TheLong HaulTen years after the birth of the 797,the world’s largest mining truckis still going strongStory by Caitlin Crawshaweoff Shantz has a photo of hisdaughter standing in front of thewheel of a Caterpillar 797 truck on“Bring your child to work day,” two years ago.Decked out in a hard hat and steel-toedrubber boots, the 14-year-old grins proudly ather dad. The top of her hard hat reaches barelya third of the way up the tire of the 797. Atmore than 20 feet high and 47 feet long, the797B boasts a maximum payload of 380 tons.To put it in perspective, if that payload werebull elephants, the 797 could hold about 70of them.Shantz, a senior reliability inspector atSyncrude’s Aurora mine in northern Alberta,explains that everything about the vehicle islarger than life. Even minor repairs on a truckare big operations, requiring huge equipmentand lots of teamwork.“It’s pretty much a minimum of two peopleand, like, a 20-ton crane. There’s nothingsmall in this truck…on every shift we’ve gotprobably 30, 40 technicians just to maintainour fleet. It’s a big piece of machinery.” Andthat’s a big understatement.Shantz has seen the 797 evolve since1999, when Syncrude began using its first Cat797 from <strong>Finning</strong> (it was purchased in 1998).At the time he was a field mechanic, who developeda hands-on knowledge of the truck.These days, he’s part of a committee comprisedof technical experts from Syncrude,<strong>Finning</strong> and Caterpillar. For the last few years,the group has worked to fine-tune the truck,improving its reliability. These days, the mostrecent incarnation, the 797B, runs at about84% availability. In other words, in a 24-hourwork day, this vehicle is on the road for morethan 20 hours.“As far as I know, between <strong>Finning</strong>, Syncrudeand Caterpillar, we’ve got the highestavailability on the 797 in the world rightnow,” says Shantz.While the truck itself is a marvel of engineering,the idea behind it is simple, explains<strong>Finning</strong>’s Alex Colquhoun, who worked withthe truck for five years as a reliability specialistin Fort McMurray, Alberta. Because of thelarge volumes of material that must be transportedin the oil sands, it’s advantageous tohave a smaller fleet of bigger vehicles.“If they wanted to move the amount ofmaterial today with smaller trucks, they’d haveto double or triple the size of the fleet. They’dneed three times as many people and threetimes as many workdays needed to do anypreventive maintenance – and they’d needthree times as many tires,” says Colquhoun,now <strong>Finning</strong>’s mining equipment manager.Paul Kearney, Syncrude’s manager ofmining at Aurora, explains that the first797s were used at the company’s MildredLake mine, and then the Aurora site whenit opened in 2000. In addition to allowingthe company to take advantage of the economyof scale, the vehicle has proven itselfin northern <strong>Canada</strong>, he says. The truck canhandle all kinds of weather, such as frozenroads in winter and soft ground in spring,68 tracks & treads • Spring 2008 www.finning.ca
REMEMBER WHEN…Service preventive maintenance check plan 1963FINELY TUNED FLEET: Each 797 contains an on-boardVital Information Management System microprocessorthat monitors machine health and payload informationand still offers a smooth ride. “The machineis very popular with the operators in comfortand how it handles,” he says.Kearney adds that over the years, thetruck’s evolution has allowed Syncrudeto move even more materials per load.The truck has grown from a 380-tontruck to a whopping 400 tons.And Caterpillar continues to makesmall changes, he says. A web-basedmonitoring system compiles detailedinformation about how the equipment isfunctioning and allows Syncrude to recommendfurther refinements to maximize theperformance of this maximal truck on its oilsands sites.<strong>Finning</strong>’s Brent Davis has also seen thetruck evolve over the last decade. He sold thefirst 797 to Syncrude in 1999, when he was“You imagine putting yourhouse in the back of a pickuptruck and driving along;it’s quite a feeling.”working as a mining account manager.“Syncrude and another oil sands company,Suncor, were getting some of the first fieldfollows in the world,“ says Davis. “It was importantat the time because it was the first bigtruck in <strong>Canada</strong> in a long time and, of course,the first truck of its kind in the world.”The 797 replaced another truck the companyhad previously been selling, the 793C,which had a payload capacity of 250 tons.Initially, <strong>Finning</strong> sold six 797s to Syncrude,and the next year, eight more. Soon, the truckwas on the fast-track to becoming an industrystandard. These days, customers are purchasinglarger fleets of 797B trucks – sometimes20 or more trucks at a time.“It definitely has evolved from a newpilot test truck that we were developingfor the oil sands. It’s very successfuland the population is getting quite largein the oil sands now,” says Davis, now ageneral manager for mining marketing(Northwest Territories and the Yukon).In fact, in 2007, <strong>Finning</strong> marked the deliveryof its 100th 797 to northern Alberta.Davis goes quiet for minute, searchingfor a way to explain the experience of the vehicle.“It’s like driving your house.” he saysfinally. And there’s a note of incredulity inhis voice, even though he has ridden shotgun.“I’ve never driven one at that speed, butwww.finning.ca Spring 2008 • TRACKS & TREADS 69