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EngineEngine Model Cat® 3524B EUIGross Power 2648 kW 3,550 hpFlywheel Power 2513 kW 3,370 hp
WeightsGross Machine 623 690 kg 1,375,000 lbOperating Weight
Operating SpecificationsNominal Payload 345 tonnes 380 tonsCapacity
797BMining Truck
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797B Mining TruckEngineered for performance, designed for comfort, built to last.
Top Performance.Developed specifically for high productionmining applications, the 797B Mining Truckkeeps material moving at high volume tolower your cost-per-ton.
Reliable, Durable Operation.Rugged construction and easy maintenanceprocedures ensure long life with lowoperating costs.
Serviceability
The 797B is designed for quick andeasy servicing. Simplified service andmaintenance features reduce downtime,allowing the machine to spend less timebeing serviced and more time onthe haul roads. pg. 16
Truck Body Systems
A variety of Caterpillar designed andbuilt truck bodies ensure optimalperformance and reliability in toughmining applications. Cat dealers canhelp build an optimum hauling systemto maximize truck payloads and extendbody and truck wear life. pg. 14
Monitoring System
Vital Information Management System(VIMS) provides operators, servicetechnicians and managers with vitalmachine health and payload data tokeep the 797B performing at peakefficiency and top production levelswhile lowering cost-per-ton. pg. 12
Engine/Power Train Integration
The Cat Data Link electronicallycombines engine, transmission, brakeand operational information to optimizeoverall truck performance. Storeddiagnostic data can be accessed via theElectronic Technician (ET) to improvetroubleshooting and reduce downtime.pg. 6
Power Train - Transmission
The Cat seven-speed power shifttransmission and mechanical powertrain, matched with the electronic unitinjection 3524B engine, providesconsistent power and efficiency forpeak power train performance. pg. 5
Power Train - Engine
The Cat 3524B High Displacementengine delivers the power and reliabilitynecessary to perform in the mostdemanding applications. Designed forefficient operation, the 3524B offersexcellent fuel efficiency, loweremissions, reduced engine noiseand lower operating costs. pg. 4
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Safety
Caterpillar sets the standard whenit comes to safety in the design andmanufacturing of heavy equipmentfor the mining industry. Safety is notan afterthought at Caterpillar, but anintegral part of all machine and systemsdesigns. pg. 18
Operator’s Station
The ergonomic cab is designed foroperator comfort and ease of operationto allow the operator to focus onproduction. Controls and gauges arepositioned within easy reach for optimumefficiency and superior control all shiftlong. pg. 11
Structures
Caterpillar truck frames are built tooptimize torsional load displacement.Mild steel provides flexibility, durabilityand resistance to impact loads. Castingsand forgings in high stress areas provideexceptional strength and durability forlong life. pg. 10
Caterpillar® Brake System
Cat oil-cooled, multiple disc brakesoffer exceptional, fade-resistant brakingand retarding for maximum performanceand productivity in all haul roadconditions. Integrated Braking Controlcombines retarding and traction controlinto one system for optimum brakingefficiency. pg. 8
Customer Support
Caterpillar dealers provide unmatchedproduct support, anywhere in the world.With industry-best parts availabilityand a wide range of maintenance andservice options, Cat dealers have whatit takes to keep your mining machinesproductive. pg. 17
Engine. The Cat 3524B HighDisplacement EUI twin turbochargedand aftercooled diesel engine delivershigh power and reliability in the world’smost demanding mining applications.
Design. The 3524B engine is a tandemunit consisting of two 3512B HDengine blocks, coupled to perform asa single engine in terms of operation,monitoring and control. The 24-cylinder,dual engine design offers superiorperformance in relation to its size,weight and speed.
EPA Compliant. The 3524B engine iscompliant with U.S. EnvironmentalProtection Agency Tier I emissionsstandards.
Altitude Compensation. Designed formaximum operating efficiencies, the3524B begins derating at 2591 m(8,500 ft) altitude and derates at 1% kPa.
Optional High Altitude Arrangement(HAA) does not derate between3048-4572 m (10,000-15,000 ft).
High Torque Rise. The 22% net torquerise provides unequalled lugging forceduring acceleration, on steep grades andin rough underfoot conditions. Torquerise effectively matches transmissionshift points for maximum efficiencyand fast cycle times.
Enhanced Life. High displacement, lowrpm rating and conservative horsepowerratings mean more time on the haulroads and less time in the shop.
Two-Piece Piston Design. Two-piecearticulated pistons with a deep bowl,low volume crevice design enhancescombustion efficiency, improves fuelefficiency and lowers emissions.
Electronic Unit Injection (EUI).The electronically controlled unitinjection fuel system senses operatingconditions and regulates fuel deliveryfor optimum fuel efficiency. The provenhigh-pressure fuel system providesimproved response times and moreefficient fuel burn with lower emissionsand less smoke.
Electronic Control Module (ECM).ECM utilizes advanced enginemanagement software to monitor,control and protect the engine utilizingself-diagnosing electronic sensors.The computerized system sensesoperating conditions and powerrequirements and adjusts engine forpeak performance and most efficientoperation at all times.
Separate Circuit Aftercooler.Allows the aftercooler circuit tooperate cooler than jacket watertemperature for a denser air chargeand greater combustion efficiency.
Oil Renewal System. Optional oilrenewal system extends engine oilchange intervals from 500 to 4000 hoursor more to increase machine availabilityand reduce cost.
Engine Protection. Computerizedsystem electronically protects theengine during cold starts, high altitudeoperation, air filter plugging, and highexhaust temperature.
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Power Train - EngineThe Cat 3524B High Displacement engine is built for power, reliability and efficiency forsuperior performance in the toughest applications.
Mechanical Power Train. The Catmechanical drive power train and powershift transmission provides unmatchedoperating efficiency and controlon steep grades, in poor underfootconditions, and on haul roads withhigh rolling resistance.
Transmission. The Cat seven-speedplanetary power shift transmission ismatched with the direct-injection 3524Bdiesel engine to deliver constant powerover a wide range of operating speeds.
Robust Design. The 797B transmissionis the largest power shift transmissionfor trucks in the world. Speciallydesigned to handle the high torqueand horsepower of the 3524B engine,the proven planetary power shifttransmission is built tough for longlife between overhauls.
Transmission Chassis Control (TCC).TCC uses electronically transferredengine rpm data to execute shifts atpreset points for optimum performance,efficiency and clutch life.
Lock-Up Torque Converter. Combinesmaximum rimpull and cushionedshifting of torque converter drive withthe efficiency and performance ofdirect drive. Engages at approximately6 km/h (4 mph), delivering more powerto the wheels.
Final Drives. Cat final drives work as asystem with the planetary power shifttransmission to deliver maximum powerto the ground. Built to withstand theforces of high torque and impact loads,double reduction final drives providehigh torque multiplication to furtherreduce drive train stress.
Steering System. Hydraulic steeringcontrol system is designed forexceptional smoothness and precisecontrol. A separate circuit preventscross contamination for long life.
Supplemental Steering. Supplementalsteering system uses pressureaccumulators and allows up to three90 degree turns in case of engine failure.
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Power Train - TransmissionCat mechanical power train delivers more power to the ground for greater productivity andlower operating costs.
Cat Data Link. Electronically integratesmachine computer systems to optimizeoverall power train performance,increase reliability and component life,and reduce operating costs.
Controlled Throttle Shifting (CTS).Regulates engine rpm during shiftingto reduce power train stress and clutchwear by controlling engine speed, torqueconverter lock-up and transmissionclutch engagement for smoother shiftsand longer component life.
Electronic Clutch Pressure Control(ECPC). Works with Continuous ThrottleShifting to effectively manage theshift’s torque and provide exceptionalshift smoothness.
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Electronically combines critical power train components to work more intelligently and tooptimize overall truck performance.
Engine/Power Train Integration
VIMSPC
VIMS
ET
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1 Gauge Cluster Module2 Message Center Module3 ADEM II Master (ECM)4 ADEM II Slave 15 ADEM II Slave 26 RAC Main Module7 CAT Data Link8 Chassis/Hoist Control Module9 Braking/Cooling Module
10 Transmission/TC Control Module
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8
9
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Directional Shift Management.Regulates engine speed duringdirectional shifts to prevent damagecaused by high speed directionalchanges.
Neutral Coast Inhibitor. Preventstransmission from shifting to neutralat speeds above 6.5 km/h (4 mph) toprotect the transmission from operatingwith insufficient lubrication.
Body-up Reverse Neutralizer.Automatically shifts the transmissionto neutral if the hoist lever is activatedwhile transmission is shifted in reverse.
Body-up Shift Inhibitor. Prevents thetransmission from shifting above apre-programmed gear without thebody fully lowered.
Overspeed Protection. The transmissioncontrol electronically senses engineconditions and automatically up-shiftsone gear to prevent overspeeding.If overspeeding occurs in top gear,the lock-up clutch is disengaged.
Programmable Top Gear. Transmissiontop gear maximum can be set using theET service tool to help the operatormaintain speed limits.
Anti-Hunt Function. Prevents gearhunting when operating near a shiftpoint and minimizes shifts by notallowing an upshift or downshiftimmediately after a shift has occurredfor increased component life.
Downshift Inhibitor. Preventsengine overspeeding by keepingthe transmission from downshiftinguntil engine speed reaches thedownshift point.
Electronic Technician (ET). ET servicetool provides service technicians witheasy access to stored diagnostic datathrough the Cat Data Link to simplifyproblem diagnosis and increasemachine availability.
Diagnostic Capability. Critical datafrom the electronic engine andtransmission controls, includingtransmission shifting, engine speedand fuel consumption, provides servicetechnicians with enhanced diagnosticcapability to reduce downtime andoperating costs.
Integrated Braking Control (IBC).IBC integrates Automatic RetarderControl and Traction Control intoone system for optimum performanceand efficiency.
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Integrated Braking System. The Catoil-cooled braking system deliversreliable performance and control in themost extreme haul road conditions.The integrated system combines theservice, secondary, parking brake andretarding functions in the same robustsystem for optimum braking efficiency.
Oil-Cooled Multiple Disc Brakes.Caterpillar four-wheel, forced oil-cooled, multiple disc service brakesare continuously cooled by water-to-oilheat exchangers for exceptional, non-fadebraking and retarding performance.
Brake Design. Cat oil-cooled discbrakes are designed with large discsand plates for reliable, adjustment-free
operation and performance. Brakes arecompletely enclosed and sealed toprevent contamination and reducemaintenance.
Long Life. An oil film prevents directcontact between the discs. This designabsorbs the braking forces by shearingthe oil molecules and carrying heataway to extend brake life.
Pistons. The Caterpillar two-pistondesign combines the service, secondary,parking brake and retarding functionsin the same system. The primary pistonhydraulically actuates both service andretarding functions. The secondarypiston is spring-applied and held inthe disengaged position by hydraulicpressure. If hydraulic system pressuredrops below a specified level, thespring-applied secondary pistonautomatically applies the brakes.
Parking Brake. Oil-cooled, spring-applied, hydraulically released parkingbrake is applied to all four wheels forsuperior parking capability on all gradesup to 18 percent.
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Reliable braking with superior control gives the operator the confidence to focuson productivity.
Caterpillar Brake System
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1 Parking/Secondary Piston2 Service/Retarding Piston3 Friction Discs4 Steel Plates5 Actuating Springs6 Cooling Oil In7 Cooling Oil Out
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Automatic Retarder Control (ARC).Electronically controls retarding ongrade to maintain optimum engine rpmand oil cooling. Additional braking maybe applied using the manual retarderor the brake pedal. ARC is deactivatedwhen the operator applies the brakesor throttle.
ARC Operating Efficiency Advantages.
Faster Speeds. ARC allows the operatorto maintain optimum engine speedsfor faster downhill hauls and greaterproductivity.
Superior Control. Automatic brakemodulation offers a smoother ride andbetter control in slippery conditions,allowing the operator to concentrateon driving.
Ease of Operation. ARC increasesoperating ease, resulting in greateroperator confidence with less fatigue.
Engine Overspeed Protection.Automatically activates ARC whenengine speed exceeds factory presetlevels, regardless of operator inputs,to avoid potentially damaging engineoverspeeds.
Four Corner Retarding. Four cornerretarding with 60/40 percent split(rear/front) in braking effort providessuperior control in slippery conditions.Balanced front to rear brake torqueprovides exceptional brakingperformance and minimizes wheellock-up, especially during retarding.
Traction Control System (TCS).Electronically monitors and controlsrear wheel slippage for greater tractionand enhanced truck performance in poorunderfoot conditions. If slippage exceedsa set limit, the oil-cooled disc brakesengage to slow the spinning wheel.Torque is then automatically transferredto the wheel with better traction.
Integrated Braking Control (IBC).Combines Automatic Retarder Control(ARC) and Traction Control System(TCS) into one integrated brake controlsystem for optimum efficiency,performance and reliability.
Cat Data Link. All control modulescommunicate via the Cat Data Link andwork together as an integrated systemto maximize production efficiency andextend component life.
Fuel Efficiency. The engine providesadditional retarding by running againstcompression on downhill hauls. Duringretarding applications the engine ECMdoes not inject fuel into the cylindersfor exceptional fuel economy.
*
10Time (Seconds)
20 30 40 50 60
Automatic Retarder Control(Maintains Engine rpm between 2160-2300)
Manual Retarder Control(Wide Variation in Engine rpm)
* Optimum Engine rpm
Engi
ne S
peed
(rpm
)
700
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TCSARC 1 Service Brake Sensor2 Engine Sensor3 ARC4 ARC Switch5 Brakes6 Service Brakes7 Axle Speed Sensor8 TCS
Frame Design. The 797B frameincorporates a box-section design andcastings. Materials and weld jointsare matched to optimize the life of thisstructure. In the main structural areas ofthe frame, full wall thickness butt-weldjoints are used to maximize life.
Steel Structures. Mild steel usedthroughout frame provides flexibility,durability and resistance to impactloads, even in cold climates, and allowsfor easy field repairs.
Castings. Castings have large radiiwith internal reinforcing ribs todissipate stress in areas of high stressconcentration. The nine major castingsare machined for precise fit before beingjoined using a robotic weld technologythat ensures full penetration welds.
Fabrications. The lower stressed areasat the front of the frame are made ofwelded fabrications.
Rollover Protective Structure (ROPS).Integral to the cab, the four-post ROPSstructure is resiliently mounted to theframe to reduce vibration and noise levels.
Suspension System. Uses oil-over-nitrogen struts to dissipate haul roadand loading impacts for longer framelife and a more comfortable ride.
Cylinders. Four independent self-contained, oil pneumatic, variable-rebound suspension cylinders aredesigned to absorb shocks in the mostsevere applications.
• Front. Front cylinders with presetcaster and camber are mounted to theframe and serve as steering kingpinsfor a tight turning radius with excellentmaneuverability and low maintenance.
• Rear. Rear cylinders allow axleoscillation and absorb bending andtwisting stresses caused by unevenand rough haul roads rather thantransmitting them to the main frame.
Rear Axle. Four-bar linkage connects therear axle to the frame with maintenancefree pins. The linkage directs the loadonto the frame allowing it to be spreadthrough the structure.
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StructuresRugged Cat structures are the backbone of the 797B mining truck’s durability.
Ergonomic Layout. The 797B operatorstation is ergonomically designed fortotal machine control in a comfortable,productive and safe environment. Allcontrols, levers switches and gauges arepositioned to maximize productivityand minimize operator error.
Quiet Cab. Integral, sound-suppressedROPS cab is resiliently mounted to themainframe to isolate the operator fromsound and vibration for a quiet, secureand comfortable ride.
Viewing Area. Designed for excellentall-around visibility and clear sight linesto the haul road, the large viewing areaenables the operator to maneuver withconfidence for high productivity.
1) Air Suspension Seats. Ergonomicallydesigned, two fully adjustable airsuspension seats with adjustable armrestsprovide optimal comfort for driver andtrainer. Wide, retractable seat beltsprovide a secure, comfortable restraint.
2) Hoist Lever. Four-position electronichoist system with fingertip control ismounted next to the operator’s seat foreasy operation.
3) Secondary Brake Pedal.Conveniently located on the floor foreasy operator control.
4) Monitoring System. VIMS features ahigh resolution display and easy-to-useoperator input keypad for vital machinestatus information.
5) Steering Column. Sport wheel withtilt and telescopic steering providesa comfortable driving position andgreater control.
6) Transmission Console. Ergonomicgear shift lever with backlit gearindicators optimize efficiency.
7) Storage Compartments. Two mainstorage compartments and door storagepockets provide an uncluttered workenvironment.
8) Overhead Console. Providesconvenient access to rocker switches forlights: head, tail, parking, hazard, fog,backup, flood, and ladder lights.
9) Operator Window. Powered operatorwindow offers simple operation and anunobstructed view.
10) Operator Controls. Easy to reachturn signal, high beam, intermittentwindshield wiper and windshieldwasher controls are designed foroptimum efficiency and comfort.
11) Heating/Air Conditioning.Electronically controlled four-speed fanand eleven vents deliver temperature-controlled air circulation for acomfortable working environment inany climate.
Radio Ready. Cab is prewired withpower converter, speakers, wiringharness, antenna and provision foradd-on communication systems.
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Operator’s StationErgonomically designed for operator comfort, superior control and high productivity.
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Vital Information Management System(VIMS). Intelligent Caterpillar designedmachine monitoring system providescritical machine health and payload datain real-time to keep the 797B performingat top production levels.
Integrated System Monitoring. Sensorslocated throughout the machine systemsenable VIMS to quickly exchange andmonitor information from all machinesystems for efficient, high performanceoperation.
Advanced Diagnostics. VIMS simplifiestroubleshooting, reduces downtime andlowers operating costs by identifyingabnormal conditions before they causeextensive damage.
Data Access. Monitoring and diagnosticinformation is stored on-board until itcan be downloaded for analysis. Datacan be accessed through the messagecenter, transmitted via optional radioor downloaded onto a computer fordetailed analysis.
Machine Management. Servicetechnicians or mine management candownload data and generate reports forbetter machine management. Data canbe used to improve effectiveness ofscheduled maintenance programs,maximize component life, improvemachine availability, and loweroperating costs.
Gauge Cluster. Maintains a constantdisplay of vital machine functions,including:
• engine coolant temperature
• brake oil temperature
• torque converter outlet temperature
• fuel level
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Vital machine health and payload data keeps the 797B performing at peak production levels.
Monitoring System
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1 Gauge Cluster Module2 Message Center Module3 ADEM II Master (ECM)4 ADEM II Slave 15 ADEM II Slave 26 RAC Main Module7 CAT Data Link8 Action Lamp9 Action Alarm
10 Radio System (optional)11 Service Lamp12 Chassis/Hoist Control Module13 Braking/Cooling Module14 Transmission/TC Module
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10 RADIOSYSTEM(Optional)
ETVIMSPC
VIMS
Speedometer/Tachometer Module.Monitors three systems: engine speed,ground speed and actual gear.
Message Center. Displays messagesrequested by operator and advisesoperator of abnormal machine conditions.
Keypad. Provides operator or servicetechnician immediate access to currentmachine information, gauge valuesand stored data through the messagecenter display.
Alert System. Three-category warningsystem alerts operator of abnormalmachine health conditions.
• Category I. Machine or system needsattention.
• Category II. Requires operator toevaluate and correct situation beforecontinuing work.
• Category III. Immediate shutdownrequired to prevent serious damageto machine or system.
Production Management. True WeightProduction Management providesaccurate production reporting byutilizing suspension strut pressuredifferentials and advanced algorithmto weigh the truck after it moves awayfrom the loading tool and shifts intosecond gear. Production data enhances
truck and loading tool effectivenessand fleet productivity, and minimizesoverloading to reduce downtime andlower operating and maintenance costs.
VIMS-PC. VIMS-PC, the off-boardreporting software program, allowsservice personnel to download acomplete record of machine health andproductivity data to a laptop computerfor diagnosis and analysis. Easy-to-usesoftware enables service techniciansand mine management to generatehealth and payload reports for moreeffective machine management.
VIMS Supervisor. Optional softwareallows mine management to easilymanage and interpret VIMS data foroptimum fleet management andproductivity.
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Payload Weight Distribution
Payload Weight (Tons)
Perc
enta
ge o
f Tot
al L
oads
Recommended Payload Range
Inefficient Payload Ranges
With Production Management
Without Production Management
Cat Truck Bodies. Caterpillar offers twospecific body styles and custom bodyoptions for the most efficient haulingsolutions at the lowest cost-per-ton.
• Flat Floor (Standard)
• Mine Specific Design (MSD)
Body Selection. Selection of the rightbody depends on material and haulroad conditions. The better the matchof body to application, the greater theefficiency. Your Cat dealer can helpyou select the right body system foryour site specific application.
Body/Chassis Integration. Caterpillartruck bodies are designed and matchedwith the integrated chassis system foroptimum structural reliability, durabilityand long life.
Electronic Hoist Control. Provides theoperator with better control of the loadwhen dumping, including over-centerload control and modulated controlthroughout the operating range. Theautomatic body snubbing featurereduces impact on the frame, hoistcylinders and operator.
Fast Hoist Cycle Times. Two-stage hoistcylinders provide fast dump cycle timesof 25 seconds for raise and 18.5 secondsfor lower.
Body Design. Cat truck bodies aredesigned for optimal strength, capacityand durability. Wear surfaces areequipped to handle even the toughestimpact and abrasion over the long haulwithout diminishing capacity.
• Wide Ribs in body floor provideincreased durability and impactsupport.
• Full-Length Stringers create strengthand rigidity throughout the bed.
• Box Section Beams offer increaseddurability in the floor, sidewall, toprail, corner, and cab canopy areas.
• Extended Top Rails made of rolledsteel guard against impact caused bythe loading tool or falling material.
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Cat designed and built for rugged performance and reliability in the toughest miningapplications.
Truck Body Systems
1) Flat Floor Body. The flat floor designwith slight incline delivers excellentpayload capacity, high dump clearancesand smooth, controlled dumping.
• Flat floor design provides consistentwear characteristics on body tail.
• 12 degree forward body slopeprovides good load retention onbetter maintained haul roads.
• 400 Brinell steel on surfacesprovides excellent wear.
2) Mine Specific Design (MSD) Body.The MSD body is based on the flat floordesign and is customized to maximizepayload potential and minimize cost-per-ton. Each MSD body design beginswith a detailed mine site profile todevelop a body suitable for a mine’sindividual needs.
Custom Body Options. Tail extensions,sideboards, tumblebars, rock boxes androck shedders are available to maintainrated payload, reduce spillage, andimprove hauling efficiencies.
• Sideboards are designed to maximizeor attain gross machine weight.
• Tail extensions are used to helpretain the rear portion of the pileand limit load spillage on haul roads,extending tire life.
Body Liners. A variety of liner optionsfor high wear areas are available tosave weight and help extend the bodysystem’s life. Wear surfaces and linersare equipped to handle tough impactloads while resisting abrasion. Optionalimpact plates are designed to deliverlong life in high impact areas.
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Servicing Ease. Easy access to dailyservice points simplifies servicingand reduces time spent on regularmaintenance procedures. Enhancedserviceability and 500-hour serviceintervals are designed to increasemachine availability and productivity.
Maintenance Platform. Provides accessto engine, air filters and batterycompartment.
In-Frame Access. Permits easy accessto major components for easy servicingand removal.
Ground-Level Access. Allows convenientservicing to tanks, filters, drains, andengine shutdown. Ground-level VIMSdata port permits easier downloadingof information.
Autolube. Automatic lubricationsystem reduces maintenance time byautomatically lubricating necessarycomponents on a regular basis.
Fast Fill Service Center. Wiggins fastfill service center features high speedfuel, coolant and oil exchange.
Oil Renewal System (ORS). Optionalsystem extends oil change intervalsand reduces waste oil handling bycontinuously burning oil from theengine oil pan through normal engineoperation. Make-up oil must becontinually added to compensatefor oil burned.
Scheduled Oil Sampling. S•O•SSM
sampling valves speed sampling andanalysis reliability.
Pressure Test Points. Disconnect valvesare conveniently located throughoutthe hydraulic systems for easypressure testing.
Air Filters. Radial seal air filters areeasy to change, reducing time requiredfor air filter maintenance.
Sealed Electrical Connectors. Electricalconnectors are sealed to lock out dustand moisture. Harnesses are braided forprotection. Wires are color coded foreasy diagnosis and repair.
Cylinder Heads. Individual cylinderheads are interchangeable for easyremoval and visual inspection ofinternal parts.
On-Board Diagnostic Systems.VIMS continuously checks all criticalmachine functions and components,and helps locate faults quickly forfaster repair. Electronic control systemenables quick diagnosis of engineconditions and effective maintenanceand repairs utilizing the ElectronicTechnician (ET) service tool.
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ServiceabilityLess time spent on maintenance means more more time on the haul roads.
Machine Selection. Make detailedcomparisons of the machines underconsideration before purchase.Cat dealers can estimate componentlife, preventive maintenance cost,and the true cost of lost production.
Purchase. Look past initial price.Consider the financing optionsavailable, as well as day-to-dayoperating costs. This is also the timeto look at dealer services that can beincluded in the cost of the machine tolower equipment owning and operatingcosts over the long run.
Financing. Your dealer is an expert atarranging affordable financing optionsfor all Caterpillar products.
Product Support. You will find nearlyall parts at your dealer parts counter.Cat dealers use a worldwide computernetwork to locate in-stock parts tominimize machine downtime. Savemoney with Cat Reman parts. Receivethe same warranty and reliability as newproducts at a savings of 40 to 70 percent.
Literature Support. Operation andmaintenance manuals are easy to use,helping you get the full value of yourequipment investment.
Customer Support Agreements.Cat dealers offer a variety of productsupport agreements, and work withcustomers to develop a plan that meetsspecific needs. Plans can cover theentire machine, including attachments,to help protect your investments.
Operation. Improving operatingtechniques can boost your profits.Your Cat dealer has training videotapes,literature and other ideas to help youincrease productivity.
Replacement. Repair, rebuild orreplace? Your Cat dealer can help youevaluate the cost involved so you canmake the right choice.
Technology Products. Cat dealers offera range of advanced mining technologyproducts for customers, dealers andoperators designed to improve fleetefficiency, increase productivity andlower costs.
www.CAT.com. For more completeinformation on Cat products, dealerservices, and industry solutions, visit uson the web at www.CAT.com.
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Customer SupportCaterpillar dealers have what it takes to keep mining haul trucks productive.
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Product Safety. Caterpillar has been andcontinues to be proactive in developingmining machines that meet or exceedsafety standards. Safety is an integralpart of all machine and systems designs.
SAE and ISO Standards. The 797B isdesigned to national and internationalstandards, and has been tested andself certified to applicable SAE andISO standards.
Integral ROPS Cab. Resiliently mountedto the main frame to reduce vibrationand sound, the integral ROPS structureis designed as an extension of the truckframe. The ROPS/FOPS structureprovides “five sided protection” forthe operator.
Ladder/Secondary Egress. A wide,stationary stairway with handrail on bothsides allow three point contact accessto and from the machine. A ladder onthe left side of the machine permitssecondary access or emergency egress.
Brake Systems. Four corner oil-cooledbraking system provides excellentcontrol in slippery conditions. The servicebrakes and retarding system are actuatedby modulated hydraulic pressure, whilesecondary and parking brake functionsare spring applied and hydraulic released.This system assures braking in the eventof complete hydraulic failure.
Steering System. A twin double-actingcylinder steering system is designed todeliver precise control under variousloading and underfoot conditions. Thesteering hydraulic system is separatefrom the main hydraulic system toprevent cross-contamination andoverheating from other sources.
Engine Shut Off Switches. Located inthe engine compartment and at groundlevel for an immediate shutdown.
Electrical System Disconnect.A disconnect switch, located outsidethe battery compartment, locks outthe electrical system.
Payload Policy. Safety is integral tomaintaining the highest productivityin mining machine operation.Caterpillar’s 10/10/20 Payload Policyassures that steering and brakingsystems have sufficient capacity toperform, even at 20% overload.
Standard Safety Features. Additionalstandard safety features include:
• Slip resistant surfaces
• Retractable, 75 mm (3 in) wideseat belts
• Wide-angle mirrors
• Body raised indicator
• Guard rails
• Reverse neutralizer when dumping
• Low interior sound level
SafetyCaterpillar mining machines and systems are designed with safety as the first priority.
19797B Mining Truck specifications
Transmission
Forward 1 11.3 kph 7 mphForward 2 15.2 kph 9.5 mphForward 3 20.5 kph 12.7 mphForward 4 27.7 kph 17.2 mphForward 5 37.2 kph 23.1 mphForward 6 50.3 kph 31.2 mphForward 7 67.6 kph 42 mphReverse 12.9 kph 8 mph
• Maximum travel speeds with standard 59/80R63 tires.
• Caterpillar seven-speed, electronically controlled, automaticpower shift transmission.
• Reverse and Forward 1 gears are both torque converterdriven with lock-up in Forward 1 through Forward 7.
• Each shift individually modulated for maximum smoothness.
• Controlled Throttle Shift and Directional Shift Managementmaximize shift smoothness and minimize drive line stress.
• Single-lever shift control provides automatic shifting inall gears.
Final Drives
Differential Ratio 1.265:1Planetary Ratio 16.67:1Total Reduction Ratio 21.09:1
• Double reduction, planetary, with full-floating axles.
Brakes
Brake Surface - Front 132 258 cm2 20,500 in2
Brake Surface - Rear 198 387 cm2 30,750 in2
Standards J-ISO 3450 JAN88,ISO 3450-1996
• Maximum operating weight up to 623 690 kg (1,375,000 lb).
• Service Brakes. Forced oil-cooled/variable capacity discbrakes with electro-hydraulic controls. Sealed andindividually serviceable.
• Parking Brakes. Spring-applied, hydraulically released;toggle switch activated. Uses same disc brakes asservice brakes.
• Secondary Brakes. Spring-applied, hydraulically released.
• Retarding System. Automatic Retarder Control standard.Applied to all wheels (40/60 split, front and rear). Handoperated lever provides modulated engagement of servicebrakes for retarding.
• Traction System. Traction Control System standard.
Engine
Engine Model Cat 3524B EUIGross Power 2648 kW 3,550 hpFlywheel Power 2513 kW 3,370 hpNet Power - Cat 2513 kW 3,370 hpNet Power - ISO 9249 2513 kW 3,370 hpNet Power - SAE J1349 (6/95) 2513 kW 3,370 hpNet Power - EEC 80/1269 2513 kW 3,370 hpBore 170 mm 6.7 inStroke 215 mm 8.5 inDisplacement 117.1 L 7,143 in3
• Net power advertised is the power available at rated speedof 1750 rpm, measured at the flywheel when the engine isequipped with fan, air cleaner, muffler and alternator.
• Ratings based on standard air conditions of 25° C (77° F)and 99 kPa (29.32 Hg) dry barometer. Power based on fuelhaving API gravity of 35 at 16° C (60° F), LHV of 42,780 kJ/kg(18,390 BTU/lb), and density of 838.9 g/L (7.001 lb/gal)when engine used at 30° C (86° F).
• No engine derating required up to 2591 m (8,500 ft) altitude.
• Compliant with U.S. Environmental Protection Agency Tier 1emissions standards.
• 24-cylinder, 4-stroke, high pressure unit injection engine.
• Full electronic controls with automatic engine derate.
• Two-piece pistons with steel crowns, thermally isolatedaluminum skirts cooled by dual oil spray. Hardenedcrankshaft journals.
• Dry-type air cleaners and pre-cleaner.
• 24-volt electrical system with two 75-amp alternators andtwo 93-amp, low maintenance, high-output, 12-volt batteries.
Weights - Approximate
Gross Machine Operating Weight 623 690 kg 1,375,000 lbChassis Weight 214 820 kg 473,600 lbBody Weight Range 38 000 - 84,000 -
63 000 kg 140,000 lb
• Chassis weight with hoist, body mounting group and tires.
• Body weight varies depending on how body is equipped.
Operating Specifications
Nominal Payload Capacity 345 tonnes 380 tonsTop Speed - Loaded 67.6 kph 42 mphMaximum Capacity CustomSteer Angle 39ºTurning Radius - Front 39.9 m 130.9 ftTurning Circle Clearance 40.5 m 132.8 ftDiameter
20 797B Mining Truck specifications
ROPS
ROPS Standards SAE J1040 APR88,SAE J231 JAN81,ISO 3471-1994, ISO 3449-1992 Level II
• ROPS (Rollover Protective Structure) for cab offered byCaterpillar meets SAE J1040 APR88, SAE J231 JAN81,ISO 3471-1994, ISO 3449-1992 Level II ROPS criteria.
Sound
Sound Standards ANSI/SAE J1166 MAY90,ANSI/SAE J88 JUN86
• The operator sound exposure Leq (equivalent soundpressure level) measured according to work cycleprocedures specified in ANSI/SAE J1166 MAY90 is lessthan 76 dB(A) for cab offered by Caterpillar, when properlyinstalled and maintained and tested with doors andwindows closed.
• Hearing protection may be needed when operating withan open operator station and cab (when not properlymaintained or doors/windows open) for extended periodsor in a noisy environment.
Steering
Steering Standards SAE J1511 OCT90,ISO 5010-1984
• Maximum operating weight up to 623 690 kg (1,375,000 lb).
• Separate hydraulic system prevents cross contamination.
• Secondary steering provided by bladder-type accumulator.
• Twin, double-acting cylinders.
• Front suspension cylinders serve as kingpins.
Tires
Standard Tire 59/80R63
• Productive capabilities of the 797B truck are such that,under certain job conditions, TKPH (TMPH) capabilities ofstandard or optional tires could be exceeded and, therefore,limit production.
• Caterpillar recommends the customer evaluate all jobconditions and consult the tire manufacturer for propertire selection.
Body Hoists
Pump Flow - High Idle 1225 L/min 323 gal/minPump Flow - Low Idle 1099 L/min 290 gal/minRelief Valve Setting - Raise 23 787 kPa 3,450 psiBody Raise Time - High Idle 25 SecondsBody Lower Time - High Idle 18.5 SecondsBody Power Down - High Idle 17.3 SecondsBody Raise Time - Low Idle 25 SecondsBody Lower Time - Low Idle 18.5 SecondsBody Power Down - Low Idle 18.1 Seconds
• Twin, two-stage hydraulic cylinders, mounted outsidemain frame.
• Power raise in both stages; power down in first stage.
• Automatic body-lower modulation reduces impact on frame.
Weight Distributions - Approximate
Front Axle - Empty 43.5 %Rear Axle - Empty 56.5 %Front Axle - Loaded 33.3 %Rear Axle - Loaded 66.7 %
Service Refill Capacities
Fuel Tank 6814 L 1,800 galCooling System 1194 L 315 galCrankcase 417 L 110 galDifferentials and Final Drives 701 L 185 galSteering Tank 235 L 62 galSteering System (Includes Tank) 432 L 114 galBrake/Hoist Hydraulic Tank 996 L 263 galBrake/Hoist System 1842 L 486 gal(Includes Tank)Torque Converter/ 190 L 50 galTransmission SumpTorque Converter/Transmission 629 L 166 galSystem (Includes Sump)
21797B Mining Truck specifications
DimensionsAll dimensions are approximate.
1 Height to Top of ROPS - Full 6351 mm 250 in1 Height to Top of ROPS - Empty 6549 mm 258 in2 Overall Body Length 14 483 mm 569 in3 Inside Body Length 9941 mm 391 in4 Overall Length 14 530 mm 572 in5 Wheelbase 7200 mm 283 in6 Rear Axle to Tail 4016 mm 158 in7 Ground Clearance - Full 869 mm 34 in7 Ground Clearance - Empty 1059 mm 42 in8 Dump Clearance 1885 mm 74 in9 Loading Height - Empty 7083 mm 278 in10 Inside Body Depth - Max 3350 mm 132 in
11 Overall Height - Body Raised 15 292 mm 602 in12 Operating Width 9154 mm 360 in13 Centerline Front Tire Width 6512 mm 256 in14 Engine Guard Clearance - Full 919 mm 36 in14 Engine Guard Clearance - Empty 1122 mm 44 in15 Outside Body Width 8524 mm 336 in16 Inside Body Width 8000 mm 315 in17 Front Canopy Height 7584 mm 299 in18 Rear Axle Clearance - Full 951 mm 37 in18 Rear Axle Clearance - Empty 1046 mm 41 in19 Centerline Rear Dual Tire Width 6233 mm 245 in20 Overall Tire Width - Full 9761 mm 384 in
10
20
19
18
17
16
15
13
14
12
45 °
2
3
1
4
5 6
78
9
11
22
To determine retarding performance: Add lengths of alldownhill segments and, using this total, refer to properretarding chart. Read from gross weight down to the percenteffective grade. Effective grade equals actual % grade minus1% for each 10 kg/t (20 lb/ton) of rolling resistance. From thisweight-effective grade point, read horizontally to the curvewith the highest obtainable gear, then down to maximumdescent speed brakes can properly handle without exceeding
cooling capacity. The following charts are based on theseconditions: 32° C (90° F) ambient temperature, at sea level,with 59/80R63 tires.
NOTE: Select the proper gear to maintain engine rpm at the highestpossible level, without overspeeding the engine. If cooling oiloverheats, reduce ground speed to allow transmission to shift tothe next lower speed range.
Retarding Performance
0 100 200 300 400 500 600 700
km/h
mph
kg x 1000
EFFE
CTIV
E G
RAD
E (F
avor
able
)
Gross Weight
lb x 1000
SPEEDContinuous Grade Length
Gross Machine Operating Weight623 690 kg/1,375,000 lb
Typical Field Empty Weight
0 200 400 600 800 1000 1200 1400
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70
0 5 10 15 20 25 30 35 40 45
4th Gear
7th Gear6th Gear
5th Gear
2nd Gear
3rd Gear
1st Gear
25%
5%
10%
15%
20%30%
LE
23
Retarding Performance
Gross Weight
SPEEDGrade Distance — 600 m (2000 ft.)
Gross Machine Operating Weight623 690 kg/1,375,000 lb
Typical Field Empty Weight
EFFE
CTIV
E G
RAD
E (F
avor
able
)
LE
5th Gear
6th Gear7th Gear
2nd Gear
1st Gear
4th Gear
3rd Gear
5%
10%
15%
20%25%30%
0 100 200 300 400 500 600 700
km/h
mph
kg x 1000
lb x 1000 0 200 400 600 800 1000 1200 1400
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70
0 5 10 15 20 25 30 35 40 45
EFFE
CTIV
E G
RAD
E (F
avor
able
)
Gross Weight
SPEEDGrade Distance — 450 m (1500 ft.)
Gross Machine Operating Weight623 690 kg/1,375,000 lb
Typical Field Empty Weight
LE
5th Gear
6th Gear
7th Gear
2nd Gear
1st Gear
4th Gear
3rd Gear
5%
10%
15%
20% 25%30%
0 100 200 300 400 500 600 700
km/h
mph
kg x 1000
lb x 1000 0 200 400 600 800 1000 1200 1400
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70
0 5 10 15 20 25 30 35 40 45
24
Retarding Performance
Gross Weight
SPEEDGrade Distance — 1500 m (5000 ft.)
Gross Machine Operating Weight623 690 kg/1,375,000 lb
Typical Field Empty Weight
EFFE
CTIV
E G
RAD
E (F
avor
able
)
LE
5th Gear
6th Gear7th Gear
2nd Gear
1st Gear
4th Gear
3rd Gear
5%
10%
15%
20%25%30%
0 100 200 300 400 500 600 700
km/h
mph
kg x 1000
lb x 1000 0 200 400 600 800 1000 1200 1400
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70
0 5 10 15 20 25 30 35 40 45
EFFE
CTIV
E G
RAD
E (F
avor
able
)
Gross Weight
SPEEDGrade Distance — 900 m (3000 ft.)
Gross Machine Operating Weight623 690 kg/1,375,000 lb
Typical Field Empty Weight
LE
5th Gear
6th Gear7th Gear
2nd Gear
1st Gear
4th Gear
3rd Gear
5%
10%
15%
20% 25%30%
0 100 200 300 400 500 600 700
km/h
mph
kg x 1000
lb x 1000 0 200 400 600 800 1000 1200 1400
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70
0 5 10 15 20 25 30 35 40 45
25
To determine gradeability performance: Read from grossweight down to the percent of total resistance. Total resistanceequals actual percent grade plus 1% for each 10 kg/t (20 lb/ton)of rolling resistance. From this weight-resistance point, read
horizontally to the curve with the highest obtainable gear, thendown to maximum speed. Usable rimpull will depend upontraction available and weight on drive wheels.
Gradeability/Speed/Rimpull
1st Gear
1st Gear
2nd Gear
3rd Gear
4th Gear
5th Gear6th Gear
7th Gear
350
300
250
200
150
100
50
0
0 5 10 15 20 25 30 35 40
0 10 20 30 40 50 60 70
160
140
120
100
80
60
40
20
0
0 100 200 300 400 500 600
0 200 400 600 800 1000 1200 1400
kg x1000
lb x1000
RIM
PULL
TOTA
L RE
SIST
AN
CE(G
rade
plu
s Ro
lling
)
SPEED
kg x 1000
lb x 1000
mph
km/h
LE
5%
10%
15%
20%
25%
30%
Gross Machine Operating Weight623 690 kg/1,375,000 lb
* At Sea Level
Typical Field Empty Weight
59/80R63 TiresGross Weight
Standard Arrangement*Torque Converter Drive
Direct Drive
Standard EquipmentStandard equipment may vary. Consult your Caterpillar dealer for details.
Engine - Caterpillar 3524B HD EUI Diesel EngineAir Cleaner w/Precleaner (5)Automatic Starter ProtectionCrankcase ProtectionElevated Low Idle ControlEther Starting Aid (Semi-automatic)Multi-point Oil Pressure SensingTurbocharging (4)/Aftercooled
Fast-fill Fuel System, WigginsGround Level
Battery DisconnectEngine ShutdownVIMS Dataport
High Speed Crankcase Oil Change (Wiggins)Lighting System
Back-up Lights (4)Engine Compartment LightDirection Signals (Front/Rear LED’s)Fog Lights (4)Front Stair Access and Service Deck LightsHeadlights, With DimmerStop and Tail Lights (LED)
Reservoirs (Separate)BrakeConverterHoist/Steering/Transmission
Rims, Center Mounted for 59/80R63 TiresRock EjectorsSteering, Auxiliary Quick Connect for TowingTie Down EyesTow Hooks, FrontTow Pin, RearTraction Control SystemTransmission
7-speed, Auto Powershift w/ECPC ControlsBody Load CounterBody-up Reverse NeutralizerBody-up Shift InhibitorControlled Throttle ShiftingDirectional Shift ManagementDownshift/Reverse Shift InhibitorNeutral Coast InhibitorNeutral Start SwitchProgrammable Top Gear
Vandalism Protection LocksVital Information Management System (VIDS) w/Payload
Monitor and MAX Payload and Speed Manager
Air Line DryerAlarm, Back-upAlternator, 75 amp (2)Antifreeze, Extended Life CoolantAutomatic Lubrication System (Lincoln)Automatic Retarder ControlAuxiliary “Buddy” Dumping Quick ConnectBody Mounting GroupBrake System
Brake Release Motor for TowingOil-cooled, Multiple-disc, Front and RearParkingSecondary, Emergency
Cab, ROPS, Insulated/Sound SuppressedAccessory Plug-in, 12VAir Cleaner Service IndicatorAir ConditionerAshtrayCigarette LighterCoat HookDome Courtesy LightElectric Window (Operator Only)Glass, TintedHeater/defroster: 11 070 kCal (43,930 Btu)HornMirrors, Right and LeftQuad-Gauge Panel
Brake Oil TemperatureCoolant TemperatureFuel LevelSteering Oil Level
Seat, Air SuspensionSeat, Passenger, Air Suspension with
Storage CompartmentsSeat Belts, 75 mm (3 in) wide retractableSpeedometerStairway AccessSteering, Automatic SupplementalSteering Wheel, Tilt, TelescopicSun VisorTachometer, ElectronicTransmission Gear IndicatorVIMS KeypadVIMS Message Center with Universal GaugeWindshield Wiper and Washer
Center Mounted Rims (6) (44 � 63) (Used for 59/80R63 Tires)Converter, 12V (2) ElectricalDriveline Operator Safety GuardElectrical System, 24-volt 90 Amp at Low Idle
26 797B Mining Truck specifications
27797B Mining Truck specifications
kg lb
Battery
Standard 63 138
Heavy Duty 126 278
Sealed 168 371
Bumper
Standard 1865 4112
Towing 2135 4707
Exhaust
Side 61 133
Rear through Body 321 706
Handrail Guard 30 65
Cover Guard 30 65
Fuel Tank
1000 Gallons 1406 3099
1800 Gallons 2727 6012
kg lb
Oil Cooler, Rear Axle 104 228
Pump, Standard 70 154
Seat
Cat Air Suspension, C500 0 0
Isringhausen Air Suspension 0 0
Starting System, Air
Vane Ingersoll 404 891
TDI Turbine 353 778
Ingersoll Turbine 360 792
Window
Passenger Door, Fixed 0 0
Passenger Door, Electric 0 0
Mandatory Equipment (with approximate changes in operating weight)
Mandatory and optional equipment may vary. Consult your Caterpillar dealer for specifics.
kg lb
Body, Flat Floor 46 294 102,060
Body Liner
Solid 3992 8800
Rock Box 1909 4210
Rear Grid 1769 3900
Engine Prelube, Air Start 3 7
External Payload Display, Left, Right 46 100
Fire Extinguisher, Portable 21 45
Heater, Large Fuel Tank 18 39
High Altitude Modification 740 1630
Hose, Cab Cleanout 7 15
kg lb
Oil Renewal System 15 32
Radiator Guard, Oil Sands 514 1132
Road Analysis Control (RAC) 6 13
Starting System, Cold Weather 94 207
2940 6480
2951 6504
Tire Rim
Spare, 44-63, Standard
Spare, 44-63, Wedge
Mounting Guard 71 156
Tires, 59/80R63 MX XDRC4** E4 31 815 70,140
Torque Converter Guard 269 591
Wiggins Service Center 59 130
Optional Equipment (with approximate changes in operating weight)
R
For more complete information on Cat products, dealer services,and industry solutions, visit us on the web at www.CAT.com
© 2003 CaterpillarPrinted in 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.AEHQ5511 (12-03)
797B Mining Truck
