Manual Capacitacion Sistema Direccion Camion 797b Caterpillar
Comparacion 797B 797F
Transcript of Comparacion 797B 797F
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Caterpillar Product Information
Comparative BulletinApril 2010
Cat797F and 797BMining Trucks
For Dealer Sales Personnel
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2 April 2010Cat797F and 797B Mining Trucks
Table of Contents
Overview ...............................................................................................................................................................................3
Engine ....................................................................................................................................................................................5
Power Train ..........................................................................................................................................................................7
Brake System .......................................................................................................................................................................9
Truck Body Systems ..........................................................................................................................................................10
Operator Environment .......................................................................................................................................................12
Machine Intelligence .......................................................................................................................................................14
Safety ...................................................................................................................................................................................15
Technical Specifications .................................................................................................................................................16
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3April 2010 Cat797F and 797B Mining Trucks
Overview
Overview. The Cat797 is the ultra-class, industry leader and now the 797F continues this tradition withadvancements to safety, productivity, serviceability and comfort.
Cat 797F and 797B Mining TrucksThe 797F Mining Truck is the largest model in the Cat Mining Truck product line with a nominal payload
capacity of 363 metric tons (400 tons) and an operating weight of 623 690 kg (1,375,000 lb). The 797F has
signicant updates which increase performance and lower operating costs.The CatC175-20 engine is U.S. EPA Tier 2 compliant, meeting stringent environmental regulations
without sacricing fuel efciency while providing 10 percent more power.
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4 April 2010Cat797F and 797B Mining Trucks
Overview
Other 797F improvements include:
Higher capacity lock-up clutch to accommodate increased horsepower
New cab mounts with increased ROPS capacity
Straight rails replace Z rails to radiator mount
New ergonomically designed cab to reduce operator fatigue, enhance operator performance and promote
safe operation with exceptional all-around visibility
New VIMS 3G monitoring system provides more information to the operator on machine status
Improved serviceability access
The 797B Mining Truck nominal payload capacity was 345 tonnes (380 tons) with a gross operating
weight of 623 690 kg (1,375,000 lb). Gross power was 2648 kW (3,550 hp). The 797B met U.S. EPA Tier 1
emission standards.
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5April 2010 Cat797F and 797B Mining Trucks
Engine
Engine. The CatC175-20 engine is built for power, reliability and efficiency.
CatC175-20 Engine
The C175-20 engine used in the 797F is a newly
developed 20-cylinder diesel engine that utilizes:
Advanced block, piston, rod, liner and head
structures
Cat Common Rail Fuel System
ADEM A4 electronic controls
Air-to-Air After Cooling
These technologies combine to yield the best engine
performance available in a large mining truck.
The C175-20 is available in two congurations
for operation based on the mines altitude:
Standard Altitude: Up to 2134 m (7,000 ft)
without derate
High Altitude: Up to 4877 m (16,000 ft)
without derate
Cat3524B High Displacement Engine
The 3524B engine used in the 797B Mining Truck
was a tandem unit consisting of two 3512B HD engine
blocks, coupled to perform as a single engine in terms
of operation, monitoring and control. The 3524B began
derating at 2591 m (8,500 ft) altitude. The optional
High Altitude Arrangement did not derate between
3048-4572 m (10,000-15,000 ft).
CatCommon Rail Fuel System (CCRFS)
A building block of both ACERT Technology andthe C175-20 engine design is the Cat Common Rail
Fuel System (CCRFS). The key objective of this system
is the exibility to work over a wide range of loads
while lowering emissions and fuel consumption.
The CCRFS also has the capability to deliver multiple
injections within a single combustion event with
unprecedented precision and repeatability. This precise
and exible fuel system also results in faster transient
response, enhanced cold start capability and reduced
white smoke. Overall, the CCRFS gives the enginethe ability to meet emissions regulations without
sacricing performance, reliability or durability.
CCRFS versus Mechanically Activated EUI Injector
The higher pressure developed in the CCRFS
gives better atomization for complete combustion
and lower combustion temperature, resulting in
lower emissions.
CCRFS gives more exibility for multiple injections.
EUI is restricted to the amount of bumps on thecamshaft lobe, while the CCRFS can inject fuel
at any point in time.
EUI can only hold constant maximum pressure for
a certain amount of time (40 cam angle) since it is
driven by camshaft rotation. EUI always injects the
same amount of fuel. CCRFS allows for rate shaping
at any point in time due to constant fuel pressure in
the rail. The injector can be opened at any time and
the amount of fuel can be controlled.
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7April 2010 Cat797F and 797B Mining Trucks
Power Train
Power Train. More power to the ground for greater productivity.
1 Transmission, 2 Lock-Up Torque Converter, 3 Final Drives
Power Train
The 797F has retained the proven design of the
797B but has additional features to accommodate
higher horsepower, provide improved powertrain protection and support application specic
performance enhancements.
Torque Converter
The 797F Mining Truckss C175-20 engine is coupled
with the E7608 ADC torque converter. It utilizes a
four-disc lockup clutch (LUC), one more than the
797B. The LUC pressure has been raised to 31.36 bar
(310 psi) to accommodate higher horsepower and
maintain durability. The LUC features ElectronicClutch Pressure Controls (ECPC), and LUC
engagement has been tuned for different shift types.
Transmission
Power ows from the torque converter through
a 20C drive shaft directly into the input yoke and
input planetary of the transmission. The transmission
output is directly splined into the differential pinion.
The transmission is comprised of an input and output
planetary group, input and output case group, wiringgroup and controls group. Changes have been made
to all of these groups on the 797F, providing improved
transmission protection while accommodating higher
horsepower. This provides durability and reliability
for long service life.
Planetary Groups
Design changes to the input and output planetarygroups were made to improve transmission durability
and reliability. Improvements were made to address
the wear often exhibited between the train 1/2 ring
gear and clutch 2/3 housing by utilizing nylon,
impregnated plastic thrust buttons. Improvements
were also made to gear trains 1 and 5 by redesigning
the gear set for optimal pitting and bending life,
while maintaining the 797B gear reduction.
Planetary Clutches and Controls Group
The 797F control group is redesigned to eliminate
the latching valves and solenoid, as well as all
medium ECPC valves. The new control group
also features an aluminum manifold for decreased
weight. The number 1 and 4 clutches have been
improved by eliminating the wave springs and
utilizing coil springs. The rotating housings have
also be redesigned for decreased weight.
Transmission Case
The input and output transmission cases have been
redesigned to decrease weight. A new lter group
has been incorporated for 1,000 hour lter element
change intervals, while maintaining the 797B
mounting location and port size.
Wiring Group and Sensors
A new internal and external transmission harness
has been designed for all electrical functions on
the transmission, including a new transmission
intermediate sensor.
To provide consistent protection for the transmission,
software cross-checks the transmission input and
dual output speeds. This redundant speed sensor
system protects the power train in the event of a
sensor or control system malfunction.
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8 April 2010Cat797F and 797B Mining Trucks
Power Train
Performance
The C175-20 engine boosts net power from 2647 to
2983 kW (3,550 to 4,000 hp). The converter drive
torque limit of 25 760 Nm (19,000 ft-lb) in rst gear
remains, but this increase in power allows the 797F tooutperform the 797B beyond that point via increased
speed on grade.
Final Drives
The 797F nal drives feature a new cover that allows
for removal of the axle shaft and thrust button on
level ground without completely draining the rear
axle. This reduces downtime during towing operations
and certain inspections.
Wheels and Rims
The front wheels of the 797F now incorporate a new
sight gauge to check the oil level. The rear wheels
have plugs for checking oil level and a new center
access cover that allows for axle removal without
signicant nal drive oil loss.
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9April 2010 Cat797F and 797B Mining Trucks
Brake System
Brake System. Superior brake control lets operators focus on productivity.
Integrated Braking System
The 797F continues use of the Cat oil-cooled braking
system to deliver reliable performance and control in
extreme haul road conditions. The integrated system
combines the service, secondary, parking brake and
retarding functions in the same robust system for
optimum braking efciency.
Brake Discs
New for the 797F the extended life carbon ber
friction discs come standard in all congurations.
These were optional on the 797B. In most operating
conditions, this new material will provide increased
wear life over standard paper friction material,
reducing operating costs. A unique bonding process
has been developed that adds strength and prevents
separation failures. This extended life friction material
is also more resistant to glazing. By resisting glazing,
the brakes have more consistent braking power with
less noise. The 797F uses 1067 mm (42 in) diameterfriction discs, employing 10 discs per side in the
front and 15 discs per side in the rear.
Brake Cooling System
The 797F has a new brake/cooling systemincorporating square coolers that are more efcient
than the round ones on the 797B. This new system
uses one less cooler. The 797F brake ECM controls
the solenoid for the brake-cooling pump in order to
adjust the ow of oil that is used for brake cooling.
The brake cooling pump has an additional small
section on the end of the stack to provide ow to the
brake actuation/park brake circuit, as well as provide
ow for the rear axle ltration and lube.
Adjustable Retarding Control
On the 797B, the rpm was set for all gears and went
to maximum rpm. On the 797F, adjustable retarding
control allows the operator to pick the rpm in each
gear. The operator can also raise and lower actual
speed within each gear, allowing the operator much
more control thus improving performance.
The Automatic Retarder Control (ARC) on the 797B
runs the engine at a xed top rpm of 1,900 (50)
and this, in turn, sets the speed for a given gear.For the 797F, the retarding speed in a gear can be
set to hold a speed below the maximum rpm point.
Retarding
The 797F offers two options for retarding. Flat/Uphill
Haul option is the standard conguration and provides
a simplied system for less maintenance. For those
applications requiring downhill loaded operation, an
optional conguration increases retarding capability.
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10 April 2010Cat797F and 797B Mining Trucks
Truck Body Systems
Truck Body Systems. Cat designed and built for rugged performance and reliability.
Body Options
Caterpillar offers four MSD II (Mine Specic Design)
body options in conjunction with a congurable liner
system to achieve the most efcient hauling solution
at the lowest cost-per-ton.
220 m 3(288 yd3)
240 m 3(315 yd3)
251 m 3(330 yd3)
266 m 3(350 yd3)
Body Selection
The Cat truck body program is committed to
providing the most efcient and highest value body
solution for every mining customers application.
The process starts with body application engineers
understanding the users application. By studying
the mine site and understanding the overall
operational requirements and constraints, the body
can be congured to meet the unique needs of the
application. The goal of the Cat body specication
process is to balance payload and structural life
(durability) within the limitations of the gross
vehicle weight.
MSD II Body Design
Cat truck bodies are designed for optimal strength,
capacity and durability. The MSD II Body was
developed using the Caterpillar patented body
design and analysis system. The internal body shell
(oor, sidewalls, frontwall and transition plates)
is 400 Brinell steel for superior impact and wear
protection. The Mine Specic Design liner options
deliver impact and wear protection that maximizes
body life and performance.
The MSD II bodies are the number one choice in themining industry. Benets of the MSD II bodies are:
Full length main rail design adds strength
and rigidity throughout the bed
Internal and external gussets have been added
to the main rail and pivot area for additional
strength
Two-piece pivot bore bushing reduces pin
walkout
New hoist bracket designs terminations wrap
around the rib and internal gussets in the ribfor better stress transition
Additional sidewall ribs help reinforce sidewall
structural integrity
Rail cap options help manage loading tool
and material contact damage
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Truck Body Systems
Two rear ribs utilize a round design to better
transmit stress in rear racking conditions
Lower sidewall lifting lug option is an
alternative body lifting process
Heated body option minimizes carry back in cohesive applications
Truck Body Liners
A variety of truck body liners are available to save
weight and extend the body life through impact and
wear management. The mine specic design system
used to build an application specic liner conguration
is called FACLT (Fragmentation, Abrasion, Cohesion
and Loading Tools). By analyzing each FACLT
element, the Caterpillar application engineers are
able to optimize the balance of payload and durability.
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12 April 2010Cat797F and 797B Mining Trucks
Operator Environment
Operator Environment. Ergonomically designed for all-day comfort, control and productivity.
Operator Station
Caterpillar is the leader in safe design, using a four-
post integral ROPS structure that provides superior
protection when compared with competitors designs.
The 797F features a completely new spacious cab
that offers excellent visibility. The controls and layout
offer operator comfort and convenience, while
maintaining Caterpillar standards for functionality
and durability. The cab is resiliently mounted and
has extra dampening and barrier material in the side
panels, oor and doors. This provides the operator
with a smoother ride, due to less vibration.
Cat Comfort Seat
The 797F features the new Cat Comfort seat with
three-point seat belt restraint. Ergonomically-designed
cushions provide the operator with support where itis needed for all-day comfort. The new shoulder belt
restraint system offers three height adjustments and
six vertical adjustment positions for optimal t and
secure travel.
The standard trainer seat is a full-size Cat Comfort
seat with suspension.
Air Conditioning and Ventilation System
The 797F has a total of 17 vents to direct airowthroughout the cab. The 797B had 11 vents.
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Operator Environment
Operator Controls
The center-mounted console now features an
automotive-style shift lever with integrated parking
brake. The hoist control has been moved from the
left side of the operators seat to the center console.
Viewing Area
Designed for all-around visibility and clear sight
lines to the haul road, the new cab features a large
viewing area that enables the operator to maneuver
with condence for high productivity. The gauge
cluster has been moved to the center of the cab to
allow the operator improved visibility in front of
the machine.
Storage Compartment
An overhead storage area has been added to the
rear between the operator and trainer seat. A bottle
and lunch box storage area with tie-downs have
also been added, along with two, variable-sized
cup holders.
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14 April 2010Cat797F and 797B Mining Trucks
Machine Intelligence
Machine Intelligence. Vital machine health and payload data keeps production at peak levels.
3rd Generation VIMS Monitoring System
The 3rd Generation VIMS Monitoring System
provides critical machine health and payload data
in real-time to keep the 797F performing at top
production levels. Sensors located throughout the
machine enable VIMS to quickly exchange and
monitor information from all machine systems.
Users can view up to 10 different machine
parameters at a time by accessing each VIMS3G-equipped machines unique web address. Service
technicians or mine personnel can quickly download
data and generate reports in the ofce, shop or in
the cab by connecting directly to the system through
an on-board Ethernet port. On-board the machine,
various levels of alerts provide the operator with
notication and severity of abnormal machine
health conditions. Data can be used to improve
effectiveness of scheduled maintenance programs,
maximize component life, improve machine
availability and lower operating costs.
External Payload Indicators
External lights signal loading tool operators when
to cease loading for optimum payloads without
overloading. Optional payload displays with digital
numeric monitor are available.
VIMSpc
This off-board software reporting program allowsservice personnel to download a complete record
of machine health and productivity data. Health and
payload reports can be generated for more effective
machine management which helps reduce downtime
and lowers operating costs.
Advisor Display
Standard on the 797F, the Advisor display provides
real-time machine performance and operating data,
as well as basic trip, maintenance and diagnosticdata using an LCD display. Various machine
parameters can be viewed on the display, including
incline, coolant temperature, oil pressure, current
gear selection, current payload, etc.
VIMS Supervisor
This optional software allows mine personnel to
easily manage and interpret VIMS data for optimum
eet management and productivity.
Reduced Horsepower Mode
The 797F can be programmed to operate in
Reduced Horsepower Mode, which uses the reduced
797B horsepower and lug curve to improve fuel
consumption, lower noise level and potentially
lengthen engine life. Reduced Horsepower Mode is
best used when a customer has extra truck capacity
and wants to lower his cost-per-ton or wants to
match his 797F performance to an existing 797B
eet. A customer who effectively uses Reduced
Horsepower Mode can reduce operating costswithout sacricing production.
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15April 2010 Cat797F and 797B Mining Trucks
Safety
Safety. Cat Mining Machines/Systems are designed with safety as the first priority.
Added Safety Features on the 797F
The following safety features are included on the 797F:
New Lockout Tagout Box with separate battery
disconnect, engine start and transmission lockoutsReduced the number of level changes on the
top deck and hoods to assist in minimizing
trip points
Strengthened area on the deck for customer
attachments (such as re suppression canisters)
Optional heated mirrors
Increased ROPS capacity, exceeding
SAE requirements
Improved rear service ladder
Added service platforms to the engine and transmission
Increased number of ground level accessible
service points
Increased number of sight gauges for simple
and easy maintenance checks
Reduced cab vibration by using new MARC
mounts and machined cab mounting pointson the frame
Removal of hydraulic lines directly above
the engine
Added driveline and PTO drive guards
Engine safety features include:
High pressure fuel lines on the lower outside
of the engine in double-walled system
Hot exhaust tubes located in the center
of the engine V
No crossover oil lines above the engineTurbos are up high and forward of the engine
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Technical Specifications
Transmission Cat 797F Cat 797B
Forward 1 km/h (mph) 11.3 (7) 11.3 (7)
Forward 2 km/h (mph) 15.2 (9.5) 15.2 (9.5)
Forward 3 km/h (mph) 20.5 (12.7) 20.5 (12.7)
Forward 4 km/h (mph) 27.7 (17.2) 27.7 (17.2)
Forward 5 km/h (mph) 37.2 (23.1) 37.2 (23.1)
Forward 6 km/h (mph) 50.3 (31.2) 50.3 (31.2)
Forward 7 km/h (mph) 67.6 (42) 67.6 (42)
Reverse km/h (mph) 11.9 (7.4) 12.9 (8)
Suspension Cat 797F Cat 797B
Effective Cylinder Stroke Front mm (in) 313.6 (12.3) 313.6 (12.3)
Effective Cylinder Stroke Rear mm (in) 165.1 (6.5) 165.1 (6.5)
Rear Axle Oscillation 4.0 degrees 4.0 degrees
Body Hoists Cat 797F Cat 797B
Pump Flow High Idle L/min (gal/min) 1200 (317) 1225 (323)
Relief Valve Setting Raise kPa (psi) 24 200 (3,510) 23 787 (3,450)
Body Raise Time High Idle Seconds 25 25
Body Lower Time Float Seconds 19 18.5
Body Power Down High Idle Seconds 18 17.3
Brakes Cat 797F Cat 797B
Number of Discs Per Side Front 10 10
Number of Discs Per Side Rear 15 15
Outside Diameter mm (in) 1067 (42) 1067 (42)
Brake Surface Front cm2(in2) 132 258 (20,500) 132 258 (20,500.03)
Brake Surface Rear cm2(in2) 198 387 (30,750) 198 387 (30,750.04)
Standards J-ISO 3450 JAN88,
ISO 3450-1996
J-ISO 3450 JAN88,
ISO 3450-1996
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18 April 2010Cat797F and 797B Mining Trucks
Technical Specifications
Weight Distributions Approximate Cat 797F Cat 797B
Front Axle Empty % 47.2 43.5
Rear Axle Empty % 52.8 56.5
Front Axle Loaded % 33.3 33.3
Rear Axle Loaded % 66.7 66.7
Capacity MSD II 100% fill factor Cat 797F Cat 797B
Struck m3(yd3) 188-213 (246-290) 188-213 (246-290)
Heaped (SAE 2:1) m3(yd3) 240-267 (314-350) 240-267 (314-350)
Service Refill Capacities Cat 797F Cat 797B
Fuel Tank L (gal) 3785 (1,000) 6814 (1,800)
Cooling System L (gal) 1160 (306) 1194 (315)
Crankcase L (gal) 390 (103) 417 (110)
Front Wheels, Each L (gal) 61 (16) 61 (16)
Final Drives, Each L (gal) 185 (49) 185 (49)
Differentials L (gal) 1176 (311) 701 (185)
Steering Tank L (gal) 254 (67) 235 (62)
Steering System (Includes Tank) L (gal) 355 (94) 432 (114)
Brake/Hoist Hydraulic Tank L (gal) 825 (218) 996 (263)
Brake/Hoist System (Includes Tank) L (gal) 1670 (441) 1842 (486)
Torque Converter/Transmission Sump L (gal) 190 (50)
Torque Converter Sump L (gal) 303 (80)
Torque Converter/Transmission System (Includes Sump) L (gal) 629 (166) 629 (166)
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19April 2010 Cat797F and 797B Mining Trucks
Technical Specifications
Tires Cat 797F Cat 797B
Standard Tire 59/80R63 59/80R63
ROPS Cat 797F Cat 797B
ROPS Standards ISO 3471-1994 SAE J1040 APR88,
SAE J231 JAN81,
ISO 3471:1994,
ISO 3449:1992 Level II
Sound Cat 797F Cat 797B
Sound Standards SAE J919:1995,
ANSI/SAE J166:2008,
ISO 6394:2008, ISO 6396:2008,
ISO 6393:2008, ISO 6395:2008,
SAW J88:2006
ANSI/SAE J1166 MAY90,
ANSI/SAE J88 JUN86
Steering Cat 797F Cat 797B
Steering Standards SAE J1511 OCT90,
ISO 5010:1992
SAE J1511 OCT90,
ISO 5010-1984
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