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Example Cover Photo

Caterpillar ® 797F Off Highway Truck

NPI – Operator Training Materials

Global Mining Division

Month Year
Safety Reminders

Emergency Contacts Emergency Information

Fire Alarm Description
•Building: <Phone #> • Evacuate
•Municipal: <Phone #> • Take cover
• All clear
•Building: <Phone #> Unique Hazards
•Municipal: <Phone #> •Room
First Responders
•Room <Identify> Emergency Procedures
•Building <Location and name> •Equipment locations
•Evacuation routes
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)

North America

Asia Pacific,
Indonesia &
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)

North America

Asia Pacific,
Indonesia &
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
• Improved Serviceability
– Ground level service
– New engine designed for serviceability
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.)

Payload (345 tonnes) 380 ton (363 tonnes) 400 ton

797F Dimensions
797F Specifications
Competitive Comparison
F Series Design for maximum production

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

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
797F Reduces Cost per Ton

Safety Maintenance Cost per Hour

• Key safety features you are used to on Cat • Continuous improvements throughout the
trucks truck target higher up-time and lower cost
(oil cooled brakes, ROPS/FOPS, 10/10/20) per hour
• Plus new enhanced safety features • VIMS System capability allows diagnostics
contribute to further lowering your costs and prognostics to extend service life of
Production components

• Optimized payload (with MSD bodies) Tire Cost per Hour

Utilization • Weight distribution and low Empty Machine

Weight (EMW)
• Traction control allows continued operation
in poor underfoot conditions • Steering geometry

Mechanical Availability • VIMS System TKPH (TMPH) Speed

• Improved reliability, higher uptime
Operator Efficiency
• C175-20 engine has lowest BMEP in its
class for added durability and reliability • Operator station comfort and ergonomics

Owning Cost • Operator confidence in braking and

retarding optimizes downhill speed
• Long economic life
Fuel Cost per Ton
• Higher resale value than competition. Even
though • Mechanical power train efficiency
a customer may not resell their truck, the • High displacement engine
high resale is indicative of the remaining • Zero fuel consumption while retarding
value in older Cat trucks
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

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
• 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
• Engine Fan Hyd. Drive
(Higher capacity cooling
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
• 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
• Two tie-rods allow optimum
steering geometry
C 175-20

This powerful single engine block offers enhanced performance, reliability, and
• 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
• High altitude arrangement available
• US EPA Tier 2 Compliant
• Retrofit available for 797B
Tier Certification

This powerful single engine block offers performance, reliability, and


• Produces less NOx, HC, CO2 and

particulate emission levels in order to
meet US EPA Tier 2 off road
• 40% lower NOx and HC than Tier 1
requirements w/ 60% less
• Thanks to engine technology C-175
is capable of meeting these
requirements, to improve fuel
efficiency up to 5%
Engine Specifications
Engine Comparisons

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
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
temperature and emissions
– Achieves Tier 2
– Mid-Support Liner allows for better
cooling of cylinders
• On demand variable speed
hydraulic cooling fan
– Reduces parasitic loss
Cooling Fan
– 5% reduction of fuel consumption
• Mesabi Radiator (Standard)
– Designed to withstand harsh
conditions and operating
– Individual folded cores for
serviceability and maintenance
– Seals allow tube to be replaced
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
– Advanced diagnostics
– Abnormal conditions
identified before damage
– Simplifies trouble shooting
• Data Access
– Data stored on-board for
– Message center in cab
– Optional wireless
– 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
• 28% stall torque
• Broad converter performance
• 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

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
• Smart shifting eliminates gear
• 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


• 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


• 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

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
• Reduces kidney loop
maintenance times. 15% Improvement in $38,790
Cost/Hour @ 60,000
20% Improvement in $48,840
Cost/Hour @ 60,000
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
• 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
enhance safety 3
1. Parking/secondary piston
• Four wheel braking 2. Service/retarding piston
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
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 • Improved traction in poor underfoot
downhill speeds conditions
• Adjustable by operator • Less slippage means less tire wear
• Less operator fatigue
• Engine overspeed protection
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
• 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



Pos 3 or 6 Pos 4 or 5 Pos 3&4 or 5&6 Pos

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
• Centralized Controls
• Full sized Trainer seat
• Powered operator window
• Passenger Power Window
• Fixed
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

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

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) • Braking system:

• ROPS cab-insulated/sound – Integrated park brake and
• Air conditioner suppressed directional selector
• 12 V DC Power Supply • Seat, air suspension – Brake release motor
• Seat, passenger – air (towing)
• Coat hook suspension – Oil-cooled, multi-disc (front
• Diagnostic connection port • Seat belt, 75 mm (3 in) wide & rear) (service, retarding,
retractable parking, secondary)
• Dome courtesy light • Steering wheel, tilt, padded, – Automatic Retarder
• Gauges/Indicators: telescopic Control
• Storage compartment – Engine overspeed
– Transmission fluid • Tinted glass
temp protection
• Window, electric powered, – Extended life brake disc
– Brake oil temp operator material
– Engine coolant temp • Windshield wiper, intermittent • Transmission:
– Fuel level control, washer – 7-speed, auto power shift
Power Train w/ECPC
– Torque converter • C175-20 Tier 2 Diesel Engine – Body-up reverse
temp • Turbocharging (4) / Aftercooled neutralizer
– Hour meter • Air cleaner w/precleaner (5) – Body-up shift inhibitor
• – Controlled throttle shifting
– Speedometer Automatic starter protection
– Directional shift
• Ground level engine shutdown
– Tachometer • Ether starting aid (automatic)
– Neutral coast inhibitor
– Transmission gear • Elevated low idle control – Neutral start switch
indicator • Crankcase protection – Programmable top gear
– VIMS message • Multi-point oil pressure sensing
center w/ advisor
797F Other Standard Equipment

Electrical • Ground level VIMS System data port

• Alarm, backup • Ground level battery disconnect
• Brushless Alternator 150 ampere
• Batteries (2), 12V, 93 amp-hour • Hi-speed crankcase oil change
• Converters (2), 12V electrical • Reservoirs (4):
• Electrical system, 24V, 10, 20 & 25 amp – Brake
• Directional signals (front & rear LED)
• Front stair access/Service deck – Hoist
• Stop/taillights (LED) – Steering/Engine Hyd. Fan
• Engine compartment light – Torque Converter/Transmission
• Headlights w/ lo-hi beam selector
• Backup and hazard lights • Rock ejectors
General • Supplemental steering (automatic)
• Traction Control System • Traction control system
• Auto lubrication system
• Aux "buddy" dumping quick connect • Tie down eyes
• Aux steering quick connect (towing) • Vandalism protection locks
• Driveline operator safety guard VIMS System
• Fast fill fuel system
• Fuel filter w/ water separator • 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
Order separately (Computer not provided)
• 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
• 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

7265 mm
Body Exhaust Heat


• 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
Attached Hardware

Lifting Options
• Lower sidewall lifting lugs
• Upper sidewall lifting lugs
• Loading target Pivot Area and Hoist Brackets
• Factory pre-assembled and
• 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
Zipper Grid
For semi-cohesive

Rock Box
for dry and non-cohesive

Mechanically Attached Wear

Plate System (MAWPS)
semi-cohesive to non-
cohesive materials
10/10/20 Overload Policy

90% of loads should fall into this

• No more than 10% of loads above 110% range
No more than 10% of loads
• No loads above 120% should exceed 110% of the target
• The average payload shall not exceed the payload
No loads should be above
target 120% of the target payload

MineStar™ System – Integrated Mine Information

GPS Infrastructure: Satellites, Repeaters, Base Station

Radio Network

MineStar… Assignment Production Machine Material Machine

Monitoring Tracking Tracking Guidance

Data Flow

Intelligence Engineering Administration
and / Management

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
• 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
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
– 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


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


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


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.

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
VIMS Data Port

Battery Charge
Battery Receptacle
(mounted beside box, not
Lockout (1) pictured)

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)
3 4
indicator for
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
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

Foot rest

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

Ride indicator

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

Throttle backup and

Throttle Lock Switch
Automatic Retarder

WAVS Camera Switch (If


Left Power window switch Right Power Window

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)

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

– 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

VIMS™ 3G with Advisor

Scroll up/left button


Preset Buttons Back


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


“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.

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
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.

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.
Caterpillar® 797F Off Highway Truck
797B to 797F Retrofit
Media Support
C175 Engines
Mining Truck Bodies
Body Maintenance
Ground Rules
Product Development Video
Show Spec Sheet AEHQ5946-01
WAVS TEKQ0647-03
Virtual Operator Training TERV0101
Mining Safety Brochure AEXQ0370
Minestar AEHQ6017-01
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;
• STMG media #SERV1872