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Big truck and big tire —
Caterpillar and Michelin
I
f you build a big truck, build a big tire to match it. Let
that haulage synergy aid the economics, productivity
and lessened maintenance for the unit. Now, Cater-
pillar and Michelin have done just that.
Discussions began in 1996. Caterpillar was making
plans for its 797 ultra-class haul truck. The development
team realized the need for a tire that could withstand
extreme loads. The 797 would weigh 558 t (615 st) and be
capable of 64 km/h (40 mph) speeds. So Caterpillar ap-
proached Michelin. The two companies realized the
benefits of jointly developing a tire for the 797.
Caterpillar teamed with Michelin to develop a tire large
enough to fit Cat’s 345-t (380-st) payload 797B haul
truck. The result was the 59/80R63 XDR tire.
Background and development
Before Caterpillar assembled the first 326 t (360 st)
payload 797 in late 1998, the two companies simulated
the new truck with a 218-t (240-st) capacity Cat 793 at
the Michelin proving grounds in Almeria, Spain.
The development team simulated 797 loads with the
793 by mounting single tires in place of duals and by
carefully designing the test track. The Michelin 55/
80R63 XKD1 tire was born from this development and
testing process.
The first generation 797 and Michelin tire system
delivered high productivity and a low cost per ton. But
another adaptation was needed of the truck and the tire.
While engineering that system, Michelin and Caterpillar
offered an interim solution, the 55/80R63 XKD1.
Then Michelin and Caterpillar began to develop the
new truck/tire system. Enter the
Caterpillar 797B and the Michelin
59/80R63 XDR tire.
Tim O’Neil, Having the Caterpillar 797 at
Almeria allowed Michelin and Cat-
Editor erpillar to study the truck and tire
36 SEPTEMBER 2002 ■ MINING ENGINEERING
o'neil, p. 36-37 copy 36
dynamics. How did they interface? How did they handle
high torque inputs and stresses? And what were the
thermal consequences? The object was to have a long-
life tire despite the rigors imposed by the big truck.
So the truck/tire system was tested beyond its nor-
mal limits. Tests were conducted with increased loads, at
higher speeds, higher than normal capacities and on
steep grades. The system was also tested through sharp,
cutting rocks and serpentine curves, at various deflec-
tions, and up and down ramps. The truck was quickly
started and stopped on proving grounds roads. That
tested the side-to-side and front-to-back load distribu-
tion.
All this simulated conditions in openpit mines. Dy-
namic loads and lateral forces were analyzed. Puncture
resistance and wear rating were monitored. The ability
was tested of the tire to deal with cuts.
Michelin tested new, tougher and more heat-resis-
tant rubber compounds and new tread-belt configura-
tions. More than 50 individual tests were performed on
the bead area and the lower sidewall. At least 30 addi-
tional tests were performed on more than 60 survey tires.
Tire wear was measured. So was the temperature of
the tire’s internal components. Tire dynamics were
checked as were deflection characteristics and tire-rim
interface. Every 100 hours, the tires were taken off the
truck and X-rayed. This analysis allowed the engineers
to monitor any internal areas of stress and fatigue.
Special test tracks were developed. An extremely
bumpy, channeled course was created. It measured truck
vibrations. Michelin and Caterpillar engineers were bet-
ter able to understand the conditions in which the truck
began to vibrate. As a result, a truck/tire system was pro-
duced that enhanced operator comfort regardless of the
vibrations.
Operators tested, too
On the truck side, the 797 test operators went
through the same training and certification process that
Caterpillar offers for mine truck operators. Productivity,
however, was not a priority. The idea was to drive each
run within a test the same way. Precisely repeat the ac-
tions in each run to help isolate the variables being mea-
sured. Tires, for example, were subjected to more than
31,500 test hours. That is the equivalent of 442,560 test
km (275,000 test miles).
Results are impressive
The joint testing effort resulted in a truck, the Cater-
pillar 797B, that can carry a 345-t (380-st) payload at high
speeds. And the Michelin 59/80R63 XDR tire is seen as
a technological breakthrough for ultra-class haul trucks.
The net here is that bigger truck payloads increase
productivity. And the new tire helps provide longer
operating life, which contributes to lower operating
costs.
9/16/02, 9:03 AM
 Michelin’s proving grounds are located in Almeria,
Spain. The facility provides nearly 3,642 hm2 (9,000
acres) for testing truck and tire dynamics.
797B — higher payload, lower cost
And now a little detail about the truck itself. The
Caterpillar 797B is the world’s biggest truck. It features
an increase in nominal payload from 326 t (360 st), with
a standard body. Gross engine power has been increased
from 2.54 to 2.65 MW (3,400 to 3,550 hp). These and
other improvements enable the new truck to reduce
hauling cost per ton by 3% to 5% compared with the
797, which the 797B replaces.
Caterpillar teamed with Michelin to develop an op-
timized tire for the 797B. The new tire uses advanced
low-profile 80 series technology developed by Michelin.
The XDR super-deep tread should extend tire life. And
robust bead architecture handles the high torque and the
high loads created by the 797B.
To ensure reliable performance at a greater vehicle
weight, braking and steering capacity has been increased
on the 797B. Increased service-brake pressure and park-
ing-brake capacity provide stopping and staying power.
Larger steering cylinders, stronger steering linkage and
more accumulator capacity assure responsive and reli-
able steering in tough mine conditions.
Many of the mild steel castings that comprise the
load-bearing frame have been strengthened while reduc-
ing the frame weight. Field testing of the first 797s began
in 1999. Since then, serviceability improvements have
reduced by 36% the labor needed for the 500-hour ser-
vice.
The 797B retains the 3524B high-displacement die-
sel engine and the mechanical power train. Electronic
controllers integrate the engine and the mechanical
power train information. This helps performance, ex-
tends component life and improves operator comfort.
Basic specifications for the 797B mining truck:
• Gross machine weight 624 t (688 st)
• Nominal payload 345 t (380 st)
• Engine model Cat 3524B HD
• Gross engine power 2.65 MW (3,550 hp)
• Transmission seven-speed planetary power shift
o'neil, p. 36-37 copy 37
The world’s biggest tire, the Michelin 59/80R63 XDR is
inspected while it cools.
• Top speed 64 km/h (40 mph)
• Tire size 59/80R63
The first 797B mining truck was shipped recently
from Caterpillar’s manufacturing plant in Decatur, IL.
For more information, visit the Caterpillar Web site at
www.cat.com.
Michelin’s 59/80R3 XDR radial tire
Michelin’s 59/80R63 XDR tire is designed for trucks
operating in large surface mines. It is currently being
tested in the oil sands of Canada. How big is this tire, the
largest tire in the world? It is more than 4 m (13 ft) tall
and nearly (5 ft) wide. It weighs more than 4.5 t (5 st).
And it can support a load of more than 91 t (100 st) a tire.
Michelin is the first tire manufacturer to put this innova-
tive tire to use in real operating conditions.
During the past few years, the mining world has
been developing larger machines. They move ever larger
amounts of material faster and under extreme condi-
tions. Economies of scale is the buzz phrase.
The new Michelin 59/80R63 XDR tire makes pos-
sible this latest load increase. It can offer up to 25%
longer life, compared with the 58/80R63 XKD1 tire.
The extra-deep tread design of the XDR tire is com-
prised of independent tread blocks. They are located in
the centerline of the tire, to help improve tire life. The
tread is engineered to allow for lower heat generation
without compromising tire life, according to Michelin.
The 59/80R63 XDR tire is the latest addition to the
XDR line and the 80 series technology, which was intro-
duced in 1998. The 59/80R63 XDR is a technological
breakthrough for giant haul trucks. Michelin will be in-
troducing two versions of the tire. One version will have
an extra-deep E4 tread for use in the harshest operating
conditions. The other version is designed for high-speed
operations.
The Michelin 59/80R63 XDR tire is standard equip-
ment on the Caterpillar 797B. But is can also be retrofit-
ted for all existing Caterpillar 797s so they, too, can
benefit from the tire’s performance. Michelin offers
more than 110 earthmoving tire sizes. And it is the only
tire manufacturer to have an earthmoving test facility —
the one mentioned in Almeria, Spain. For more informa-
tion about Michelin’s tires, check its Web site, www.-
michelin.com/earthmover. ■
MINING ENGINEERING ■ SEPTEMBER 2002 37
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