Dust Control – Soil Stabilization – Erosion Control

The design of the latest Cat mining trucks exceeds its predecessors and offers the ultimate in productivity, durability and low cost of operation even in the most challenging mining operations.

97F Cat® Mining Truck
The 797F, with 4,000-horsepower (2983 kW) and rated payload capacities to 363 tonnes, combines the strengths of its predecessors with a new engine, redesigned operator station and custom body systems to deliver even lower costs per tonne – with less environmental impact.

The 797F also offers easier maintenance and enhanced safety provisions. Ground level service points ease access, and 1,000-hour hydraulic filter service intervals reduce required maintenance. Safety enhancements include wider walkways, a rear access ladder and a bumper-mounted, three-way, lock-out tag-out box.

The 20-cylinder, 4,000-gross-horsepower Cat C175-20 ACERT engine has a single engine block and is the heart of the new truck. The engine has accumulated more than a quarter-million hours of field testing in mining trucks and power-generating systems. The C175 displaces 5.3 litres (323 in³) per cylinder – for a total displacement of 106 litres (6,458 in³). The 797F develops 450 horsepower more than its predecessor, the 797B, which used a 24-cylinder Cat 3524B engine displacing 117 litres (7,143 in³).

The cross-flow engine design uses four turbochargers, an air-to-air after cooler and an electronically controlled common-rail fuel system, which precisely delivers multiple injections in a single combustion event. These electronically controlled systems account for much of the high power density and low emissions and contribute to the 797F fuel efficiency and responsive performance. The engine meets EPA Tier 2 emissions standards. The engine-cooling system, also electronically controlled, uses the engine cooling fan only as needed, which conserves power and fuel.

The engine control module, the Cat ADEM™ A4, has 50 times the computing power of its predecessor. The new module monitors more than 30 critical engine functions, drives the 20 fuel injectors and communicates more than 100 engine parameters that describe engine health and assist in diagnosing problems.

A robust drive shaft transfers the immense torque of the C175-20 engine to the rear-axle-mounted, seven-speed planetary transmission, which delivers a smooth flow of power through the massive rear axle to double-reduction final drives. An integral lock-up torque converter enhances high speed performance and fuel efficiency.

The Cat Electronic Clutch Pressure Control system effectively manages transmission-clutch operation under varying speed and load conditions, assuring that gear changes occur with no power loss and that clutch engagement is modulated to promote smooth shifts and long clutch life. A separate fluid system assures a dedicated supply of clean, cool oil for clutch operation and transmission lubrication. Transmission features include engine over-speed protection, downshift inhibitor (at high speeds) and programmable top speeds.

The 797F integrated braking system combines three brake functions (primary, secondary and parking) with an automatic, hydraulically actuated retarder in a single assembly located at each wheel. These immense, oil-cooled, multiple-disc assemblies provide a total braking/retarding surface of 51,250 in² (330 645 cm²). An integral heat exchanger controls brake-oil temperature to maintain no-fade performance and to extend brake life.

A robotically welded and ultrasonically checked frame incorporates nine mild-steel castings. The large radii castings are resilient to absorb frame flexing and ensure long life. The mild steel castings and fabrications provide flexibility, durability and resistance to impact loads, even in cold climates.

Available for the 797F is a choice of four Mine Specific Design (MSD II) body options that can be used in conjunction with a configurable liner system to provide an optimal blend of payload capacity and durability in a given application. Customers can tailor body systems to production demands and operating constraints, and payload capacity can be as much as 18 tonnes greater in some instance than was available with the 797B.

793F Cat® Mining Truck
The new 793F Cat® Mining Truck, the fifth generation of the 793, builds on the proven, 20-year performance record of its predecessors with a powerful new engine, choice of power train options, choice of body systems and a completely redesigned operator station. These refinements take the 793F – now with 2,650 horsepower (1976 kW) and a 226.8-tonne payload capacity – to higher standards of productivity, durability, operating ease, altitude capability, fuel efficiency and emissions control.

The 793F also offers enhanced serviceability through its ground level service points and 1,000-hour hydraulic filter service intervals. Other changes promote safe operator and technician access—wider walkways, flat upper deck, rear access ladder and a three-way lock-out tag-out box mounted on the bumper.

The 16-cylinder, 2,650-gross-horsepower Cat C175-16 diesel engine displaces 5.3 litres (323 in³) per cylinder – for a total displacement of 85 litres (5,187 in³). The 793F develops 235 horsepower more than its predecessor, the 793D, which used a 16-cylinder Cat 3516B engine displacing 78 litres (4,760 in³).

The 793F electronically controlled six-speed planetary transmission, with an integral lock-up torque converter, drives through the massive rear-axle differential and double reduction final drives, which together provide an overall reduction-ratio of 29:1.

The 793F standard braking system combines three brake functions (primary, secondary and parking) with an automatic, hydraulically actuated retarder operating on all four corners of the truck. These sealed, oil-cooled assemblies use a number of 34.5-inch (874.5-cm) diameter friction discs stacked alternately with same-diameter steel plates. Compressing this assembly with a hydraulically actuated piston (primary braking/retarding) or via spring pressure (secondary/parking brake) slows and stops the truck.

The 793F continues to offer the Additional Retarding option designed for long, steep downhill hauls. This option includes the Extended Life Wheel Stations package and adds a second oil-to-water cooler for brake oil, a second water pump in the brake-cooling system and larger-diameter cooling lines. Equipped with the Additional Retarding option, the 793F typically can negotiate downhill grades one gear higher, compared with trucks having standard brake/retarder assemblies. The higher gear normally allows an approximate 25-percent increase in attainable speed.

The 793F is offered with three body options: X-Body; MSD II (Mine Specific Design); and Gateless Coal Body. The X-Body uses a particularly heavy-duty design and accommodates a larger volume than previous Cat dual-slope or flat-floor bodies – but design enhancements keep the weight of the new body the same as previous bodies. The X-Body is designed primarily for new mine sites, where materials of different densities frequently must be hauled.

The MSD II Body is configured based on an evaluation of parameters at specific sites, including material density, material abrasiveness, impact potential, type of loading tool, haul road conditions and conditions at the loading and dumping sites. The MSD II Body then is custom designed to yield the best balance of payload capacity and durability when working at established mine sites, where material density likely will be consistent.

When hauling coal is the primary task, the Gateless Coal Body can be used to achieve consistently large payloads. The body is designed to retain full loads without the additional weight and complexity of a tailgate. The Gateless Coal Body is designed to be used without liners.
The new F-Series cab features an angled, centre-mounted instrument panel and a centre console. The cab provides greater viewing area when compared to the previous model. Ergonomic design of controls and displays promotes efficient and comfortable operation. Analogue-type gauges are quickly checked without losing sight of the haul road, and the integral Vital Information Management System (a powerful third-generation configuration) provides machine health and payload data, plus easy access to diagnostic and machine management information either onboard or off, via internet-based access.

Levers and switches in the console are comfortably positioned just forward of the right armrest to allow easy control with minimum effort. The fully adjustable air-suspension seat assures all-shift comfort for the operator and is available as an option for the trainer. The newly designed front and side windows give a commanding view of the haul road and work area. A 600-mm-wide (24-in-wide) stairway and walkway, assist safe entry and exit, and wide-angle mirrors, body-raised indicator, double body-retaining cables and reverse-neutralizer (when dumping) further promote safe operation.