Caterpillar 797

The Caterpillar 797 is a series of off-highway, ultra class, two-axle,

mechanical powertrain haul trucks developed and manufactured in the
Caterpillar 797 Series
United States by Caterpillar Inc. specifically for high-production mining
and heavy-duty construction applications worldwide.[1] In production
since 1998, the 797 series represents Caterpillar’s largest, highest capacity
haul trucks.[2] The current, third-generation model, the 797F, offers one of
the largest haul truck payload capacities in the world, up to 400 short tons
(363 t) and has the highest payload capacity among mechanical drive haul
trucks.[3]

Contents Caterpillar 797 (first generation)

Overview
Initial development
797 (1998–2002) Manufacturer Caterpillar Inc.
Testing Production Since September 22, 1998
Full worldwide marketing
Assembly North America
797B (2002–2009)
Body and chassis
797F (2009 onwards)
Class Ultra class
Powertrain
797 engine Body style Dump
797B engine
Layout Front engine, rear wheel
797F engine
drive
Transmission
Powertrain
Wheels and tires
Manufacturing and assembly Transmission Seven speed planetary
gearset
Transportation
Final assembly
Cost
Service life
Competition
Comparison chart
See also
References
External links

Initial development
In 1997, Caterpillar decided to begin development of a 360 short tons (327 t) payload capacity haul truck to meet the demand from
large-scale mine operators wanting to reduce operating costs at mines using 80 to 90 short tons (73 to 82 t) per pass shovels.[4]
Engineers at Caterpillar's Mining & Construction Equipment Division in Decatur, Illinois, created a new design for the 797 using
[4]
computer-aided design technology. This was the first time CAD tools had been used extensively to design a Caterpillar truck.
797 (1998–2002)
Caterpillar first unveiled a completed 797 on September 29, 1998, at its assembly plant in Decatur
, Illinois.

Testing
The first two 797s produced were transported to Caterpillar's Arizona proving grounds for testing. In the second quarter of 1999, the
third and fourth 797s produced were the first to be placed in service with a customer at the Bingham Canyon Mine in Utah.
Caterpillar put 18 additional 797s into service with mine operators worldwide as production development units.

Full worldwide marketing

Caterpillar began marketing the 797 inNorth America in 2000, with full worldwidemarketing following in 2001. The first generation
serial number prefix is 5YW.[4]

797B (2002–2009)
Caterpillar introduced the 797B in spring of 2002, replacing the first-generation 797. Caterpillar increased the power output of the
Cat 3524B engine to cope with the 797B's higher payload capacity of up to 380 short tons (345 t), a 20 short tons (18 t) improvement
, 2002.[5]
over the 797. The first 797B units entered service with customers in October

797F (2009 onwards)

Caterpillar introduced the latest 797 in the series, the 797F, at MINExpo International in September 2008. When Caterpillar began
full production of the 797F in late 2009, the 797F replaced the 797B.[6] [7] [8] The 797F comes equipped with a new, more powerful
and more efficient Cat C175-20 engine and an increased payload capacity of up to 400 short tons (363 t).

Powertrain
The Caterpillar 797 series trucks employ mechanical drive powertrains in contrast to the diesel-electric powertrains of similar haul
trucks offered by competitors.[4] During initial development in 1997, a diesel-electric powertrain was considered for the 797, but this
powertrain configuration was not developed because Caterpillar considered a mechanical drive powertrain more appropriate for
market conditions at that time.[8]

797 engine
A gross 3,400 hp (2,535 kW) [net 3,211 hp (2,394 kW)] Cat 3524B HD EUI 24-cylinder, displacement]], electronic unit injection,
quad single-stage turbocharged, liquid aftercooled, four-stroke diesel engine powers the 797.[9][10] The Cat 3524B HD engine is a
tandem unit consisting of two 12-cylinder Cat 3512B HD engine blocks coupled to operate as a single engine with a combined
displacement of 106 liters (6468 cubic inches).[11]

797B engine
A gross 3,550 hp (2,647 kW) [net 3,370 hp (2,513 kW)], quad turbocharged Caterpillar 3524B engine powers the 797B.[12] The
power rating of the 3524B is valid up to an elevation of 8,500 ft (2,591 m) or 15,000 ft (4,572 m) with a high altitude
arrangement.[13]

797F engine
A gross 4,000 hp (2,983 kW) [net 3,793 hp (2,828 kW)] Cat C175-20 ACERT single block, 20-cylinder, electronic common rail
injection, quad turbocharged, air-to-air aftercooled, four-stroke diesel engine powers the 797F.[14] The power rating of the C175-20 is
[15]
valid up to an elevation of 7,000 ft (2,134 m) or up to 16,000 ft (4,877 m) with a high altitude arrangement.

Transmission
The 797 series haul trucks are equipped with a rear-axle-mounted, computer-controlled, seven-speed planetary transmission with a
[16]
separate lock-up torque converter. Both transmission and torque converter use a common powertrain oil.

Wheels and tires

Each 797 wheel is attached to the axle using 54 - 36-mm nuts that are torqued to 2,300 lb⋅ft (3,118 N⋅m).[17] A size 55/80R63 radial
tire was developed by Michelin in conjunction with Caterpillar specifically for the first generation 797.[18] The Caterpillar 797B and
797F run 4.028 m (13.22 ft) tall, 5,300 kg (11,680 lb) Michelin 59/80R63 XDR. Most first generation 797s have been retrofitted to
use the 59/80R63 tires as well.[19] Six tires are required per truck at a cost in 2009 of approximately US$42,500 per tire.
[20]

Manufacturing and assembly

Major components of the 797 are manufactured and
assembled at seven Caterpillar or supplier facilities located
throughout North America, then shipped to the customer
site for final assembly by Caterpillar technicians.

The engine is manufactured by Caterpillar in Lafayette,

Indiana, and is then shipped to Caterpillar's assembly plant
in Decatur, Illinois.

The transmission and torque converter are manufactured by

Caterpillar in East Peoria, Illinois, and is then shipped to
Caterpillar's assembly plant inDecatur, Illinois.

The axle assemblies are manufactured by Caterpillar in CAT 797 haul truck at the North Antelope Rochelle opencut
Winston-Salem, North Carolina, and are shipped to the coal mine.

customer site.[21]

The tires are manufactured by Michelin North America at the US7 Earthmover Manufacturing plant in Lexington, South Carolina,
and are shipped to the customer site.

The driver's cab is manufactured by Bergstrom Climate Control Systems' Contract Assembly division in Joliet, Illinois. Each cab is
assembled by one person and requires forty hours to complete. The cab is shipped to the customer site.

The dump body is composed of five components: the floor, the two sides, the front wall and the canopy. The dump body is
manufactured at Caterpillar Mexico in Monterrey, Mexico, and shipped in component form to the customer site where it is assembled
and welded into a monolithic structure before being joined to the frame during final assembly
.

The frame is created from nine individual metal castings manufactured by Amite Foundry and Machine, Inc., in Amite City,
Louisiana. The smallest casting weighs 500 lb (230 kg) and the largest casting weighs 12,000 lb (5,400 kg). The rough castings are
shipped to the Caterpillar Decatur, Illinois, assembly plant.

At Caterpillar's assembly plant in Decatur, Illinois, the frame is assembled and the powertrain is ins
talled and tested.
The nine castings that compose the frame are machined to provide clean welding surfaces. The castings are placed in a jig and are
initially joined by human welders. The frame is moved to a second welding station for further welding by robots. The third and final
welding stage is completed by human welders. To ensure quality, welds are tested using an ultrasonic flaw detector. In total, 275 lb
(125 kg) of welding wire is used to join the individual castings into a monolithic frame.

After the frame assembly is completed, production workers attach hydraulic lines and electrical wiring to the frame before installing
the engine and rear axle. The frame/powertrain assembly is tested and then partially disassembled to facilitate shipping from
Caterpillar's Decatur, Illinois assembly plant to the customer site.[17]

Transportation
The engine, frame, axles and differential requires six to seven semi-trailer truck loads, the cab requires one semi-trailer load, the six
tires require two semi-trailer loads and the dump body requires four semi-trailer loads. In total, one 797 requires 12 to 13 semi-trailer
truck loads that originate at various manufacturing facilities and deliver to the customer site. If a 797 must be moved from one job
site to another for any reason, it can not be driven on public roads due to its exceptional size and weight. Moving a 797 requires dis-
assembly, loading onto semi-trailer trucks, transport and re-assembly at the new location.

Final assembly
Final assembly of the 797 is completed by Caterpillar field mechanics at or near the customer site. Before the dump body can be
joined to the frame, the dump body components must be assembled and welded together by a dedicated team, requiring seven to ten
days per dump body. Final assembly of one 797 requires a team of seven mechanics working in three shifts around the clock, for 20
.[17]
days, in addition to the time required to assemble and weld the dump body

Cost
[17]
Although the price varies based on individual customer specifications, each 797 costs approximately US$5,000,000.

Service life
All major components of the 797 can be serviced or replaced during the useful life of the truck, except for the frame. The overall
service life of the truck is therefore dependent upon the durability of the frame which Caterpillar estimates to have a twenty-year
service life.[17]

Competition
The Liebherr T 282 B and Bucyrus MT6300AC both match the Caterpillar 797F's 400 short tons (363 t) payload capacity
, but employ
diesel/electric powertrains in contrast to the 797F's diesel-powered, mechanical powertrain. Both fall short of the BelAZ 75710's 500
short ton capacity, the largest of any haul truck in the world, which also employs a diesel/electric powertrain. Depending on customer
requirements, lower payload capacity 360 short tons (327 t) products such as the Komatsu 960E-1 and Belaz 75600 may also place
competitive pressure on sales of the 797F.

Comparison chart

Introduction to Service
Nominal Payload Capacity
Engine Power
Engine Model
Engine Arrangement
Top Speed (Loaded)
Gross Machine Operating
Weight
Overall Height to Top of
ROPS (Empty)
Overall Height (Body
Raised)
Overall Length
Overall Tire Width
Fuel Tank Refill Capacity
Caterpillar 797 Series Comparison Chart
797 797B 797F
1999 2002 2008
360 short tons (327 t) 380 short tons (345 t) 400 short tons (363 t)
3,211 hp (2,394 kW) 3,370 hp (2,513 kW) net 3,793 hp (2,828 kW) net
net (SAE J1349) (SAE J1349)
3524B High Cat 3524B High
Cat C175-20 ACERT
Displacement EUI Displacement EUI
V-12 x 2 V-12 x 2 V-20
40 mph (64 km/h) 42 mph (68 km/h) 42 mph (68 km/h)
1,230,000 lb
1,375,000 lb (623,700 kg) 1,375,000 lb (623,700 kg)
(557,900 kg)
23 ft 8 in (7.21 m) 24 ft 11 in (7.59 m) 24 ft 5 in (7.44 m)
49 ft 3 in (15.01 m) 50 ft 2 in (15.29 m) 51 ft 6 in (15.70 m)
47 ft 7 in (14.50 m) 47 ft 5 in (14.45 m) 49 ft 6 in (15.09 m)
30 ft 0 in (9.14 m) 32 ft 0 in (9.75 m) 31 ft 3 in (9.53 m)
1,000 US gal (3,785 l) 1,800 US gal (6,814 l) 2,000 US gal (7,571 l)

See also
Haul truck

References
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m0FZX/is_6_65/ai_55084212/). Diesel Progress North American Edition. CBS Interactive Inc. p. 1. Retrieved
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 7. "Release Number: 231PR09 - Caterpillar Moves Forward with New Large Miningrucks" T (https://www.webcitation.or
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=264225&x=7) (Press release). Caterpillar Inc. July 2009. Archived fromthe original (http://www.cat.com/cda/files/17
01756/7/231PR09%20F%20Series%20Mining%20T rucks.doc?m=264225&x=7)(Microsoft Word 97-2003
Document) on 2009-10-21. Retrieved 2009-10-21. "… go into full production…late this year."
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es/1060462/7/). Caterpillar Inc. 2008 - Issue 4. p. 3. Archived fromthe original (http://www.cat.com/cda/files/103437
9/7/Viewpoint_2008_issue4.pdf)(PDF) on 2009-10-21. Retrieved 2009-10-21. "... the flagship 797B will be replaced
by the new 797F ..." Check date values in: |date= (help)
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Palmer. Colossal Caterpillar: The Ultimate Earthmover(https://books.google.com/?id=_dvp_jVSuEQC&printsec=fron
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2009-10-27.
10. Mercer, Mike (March 1999). "New era of mine haul truck giants"(http://findarticles.com/p/articles/mi_m0FZX/is_3_65/
ai_54422720/). Diesel Progress North American Edition. CBS Interactive Inc. p. 3. Retrieved 2009-12-10. "... diesel
engine, which features electronic unit injection, an ADEM II electronic controller
, aftercooling and four single-stage
turbochargers."
11. "Products " Machines " Off-Highway Trucks " Mining Trucks " 797B Benefits & Features Powertrain - Engine"(https://
www.webcitation.org/5lvnkfIv9?url=http://www .cat.com/cda/components/fullArticleNoNav?x=7&id=518627).
Caterpillar Website. Caterpillar Inc. Archived fromthe original (http://www.cat.com/cda/layout?m=308669&x=7) on
2009-12-11. Retrieved 2009-12-10. "The 3524B engine is a tandem unit consisting of two 3512B HD engine
blocks ..."
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www.cat.com/cmms/images/C198751.pdf)(PDF). Caterpillar Website. Caterpillar Inc. December 2003. p. 1.
Archived from the original (http://www.cat.com/cmms/images/C198751.pdf) (PDF) on 2009-10-28. Retrieved
2009-10-28. "Gross Power 2648 kW 3550 hp Flywheel Power 2513 kW 3370hp "
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www.cat.com/cmms/images/C198751.pdf)(PDF). Caterpillar Website. Caterpillar Inc. December 2003. p. 4.
Archived from the original (http://www.cat.com/cmms/images/C198751.pdf) (PDF) on 2009-10-28. Retrieved
2009-10-28. "... 3524B begins derating at 2591 m altitude .... Optional High Altitude Arrangement does not derate
between 3048-4572 m ..."
14. "Caterpillar 797F Mining Truck Product Brochure (AEHQ6039)" (https://www.webcitation.org/5khS1wxbr?url=http://w
ww.cat.com/cda/files/1882082/7/797F%2C%20AEHQ6039.pdf?m=264225&x=7)(PDF). Caterpillar Website.
Caterpillar Inc. September 2009. pp. 1, 3. Archived fromthe original (http://www.cat.com/cda/files/1882082/7/797F,%
20AEHQ6039.pdf?m=264225&x=7)(PDF) on 2009-10-21. Retrieved 2009-10-28. "Gross Power - SAE J1995 2983
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, single
block, four stroke design ..."
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ww.cat.com/cda/files/1882082/7/797F%2C%20AEHQ6039.pdf?m=264225&x=7)(PDF). Caterpillar Website.
Caterpillar Inc. September 2009. p. 14. Archived fromthe original (http://www.cat.com/cda/files/1882082/7/797F,%20
AEHQ6039.pdf?m=264225&x=7)(PDF) on 2009-10-21. Retrieved 2009-10-28. "No low altitude arrangement (LAA)
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www.cat.com/cmms/images/C198751.pdf)(PDF). Caterpillar Website. Caterpillar Inc. December 2003. p. 5.
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2009-10-28. "The Cat seven-speed planetary power shift transmission ...
"
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te-factories/3327/Overview). Ultimate Factories. Season unknown. Episode 10. National Geographic Channel.
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m0FZX/is_6_65/ai_55084212/pg_2/). Diesel Progress North American Edition. CBS Interactive Inc. p. 2. Retrieved
2009-10-27. "This new tire was developed in conjunction with Caterpillar for this application."
19. "Michelin Factbook - 2007 Edition"(https://www.webcitation.org/5kqaUeJSE?url=http://www.michelin.com/corporate/I
mageServlet?imageCode=8910611033&codeSite=MICHCORP&UIFONTSIZE=10&UISMALLFONTSIZE=10) .
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original (http://www.michelin.com/corporate/ImageServlet?imageCode=8910611033&codeSite=MICHCORP&UIFON
TSIZE=10&UISMALLFONTSIZE=10)(Shockwave Flash Presentation)on 2009-10-27. Retrieved 2009-10-27. "59/80
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20. "Michelin, Bridgestone, Goodyear, Firestone, Taylor OTR Tires" (https://www.webcitation.org/5kqZJt1X4?url=http://w
ww.infomine.com/equipment/sellers/evergreen/evergreen_tires.html). Global InfoMine Website. InfoMine Inc.
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External links
2009 F-Series Mining Trucks Press Kit - Caterpillar Inc.
Product Safety > Off-Highway Tractors and Trucks - Caterpillar Inc.
Viewpoint - Perspectives on Modern Mining- Caterpillar Inc.

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