maximize body life and performance.

Truck Body Liners. A variety of liner options are

available to save weight and extend the body
life through impact and wear management.
Caterpillar application engineers use a mine
specific design system to build an application
specific liner configuration. By doing so, the
engineers are able to optimize the balance of
payload and durability. The liner options utilized
by Caterpillar include 400 and 450 Brinell smooth
plate (available in a variety of thicknesses),
chromium carbide overlay, Zipper Grid, Rock
Box and Mechanically Attached Wear Plates
(MAWPS). Zipper Grid, Rock Box and MAWPS
are all Caterpillar patented products.

12 TEJB9521 Cat 797F Mining Trucks December 2009

 Operator Environment

Operator Environment. The ergonomic cab is designed for operator comfort and ease of operation
to allow the operator to focus on production. Controls and gauges are positioned within easy reach
for optimum efficiency and superior control.

Cab. A four-post, integral ROPS structure

provides increased operator protection compared
to competitors’ designs. The 797F cab offers
overall spaciousness and an excellent viewing
area. The controls and layout contribute to
operator comfort, convenience, functionality and
durability. Lower noise levels and less vibration
are a result of the cab being resiliently mounted,
along with extra dampening and barrier material
in the side panel, floor and doors.

Operator Seat. The 797F features the Cat®

Comfort Seat, which is ergonomically designed
to provide operator support exactly where needed
for all-day comfort. Highlights of the seat are:

• High seat back

• Positive and negative rake in seat cushion

• Anti-cinch, three-point shoulder belt restraint

• Adjustable shock with improved dampening

performance

December 2009 TEJB9521 Cat 797F Mining Trucks 13

Operator Environment

Operator Controls. The turn signal, high beam,

intermittent windshield wiper and windshield
washer controls are designed for optimum
efficiency and control. The center-mounted
console houses the automotive-style shift lever
with integrated parking brake and hoist lever.

Optional Throttle Lock. Throttle lock will

maintain engine speed at full throttle in first-third
gear without the use of the accelerator pedal.
It will automatically deactivate if any of the
following conditions occur:

• Application of brakes

• Direction/speed control is moved

• Any failure of a critical system component

Trainer Seat. A full-size, suspension Cat Comfort
Seat is standard on the 797F. Throttle lock is disabled as a default setting
from the factory. The Cat Electronic Technician
Ventilation System. The operator station has a
(Cat ET) service tool adjusts the parameters
four-speed fan for greater airflow control. A total
in order to program the gear range and allows
of 17 vents are used to direct airflow throughout
activation of the throttle lock feature.
the cab. The automotive-styled heating and air
conditioning controls are located on the dash Viewing Area. Designed for excellent all-around
panel within easy reach of the operator. The air visibility and clear sight lines to the haul road,
conditioning is controlled with an electronically the new cab features a large viewing area enabling
operated water valve that can be operated manually the operator to maneuver with confidence for
or by the Automatic Temperature Control system. high productivity.
Hose connections with self-sealing couplings are
used to connect the air conditioning compressor Storage Compartment. A rear tray, along with
on the engine. The self-sealing couplings (which an overhead storage area, has been added behind
are also used between the cab and machine) allow the operator and trainer seats. A thermal bottle
for engine service while retaining refrigerant and lunch box storage area with tie downs have
within the system to minimize service time. been added, as well as two cup holders in
varying sizes.
Communication System Ready. Electrical
connectors and mounting locations are available
for installation of closed circuit TV, MineStar™
systems or add-on radios for the 797F.

14 TEJB9521 Cat 797F Mining Trucks December 2009

 Operator Environment

Work Area Vision System (WAVS). The WAVS

optional attachment consists of an adjustable
LCD color monitor with auto-sense illumination
for changing light conditions and three heavy-
duty cameras capable of withstanding vibration
and pressure washing. It increases operator
awareness by providing views of the rear,
right side and front of the machine.

Advisor Display. The Advisor display provides

real-time machine performance and basic trip,
maintenance and diagnostic data. Various machine
parameters can be viewed on the display including
coolant temperature, oil pressure, current gear
selection, current payload and more.

December 2009 TEJB9521 Cat 797F Mining Trucks 15

Monitoring System

Monitoring System. The VIMS™ 3G Monitoring System provides operators, service technicians and
mine personnel with vital machine health and payload data to keep the 793F performing at peak
efficiency and top production levels while lowering cost-per-ton.

Real Time Browser. VIMS 3G allows users to view On the 797F, the alert system is deeply integrated
near-real-time machine data in an easy-to-access into the machine electronic system. Individual
web browser. An intuitive browser interface Electronic Control Modules (ECMs) monitor
provides information from up to 10 machine the various machine subsystems such as engine
parameters at a time, including parameters such and transmission and provide the information
as coolant temperature, oil pressure, current gear to the Advisor for faster operator notification.
selection, current payload and more. This new VIMS 3G collects data and events from the
feature also enables the triggering of snapshots individual ECMs, puts it in chronological
and data downloads instantly from a wirelessly- order with time stamps and makes it available
connected remote location. Each VIMS 3G- to download through VIMSpc or MineStar.
equipped machine has its own web address,
accessible from any web browser to the mine Production and Payload Management.
site’s communications network. This allows the Max Payload Speed Manager is a feature that
customer to instantly access information to help aids in managing the Caterpillar 10/10/20 Overload
manage the health of the machine and lower Policy. Based on target payload weight and
cost‑per-ton. overload settings, the VIMS system logs and
warns the operator when the truck reaches
Faster Downloads, Improved Connectivity. overload after second gear reweigh. The truck
VIMS 3G downloads faster than the previous will be limited to second gear, engine high idle
version of VIMS and moves a significantly larger will be limited to 1,750 rpm and the automatic
amount of data due to the new features built into retarder speed setting is reduced to 1,750 rpm
the system. It also has an embedded Ethernet until the load is dumped. The Payload Weight
controller which enables expanded broadband Distribution chart illustrates the benefits of
capability. VIMS 3G is compatible with most managing payloads with VIMS production
of the fastest and widely-used radio and cellular management tools.
broadband systems. In addition, it allows direct
connection to a laptop through an on-board Road Analysis Control (RAC). This optional
Ethernet port. system monitors haul road conditions by measuring
frame rack and pitch to improve haul road
Alert System. Three category warning system alerts maintenance, cycle times, tire life and fuel efficiency.
operator of abnormal machine health conditions.
VIMS Supervisor. Optional software allows
• Category I – Machine or system needs attention mine personnel to easily manage and interpret
VIMS data for optimum fleet management and
• Category II – Requires operator to evaluate productivity.
and correct situation before continuing work

• Category III – Immediate shutdown required to

prevent serious damage to machine or system

16 TEJB9521 Cat 797F Mining Trucks December 2009

 Machine Intelligence

Machine Intelligence. Cat Data Link and electronic control modules work together in numerous ways
to make the 797F the most productive and efficient truck on the job site.

Cat Data Link. Cat Data Link is an electrical inhibitor that keeps the truck from shifting above
coupling device that allows integration of a pre-set gear with the body up. This allows the
machine computer systems to communicate machine to move forward, but limits the speed
with each other. The Cat Data Link port is used to avoid excessive racking when pulling away
to perform programming functions on all the from a dump site. The shift inhibitor is set to first
electronic controls. Both connectors are easy to gear at shipping, but it can be programmed up to
reach and give excellent access for diagnostics. third gear.
All the information from these controls can be
accessed through the VIMS message center Anti-Hunt Function. The anti-hunt function
or a laptop computer equipped with Cat ET prevents gear hunting when operating near a shift
or VIMSpc software. point and minimizes shifts by not allowing an
up‑shift or down-shift immediately after a shift
Acceleration Delay. The ECM disables acceleration has occurred for increased component life.
on startup for two seconds after the engine attains
low idle. This slight delay gives all machine Control Throttle Shifting (CTS). CTS reduces
lubrication and cooling systems time to achieve the stress on the power train, clutch energy and
full pressure and flow. wear by electronically controlling engine speed
during shifting. This provides for smoother shifts,
Altitude Compensation. The ECM adapts engine reduced operator fatigue and improved power
operation to current conditions. The system train component life, resulting in lower major
automatically beings to derate power by limiting component costs and decreased cost-per-ton.
fuel when the system’s atmospheric pressure
sensor indicates elevation reaches 2134 m Directional Shift Management. With directional
(7,000 ft). This prevents excessive exhaust gas shift management, when an operator changes
temperatures and related damage. direction without stopping, the transmission
sends a signal to the ECM to momentarily
Engine/Power Train Integration. The 797F reduce engine speed while the transmission shifts,
electronically combines critical power train reducing the potential for damage and related
components to work more intelligently with the driveline component failures.
engine and to optimize overall truck performance.
Reduced Horsepower Mode. The 797F can be
Cold Mode Start Capability. Cold mode operation programmed to operate in Reduced Horsepower
provides engine protection during cold starts. Mode which uses the reduced 797B horsepower
This helps eliminate piston scuffing and seizure and lug curve to improve fuel consumption,
and protects the engine from unequal distribution lower noise level and potentially lengthen engine
of load at start-up. life. Reduced Horsepower Mode is best used
when a customer has extra truck capacity and
Transmission Control Chassis (TCC). TCC uses wants to lower his cost-per-ton or wants to match
electronically transferred engine rpm data to his 797F performance to an existing 797B fleet.
execute shifts at preset points for optimum A customer who effectively uses Reduced
performance, efficiency and clutch life. The TCC Horsepower Mode can reduce operating costs
also features a programmable body-up shift without sacrificing production.

December 2009 TEJB9521 Cat 797F Mining Trucks 17

Machine Intelligence

Cat Electronic Technician (Cat ET). Using Cat ET,

a service technician can access active and stored
faults, logged events, shift histograms, fuel
consumption, injector solenoid information and
activate cylinder cutout.

18 TEJB9521 Cat 797F Mining Trucks December 2009

 Safety

Safety. Caterpillar sets the standard when it comes to safety in the design and manufacturing of heavy
equipment for the mining industry. Safety is not an afterthought at Caterpillar, but an integral part of all
machine and system designs.

Safety Features. These standard features help Additional Safety Features. These features have
create a safe working environment for the 797F: been added to the F-Series to make it even safer:

• Slip-resistant surfaces • Lockout tag box mounted on front bumper

includes engine shutdown switch, battery
• 600 mm (23.6 in) wide stairway and walkways lockout, starter lockout and transmission
lockout
• Guardrails with toe kicks
• Reduced stepped level changes on the top
• Ground level engine shutdown switch deck and hoods to assist in minimizing
trip points
• Body raised indicator
• Strengthened area on the deck for customer
• Body retaining cables
attachments (e.g. fire suppression canisters)
• Wide-angle mirrors
• Increased ROPS capacity which exceeds
• Reverse neutralizer when dumping SAE requirements

• 75 mm (3 in) wide orange, three-point • Improved rear service ladder

operator restraint
• Added service platforms to the engine and
• Low interior sound level transmission

• Increased number of ground level accessible

service points

• Increased number of sight gauges for simple

and easy maintenance checks

• Eliminated hydraulic reservoirs and hydraulic

lines directly above the engine

• Hydraulic radiator fan motor guard with drain

to ground

• Added driveline and PTO drive guards

• Optional heated mirrors

December 2009 TEJB9521 Cat 797F Mining Trucks 19

Safety

Engine Safety Features.

• High pressure fuel lines on the lower outside

of the engine in double-walled system

• Hot exhaust tubes are in the center of the

engine “V”

• No crossover oil lines above the engine

• Turbos are up high and forward of the engine

High Intensity Discharge (HID) Lighting. Visibility

during night operations is improved with the use
of the optional configuration of HID mixed with
halogen lamps.

• Four HID head lamps (high beam) in bumper

and fenders

• Four halogen head lamps (low beam) in

bumper and fenders

• Two HID reversing lamps

HID lights are approximately 70 percent

efficient and twice as bright when compared
with 20-25 percent efficiency for halogen lights
because more energy is given off as light instead
of heat. HID life expectancy is also four to
eight times longer than halogen lights.

Additional Lighting Configuration. Another lighting

option is for two halogen lamps that are mounted
under the left and right mirrors. These lamps are
operated by a switch located in the operator’s station.

20 TEJB9521 Cat 797F Mining Trucks December 2009

 Serviceability

Serviceability. Less time spent on maintenance means more time on the haul roads.

Service Ease. Easy access to daily service • Engine oil sight glass
points simplifies servicing and reduces time
spend on regular maintenance procedures. • S•O•SSM ports
Enhanced serviceability and 500-hour service
intervals are designed to increase machine • Fast fill service center (optional)
availability and productivity.
Maintenance Platform. The maintenance
Few service areas also make servicing easy: platform provides access to the engine.

• Single hydraulic tank AutoLube. AutoLube provides an automatic

lubrication system for all grease points on the
• Consolidated air system 797F. This function reduces maintenance time
and ensures proper lubrication.
• No service points on upper platforms
Scheduled Oil Sampling. S•O•SSM sampling
In-Frame Access. Easy access to major valves speed sampling and analysis reliability.
components for easy servicing and removal
through in-frame access. Air Filters. Radial seal air filters are easy to
change, reducing time required for maintenance.

Sealed Electrical Connectors. Electrical connectors

are sealed to lock out dust and moisture.
Harnesses are braided for protection. Wires are
color coded for easy diagnostics and repair.

Fast Fill Service Center. The optional fast fill

service center features high speed fuel and oil
exchange with Wiggins fittings.

Cab Rear Service Platform. An optional rear

service platform is available for servicing the
Ground Level Access. Ground level access allows HVAC unit located in the rear of the cab and
for convenient servicing of tanks, filters and for cleaning the rear window.
drains. Ground level VIMS data ports permit
easier downloading of information. Ground level
service points include:

• Filters

• Batteries

• Air system service

• AutoLube

December 2009 TEJB9521 Cat 797F Mining Trucks 21

Technical Specifications

Engine Final Drives

Engine Model Cat® C175-20 Differential Ratio 1.276:1
Rated Power 2983 kW 4,000 hp Planetary Ratio 16.67:1
Gross Power – SAE J1995 2983 kW 4,000 hp Total Reduction Ratio 21.26:1
Net Power – SAE J1349 2828 kW 3,793 hp
Net Power 2828 kW 3,793 hp
• Double reduction, planetary with full floating axles.
Bore 175 mm 6.9 in
Stroke 220 mm 8.7 in Transmission
Displacement 106 L 6,469 in3
Forward 1 11.3 km/h 7 mph
• Power ratings apply at 1,750 rpm when tested under Forward 2 15.2 km/h 9.5 mph
the specific conditions for the specified standard. Forward 3 20.5 km/h 12.7 mph
• Ratings based on SAE J1995 standard air conditions Forward 4 27.7 km/h 17.2 mph
of 25° C (77° F) and 99 kPa (29.32 Hg) barometer.
Forward 5 37.2 km/h 23.1 mph
Power based on fuel having API gravity of 35 at 16° C
(69° F) and an LHV of 42 780 kJ/kg (18,390 Btu/lb) when Forward 6 50.3 km/h 31.2 mph
engine is used at 30° C (38° F). Forward 7 67.6 km/h 42 mph
• No low altitude arrangement (LAA) engine derating Reverse 11.9 km/h 7.4 mph
required up to 2134 m (7,000 ft) altitude.
• No high altitude arrangement (HAA) engine derating
required up to 4877 m (16,000 ft) altitude. Suspension
• Compliant with U.S. Environmental Protection Agency
Tier 2 emission standards. Effective Cylinder Stroke 313.6 mm 12.3 in
– Front
Effective Cylinder Stroke 165.1 mm 6.5 in
Weights – Approximate – Rear
Rear Axle Oscillation ±4.0 degrees
Gross Machine Operating 623 690 kg 1,375,000 lb
Weight (GMW)
Body Weight Range 41 368- 91,200-
Body Hoists
61 235 kg 135,000 lb
Chassis Weight Range 210 630- 464,359- Pump Flow – High Idle 1200 L/min 317 gal/min
219 146 kg 483,134 lb
Relief Valve Setting – Raise 24 200 kPa 3,510 psi
• Refer to the Caterpillar Mining Truck 10/10/20 Payload Body Raise Time – High Idle 25 Seconds
Policy for maximum gross machine weight limitations. High Idle Body Lower Time 19 Seconds
• Body weight varies depending on body and liner – Float
configuration. Weight range for known applications.
• Chassis weight with 100 percent fuel, hoist, body
mounting group, rims and tires. Brakes
Number of Discs Per Side 10
Operating Specifications – Front
Number of Discs Per Side 15
Nominal Payload Capacity 363 tonnes 400 tons – Rear
Heaped SAE (2:1) Capacity 240-267 m3 314-350 yd3 Outside Diameter 1067 mm 42 in
Top Speed – Loaded 67.6 km/h 42 mph Brake Surface 330 517 cm2 51,243 in2
Steer Angle 40 Degrees Standards J-ISO 3450 JAN88,
Machine Clearance 42 m 138 ft ISO 3450-1996
Turning Diameter

22 TEJB9521 Cat 797F Mining Trucks December 2009

 Technical Specifications

Approximate Weights – MSD II Tires

Front Axle – Empty 47.2% Tire 59/80R63 – Michelin or
Front Axle – Loaded 33.3% Bridgestone
Rear Axle – Empty 52.8%
• Productive capabilities of the 797F are such that, under
Rear Axle – Loaded 66.7% certain job conditions, TKPH (TMPH) capabilities of
standard tires could be exceeded and, therefore, limit
production.
Weight Distributions – Approximate
Front Axle – Empty 47.2% ROPS
Rear Axle – Empty 52.8%
Front Axle – Loaded 33.3% ROPS Standards
Rear Axle – Loaded 66.7%
• ROPS (Rollover Protective Structure) for cab offered
by Caterpillar meets ISO 3741:1994 ROPS criteria.
Capacity – MSD II – 100% fill factor • FOPS (Falling Objects Protective Structure) meets
ISO 3449:1992 Level II FOPS criteria.
Struck 188-213 m3
246-290 yd 3

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

• Consult your local Cat dealer for truck body Sound Standards
recommendations.
• The operator sound pressure level measured according
to work cycle procedures specified in ISO 6394 and 6396
Service Refill Capacities is 76 dB(A) for cab offered by Caterpillar when properly
installed and maintained and tested with doors and
Fuel Tank 3785 L 1,000 gal
windows closed.
Cooling System 1160 L 306 gal • Hearing protection may be needed when operating with
Crankcase 319 L 84 gal an open operator station and cab (when not properly
Front Wheels, Each 61 L 16 gal maintained or doors/windows open) for extended
Final Drives, Each 185 L 49 gal periods or in a noisy environment.
Differentials 1176 L 311 gal
Steering Tank 254 L 67 gal Steering
Steering System 355 L 94 gal
(Includes Tank) Steering Standards SAE J15111 OCT90,
Brake/Hoist Hydraulic Tank 825 L 28 gal ISO 5010:1992
Brake/Hoist System 1670 L 441 gal
(Includes Tank)
Brake/Hoist Tank 830 L 219 gal
Torque Converter Sump 303 L 80 gal
Torque Converter/ 629 L 166 gal
Transmission System
(Includes Sump)

December 2009 TEJB9521 Cat 797F Mining Trucks 23

For more complete information on Cat products, dealer services, and industry solutions, visit us on the web
at www.cat.com.

TEJB9521 (12-2009)
© 2009 Caterpillar Inc.
All rights reserved
Printed in the U.S.A.

Materials and specifications are subject to change without notice. Featured machines in photos may
include additional equipment. See your Caterpillar dealer for available options.
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