Caterpillar Product Information

Product Bulletin
July 2007

Cat® 777D
Off-Highway Trucks

For Dealer Sales Personnel

This document supplements information in the Specalog. Marketing
content will be available only on secured dealer extranets and by
accessing the PDF in the Electronic Sales Library.
Table of Contents

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
777D Strategy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Gross Machine Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Power Train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Additional Machine Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Truck Body Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Operator’s Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Attachments/Custom Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

2 Cat 777D Off-Highway Trucks July 2007

 Overview

777D Strategy

The 777D provides customers with the only “true” 100 ton (91 tonne) truck on the market. Only the
777D allows this payload, even when equipped with liners, and remains within its Gross Machine
Weight. Unlike many competitors, the 777D features more than a spec sheet change – there is iron to
back it up.

Caterpillar has already proven itself the leader in the off-highway truck market. In 1992, Caterpillar
introduced the first truck with electronically integrated power train control functions using the Cat data
link – significantly improving component life and fuel efficiency to lower cost per ton.

The changes to the earlier models have proven extremely successful:

• Longer transmission life – Control Throttle Shifting, Directional Shift Management and material
changes

• Improved engine life – no power growth from governor wear, two-piece piston, auto derate, operator
alerts, and improved fuel efficiency

Building on this success, power train integration has been incorporated in all of the Cat® trucks, from
the 769D to the 793D trucks, the 777D represents another step in the evolution of the Cat® Construction,
Mining and Quarry Trucks.

The 777D is the first Caterpillar® machine using a B-Series 3500 engine for improved reliability, improved fuel
efficiency, reduced emissions and increased horsepower. The 777D also provides increased capacity
and performance over the earlier models. With a 163,360 kg (360,143 lb) GMW rating, the 777D can
haul 90.4 tonnes (100 tons) even when equipped with all options.

July 2007 Cat 777D Off-Highway Trucks 3

Overview

The 777D provides a means to lower the cost per ton in this size class by allowing a larger payload
along with a more reliable and durable power train.

Additionally, the 777D cab has been designed to greatly improve operator comfort while maintaining
a high level of functionality and durability. The improved ergonomics and additional design features
make this the cab of choice for operators who play an increasing role in some buying decisions.

Features

• 3508B with Electronic Unit Injection (EUI) fuel system

– 746 kW (1,000 hp) gross and 699 kW (938 hp) net power

– Decreased NOx and particulate emissions

– Improved fuel efficiency

• Electronic Technician (ET) support

– Improved diagnostic capability

• Industry Standard Operator’s Environment

– Larger cabin width

– Automotive style look and feel

– Ergonomic layout

– Redesigned transmission console with backlit display

– Repositioned heater and air conditioner controls

– Caterpillar Electronic Monitoring System display

– Improved steering wheel

– Improved hoist lever

– Increased storage space

– Standard Caterpillar Air Suspension Seat

– New dawn gray color

4 Cat 777D Off-Highway Trucks July 2007

 Overview

• Improved Power Train Components

– Larger Rear Wheel Spindle

– Larger Wheel Bearings

– Increased number of brake discs and plates

• Increased Performance

– Larger payload capacity

– Increased horsepower

• Body Design

– Dual slope design with 18 degree ducktail slope for better retention of loads on steep grades

– 60.1 m3 (78.6 yd3) to suite varying applications

– Improved canopy coverage

– Excellent tire coverage

• Automatic Retarder Control (ARC) option

• Traction Control System (TCS) option

• Integrated Brake control (IBC) option

• HVAC option

July 2007 Cat 777D Off-Highway Trucks 5

Overview

The long list of new features on the 777D Truck, along with its increased performance and reliability,
make it the best 100 ton hauler on the market. The new 3508B engine will provide very substantial benefits
to customers through greater horsepower, improved specific fuel consumption and decreased smoke and
emissions. The larger load capacity, increased performance, other power train improvements and the new
cab combine to provide a new standard for comfort and the lowest cost per ton in this size class.

Gross Machine Weight

Maximum Gross Machine Weight (GMW) is 163 360 kg (360,143 lb). This allows the 777D to carry
95.8 tonne (106 ton) in base configuration or 90.4 tonne (100 ton) payload with liners. Refer to the
Weight/Payload Calculation chart for an example of calculating the target payload for the 777D.

Performance

The 777D is designed to perform better than the earlier models when compared at their respective gross
machine weights, and field tests have confirmed this. If the 777D is loaded to the same GMW as the
earlier models, overall performance will be improved due to the greater horsepower.

777D Gross Machine Weight

Net HP 938
(Rated GMW) – kg/net HP 174
(Empty) – kg/net HP 72

6 Cat 777D Off-Highway Trucks July 2007


Power Train. The Cat® 3508B engine is built for power, reliability and efficiency for superior
performance in the toughest applications.
Cat 3508B Engine. Several improvements have
been made to the Cat 3508B EUI engine to enhance
performance and durability. To improve hauling
performance, the 777D is rated at 746 kW (1,000 hp)
gross power. A new air induction system and
aftercooler design help improve airflow to
the engine, improving combustion and lowering
smoke and emission levels.
The engine provides several major improvements:
• 746 kW (1,000 hp) gross power/
699 kW (938 hp) net power
• Improved fuel efficiency
• Decreased smoke levels
July 2007 Cat 777D Off-Highway Trucks
Power Train
• Decreased emissions
• Streamlined intake and exhaust system
• Better reliability through heavier components
and improved diagnostics
• Improved access to the engine compartment
Air System.
• Air Cleaners. The air cleaners are located on
the top deck to provide a cleaner environment
for longer service life and better accessibility for
servicing.
• Intake and Exhaust. Well laid air induction and
exhaust system improves airflow. This decreases
pumping losses and allows more air to enter the
combustion chamber, resulting in lower exhaust
temperatures.
7
Power Train
Combustion Efficiency.
• Decreased Emissions. The NOx levels for the
3508B are decreased dramatically by combustion
system improvements.
• Improved Fuel Consumption. BSFC has
improved approximately three percent over the
previous 3508 engine.
• Soot Reduction. The 3508B has demonstrated a
30-40 percent reduction in crankcase oil sooting
rate. The decrease in soot level should provide
improved oil condition throughout the change
interval – possibly extending the interval in some
circumstances.
• Higher Injection Pressure. Injection pressure
has increased from 124,010 kPa (18,000 psi)
to 151,685 kPa (22,000 psi) for increased
combustion efficiency.
• Injection Duration. With the 3500B-Series,
injection duration has been reduced 10-20 percent.
This allows more fuel to be burned near the
optimum part of the injection cycle.
Iron Changes.
• Larger Camshaft. The width of the camshaft
lobes has increased along with the diameter of the
camshaft 98 mm (3.85") versus 92 mm (3.62")
to accommodate the higher injection pressure,
yet maintain reliability and durability. The steel
forged rocker arms, camshaft followers and push
rods have also been strengthened.
• Rear Gear Train. The rear gear train has also
seen changes to maintain durability. The width
of the carburized and hardened steel rear gears
has been increased and the gear tooth size is
also larger.
8 Cat 777D Off-Highway Trucks
• Deep Crater Piston. The 3508B continues to use
a two-piece piston with a forged steel crown and
aluminum skirt. The piston has been changed,
however, to provide a cleaner, more efficient
combustion by utilizing a deep crater and low
crevice volume to optimize combustion.
Electronic Engine Controls. The 3508B engine is
designed for electronic control. The electronic unit
injectors, sensors and Electronic Control Module
(ECM) operate the engine. The ECM consists of
two components: the control computer and the
control software. The control software contains
the operating maps which define the horsepower,
torque curves, air/fuel ratio and transmission
shift strategies. The ECM controls the injectors
using feedback from the various engine sensors.
Based on these inputs, the ECM determines which
timing and air/fuel ratio map to use for optimum
performance.
Fuel injection timing depends on engine speed,
load and other sensor inputs. The ECM knows
where each cylinder’s top dead center is by the
signal provided by the speed/timing sensor.
The sensor decides when injection should occur
relative to top dead center and provides the signal
to each injector at the appropriate time. The ECM
sends a signal to the solenoid to begin injection.
By controlling the timing and duration of the
signal, the ECM can control injection timing and
the amount of fuel injected. The ECM sets limits
on the amount of fuel that can be injected based
on the air/fuel ratio.
July 2007

The 3508B engine also has the ability to diagnose
itself. When a problem is detected, a diagnostic
code is generated and stored in the memory.
Current diagnostic codes (“Active”) indicate
that a problem currently exists. A non-active
problem may have been either intermittent or
may have been repaired since it was logged.
Logged events and diagnostic codes will be
recorded with this information: event description,
number of occurrences, ECM hour of first and last
occurrence and total ECM hours.
Logged diagnostic codes can be helpful in
troubleshooting. The codes are accessed either
via the Electronic Technician (ET) service tool
or through the Caterpillar Electronic Monitoring
System display in the operator’s compartment.
Cat Data Link. The ECM is part of a larger electronic
network known as the Cat Data Link. This data
link allows many of the machine’s computer systems
to communicate with each other and allows easier
troubleshooting of electrical problems. On the 777D,
the ECM engine controller, Transmission/Chassis
ECM (TCC), the ARC retarder controller, Traction
Control System (TCS) and the Caterpillar
Electronic Monitoring System are all connected
via the Cat Data Link. The data link can be accessed
using the Electronic Technician service tool. The
electronic engine control and datalink provide
many benefits that add value to the machine:
• Engine Overspeed Control Integrated in Data Link.
If the engine reaches 2,100 rpm, a warning horn
and check engine light will activate. At 2,300 rpm,
the transmission will automatically upshift
one gear, regardless of cane position. If the
transmission is in top gear, the torque converter
lock up will disengage. An overspeed upshift
event will be logged in the memory. On machines
equipped with the Automatic Retarder Control
option, the ARC computer will automatically
activate in an overspeed condition to control
engine speed from 2,075 to 2,100 rpm.
July 2007 Cat 777D Off-Highway Trucks
Power Train
• Acceleration Delay on Startup. To reduce wear
on lubricated components, engine acceleration is
disabled for two seconds after low idle has been
attained (on startup only). This allows time for
all machine lubrication and cooling systems to
achieve pressure and flow before operating at
higher speeds.
• Elevated Low Idle. In cold weather conditions,
low idle is elevated to between 1,000 and 1,300 rpm
to allow the engine to achieve operating temperature
more quickly and/or maintain temperature.
The transmission must be in neutral, the parking
brake must be set and engine coolant temperature
must be less than 70° C (158° F). Standard low
idle is 700 rpm.
• Cold Mode Start Capability. Starting and
performance are improved in cold weather
by retarding timing when the engine is below
operating temperature. Retarded timing reduces
peak cylinder pressure and cylinder pressure rate
of rise. The engine operates in “cold mode” when
engine coolant temperature is below 60° C (140° F).
• Air Filter Restriction. The air intake system is
monitored. When the inlet restriction indicator
point is reached, the system will activate a
warning and record the event in system memory.
The system will automatically derate as air intake
restriction increases beyond the indicator point.
When restriction reaches 660 mm (26 in) of H2O,
fuel is limited one percent. For higher restriction,
fuel is limited two percent per 101 mm (4 in)
of H2O (up to a maximum of 20 percent).
• Altitude Compensation. The system automatically
derates power by limiting fuel to prevent excessive
exhaust gas temperatures and related damage.
The 3508B begins derating at 3050 m (10,000 ft)
and derates at three percent per 305 m (1,000 ft)
to a maximum of 24 percent at 5485 m (18,000 ft).
9
Power Train
• Diagnostics. The ECM is compatible with
the Cat Electronic Technician tool (ET), and
interfaces with the TCC transmission control and
the Automatic Retarder Control (ARC) via the Cat
Data Link. The ET plugs into a connector located
on the fuse panel behind the operator’s seat.
The ET can retrieve and display boost pressure,
fuel flow rate, engine rpm, diagnostics, logged
events, overspeed events, air filter restriction, oil
pressure, over heating, low oil pressure and any
other sensor output on the ECM, TCC or ARC
controllers.
The ET also provides numerous service features:
individual cylinder cut out, crank without injection,
timing calibration and injector solenoid test.
• Fuel Use Record. Provides a cumulative record
of fuel consumed. This record is accessible via the
Electronic Technician.
• Multi-Point Pressure Sensing (MPPS). The engine
oil pressure alarm will be activated by monitoring
oil pressure as a function of engine speed. This will
allow the Caterpillar Electronic Monitoring System
alarm to activate with less pressure drop at higher
engine speeds, decreasing the risk of engine damage.
• Throttle Backup. In case of throttle signal failure,
a backup switch is available for “limp home.”
10 Cat 777D Off-Highway Trucks
920 Horsepower Option. The 777D has the
capability to run at a 686 kW (920 hp) power
using the ET. The 920 horsepower option can
benefit operation in two scenarios:
• If the loading match does not effectively
allow the full use of the additional payload
capacity, the 686 kW (920 hp) power setting
would allow the 777D to run evenly with
former models of the 777.
• If the operation is limited with the crusher or
loading tool creating a wait time, the lower
horsepower setting would increase cycle
times without affecting production to possibly
decrease fuel consumption.
Transmission. Power train integration of the
engine and transmission was first introduced
in the earlier models and has proven extremely
successful. The electronic engine control and the
Cat Data Link allow the transmission and the
engine to communicate using the transmission
controller (TCC) and the ECM engine controller.
Allowing these two key power train components
to communicate has provided some major
improvements in component life and operator
comfort.
July 2007
 Power Train

Control Throttle Shifting Directional Shift Management

Transmission Output Torque (N-M)

Shift without CTS

HP/sq. in.

Shift with CTS

0
Clutch Power (HP/Square Inch)

Shift without CTS

Shift with CTS

0

Reductions in transmission output torque and clutch power through Controlled Throttle Shifting. Neutral>1 Neutral>Reverse 1>Reverse Reverse>1 Automatic Shift

Control Throttle Shifting. Transmission life is a

No Control Control Enabled

function of two items: the number of shifts and

the level of stress on the transmission during each Directional Shift Management. The objective of
shift. The Control Throttle Shift feature reduces Directional Shift Management is to reduce drive
considerably the stress on the power train and the line torque spikes and transmission clutch energy
clutch energy and wear by electronically controlling spikes. If shifts are made from reverse to forward,
engine speed during shifting. This provides smoother or if shifts are made from neutral to reverse or
shifts, reduces operator fatigue and improves power forward at high engine speed, high torque spikes
train component life. can be generated. These spikes can result in
accelerated transmission wear and/or premature
• The TCC sends a signal to the ECM, letting final drive or differential failures.
it know the transmission is preparing
to change gears. Directional Shift Management electronically
prevents these high torque levels, reducing
• During an upshift, the ECM reduces engine the potential for abuse and related drive line
throttle for a fraction of a second. This reduces component failures. In operation, whenever
the torque created by the engine and allows the shift cane passes through neutral and the
the transmission and lockup clutches to engine speed is above 1,350 rpm, the transmission
engage smoothly. sends a signal to the ECM to momentarily reduce
the engine throttle while the transmission shifts.
• During a downshift, the opposite strategy This prevents the operator from abusing the
is used to increase the engine throttle for machine and leads to improved component life.
a fraction of a second. This speeds up the
engine and allows the transmission speed to
synchronize for a smoother shift.

• The benefits of Control Throttle Shifting extend

beyond the transmission. The reduced torque
levels also lead to improved life of the driveshaft,
differential, axles and final drives. This means
lower maintenance costs and, therefore,
decreased cost per ton.

July 2007 Cat 777D Off-Highway Trucks 11

Power Train
Neutral Coast Inhibiting. When the transmission is
in gear and the shift lever is placed in NEUTRAL,
the machine will remain in gear until the machine
travel speed has been reduced from the lL to
lC shift point (Lockup to Converter drive)
[(approximately 8 km/h (5 mph)].
At approximately 8 km/h (5 mph), the
Transmission/Chassis ECM will shift the
transmission to NEUTRAL. Keeping the
transmission in gear above 8 km/h (5 mph) will
discourage high-speed coasting in NEUTRAL.
High-speed coasting in NEUTRAL can reduce
transmission life. This function does not prevent
coasting in NEUTRAL, but makes it more
difficult.
The operator CAN COAST in NEUTRAL if he
starts down a hill in NEUTRAL and travel speed
is below 8 km/h (5 mph). If the operator does coast
in NEUTRAL, at speeds above 19.3 km/h (12 mph),
engine speed will increase to 1,300 rpm and an
event will be logged by the Transmission/Chassis
ECM as “Coasting In Neutral.” This information
can be reviewed using the ET Service Tool.
Shifts to REVERSE from a Forward Gear are
inhibited until travel speed is below 4.8 km/h
(3 mph).
Event Memory. The TCC records machine
management data, which can be accessed using
the ET service tool. The information retrieved
can be useful in identifying operator abuse and
planning haul road design. The information
recorded includes:
• Shift Histograms. Record the number of shifts in
and out of every gear – up to one million for each
upshift/downshift.
• Operator induced events. Record attempts to
coast in neutral and engine overspeed.
12 Cat 777D Off-Highway Trucks
• Lock-up clutch counter. Log a maximum of
1.2 million counts for each transmission gear
position. To log an additional count, the transmission
gear switch position must change and hold the new
position for 0.5 seconds. It also logs a maximum
of 12 million counts for the torque converter lockup
clutch counter.
• Machine overspeed. If the operator positions
the shift lever in the maximum gear available
position, an action lamp will illuminate and an
alarm will sound at 2,100 rpm. If engine speed
exceeds 2,300 rpm, the Transmission/Chassis
ECM will unlock the torque converter to protect
the engine. After the torque converter is unlocked,
if engine speed again exceeds 2,300 rpm, an event
will be logged by the Transmission/Chassis ECM
as a “Machine Overspeed” event.
• Transmission overspeed. Records when the
machine travels faster than 16 km/h (10 mph)
while in neutral.
• Body up counter. Records the number of times
the body has been raised.
Power Train Intelligence. Many other electronic
power train features are used in the 777D Truck:
• Reverse Shift Inhibitor. Prevents shifts into reverse
when forward ground speeds are in excess of
4.8 kph (3 mph). This protects the transmission
from high shock loads created by abusive
directional shifts.
• Body Raise Interlock. Automatically shifts the
transmission into neutral if the truck body is
being raised and the transmission is in reverse.
The transmission will remain in neutral until the
shift lever has been cycled in and out of neutral.
Forward travel is not affected.
July 2007

• Rapid Downshift Function (Shift Hunting
Prevention). During normal shifting, the ECM
does not allow a turnaround shift for 2.3 seconds
after a shift occurs. A turnaround shift is an opposite
shift from the previous shift. For example, a downshift
is prevented for 2.3 seconds after an upshift and
an upshift is prevented for 2.3 seconds after
a downshift. This turnaround time delay allows
conditions to stabilize before an opposite shift.
The delay prevents hunting between gears.
The ECM overrides the turnaround time
delay when the operator applies the brakes.
Downshifts now occur immediately as a result
of the decreasing transmission output speed.
This function is provided in case the operator is
required to make a sudden stop.
• Engine Overspeed Protection. The transmission
will upshift one gear beyond the selected gear to
avoid engine overspeed. If the top gear is selected,
the lockup clutch will disengage. An engine overspeed
event will be logged and can be retrieved with
the ET tool.
• Top Gear Limit. Field programmable from
fourth to seventh by use of the ET service tool.
The Transmission/Chassis ECM comes from
the factory set to the maximum gear available
(seventh gear). The transmission will never shift
to a gear above the programmed top gear.
• Hoist SNUB position. A fifth position of the hoist
valve is called the SNUB position. The operator
does not have control over the SNUB position.
The body up switch controls the SNUB position
of the hoist valve. When the body is lowered,
just before the body contacts the frame, the
Transmission/Chassis ECM signals the hoist
solenoids to move the hoist valve spool to the
SNUB position. In the SNUB position, the body
float speed is reduced to prevent hard contact of
the body with the frame.
July 2007 Cat 777D Off-Highway Trucks
Power Train
• Body Up-Shift Limiter. Prevents the transmission
from shifting above a programmed gear without
the body fully lowered. This allows the machine
to move forward, but limits speed to prevent
excessive frame racking. It also serves as a
reminder to the operator that the body is up to
help prevent unsafe operation of high speed
travel with the body raised. The shift limiter is
shipped with first gear programmed, but can be
programmed up to third gear. An indicator light on
the dash notifies the operator when the body is up.
Caterpillar Electronic Technician (ET). The Cat ET
is a Microsoft Windows™ based software program,
which provides the capability to access the ECM
and Transmission/Chassis control ECM. Some of
the diagnostic and programming functions that the
service tools can perform are:
• Display the real time status of the input and
output parameters.
• Display the internal clock hour reading.
• Display the number of occurrences and the
hour reading of the first and last occurrence
for each logged diagnostic code and event.
• Display the definition for each logged
diagnostic code and event.
• Display the supply and control solenoid
engagement counter.
• Program the ARC control speed.
• Perform ARC diagnostic tests.
• Upload new Flash files.
13
Additional Machine Features
Wheel Groups.
Spindle and Bearings. With the laser hardened
spindle and improved bearings, the wheel bearing
adjustment and oil change can be carried out at
4,000 hours interval with FDAO oil.
Brakes. Reliable braking with superior control
gives the operator the confidence to focus on
productivity.
Integrated Braking System. The Cat oil-cooled
braking system delivers reliable performance and
control in the most extreme haul road conditions.
The integrated system combines the service,
secondary, parking brake and retarding functions
in the same robust system for optimum braking
efficiency.
Rear Oil-Cooled Multiple Disc Brakes. Caterpillar
rear-wheel, forced oil-cooled, multiple disc service
brakes are continuously cooled by water-to-oil
heat exchangers for exceptional, nonfade braking
and retarding performance.
14 Cat 777D Off-Highway Trucks
Brake Design. Cat oil-cooled disc brakes are
designed with large discs and plates for reliable,
adjustment-free operation and performance.
Brakes are completely enclosed and sealed to
prevent contamination and reduce maintenance.
Long Life. An oil film prevents direct contact
between the discs. This design absorbs the braking
forces by shearing the oil molecules and carrying
heat away to extend brake life.
Dry Front Caliper Disc Brakes. Disc brakes fitted
on front wheels as standard fitment.
Pistons. The Caterpillar two-piston design combines
the service, secondary, parking brake and retarding
functions in the same system. The primary piston
hydraulically actuates both service and retarding
functions. The secondary piston is spring-applied
and held in the disengaged position by hydraulic
pressure. If hydraulic system pressure drops below
a specified level, the spring-applied secondary
piston automatically applies the brakes.
Parking Brake. Oil-cooled, spring applied,
hydraulically released parking brake is applied to
rear wheels for superior parking capability on all
grades up to 15 percent.
Hours of Operation Before Refuel
Entire Tank 10% Reserve
30% Load Factor 22.2 20
40% Load Factor 16.6 15
Fuel Tank. The fuel tank capacity is 1137 liters
(300 gal) with an optional tank of 1325 liters
(350 gal) providing sufficient operating time
at the required horsepower.
Hydraulic System Hoist Pressure. Hoist Pressure
has been increased to 18,962 kPa (2,750 psi). This
increase accommodates the higher load capability
of the 777D.
July 2007
 Additional Machine Features

Tires. The standard 27.00R49 radial tires on

the 777D provide the capacity for a 163 360 kg
(360,143 lb) GMW. Bias ply 27.00-49 tires can
still be used, but the GMW must be adjusted to
meet the tire load carrying capability — consult
the tire manufacturer for load capabilities. Bias or
radial 24.00-49 tires will not be available on the 777D.

July 2007 Cat 777D Off-Highway Trucks 15

Truck Body Systems

Truck Body Systems. Cat designed and built for rugged performance and reliability in the toughest
hauling applications.

Body Design. Cat truck bodies are designed

for optimal strength, capacity and durability.
Wear surfaces are equipped to handle even the
toughest impact and abrasion over the long haul
without diminishing capacity.

• Five-Sided Beams join the sidewall and floor

junctions for increased body rigidity and
strength.

• Wide Ribs in body floor provide increased

durability and impact support.

• Full-Length Stringers create strength and

rigidity throughout the bed.

• Box Section Beams offer increased durability

Body/Chassis Integration. Caterpillar truck bodies
are designed and matched with the integrated
chassis system for optimum structural reliability,
durability and long life.
in the floor, sidewall, top rail, corner, and cab
canopy areas.
• Wide Body Design provides complete coverage
of tires, eliminating the need for rock deflectors.

Electronic Hoist Control. Provides the operator with

better control of the load when dumping, including
over-center load control and modulated control
throughout the operating range. The automatic
body snubbing feature reduces impact on the frame,
hoist cylinders and operator.

Fast Hoist Cycle Times. Two-stage hoist cylinders

provide fast dump cycle times of 15 seconds for
raise and 13 seconds for lower.

Body Capacity. Body capacity is capable of

accommodating the GMW and corresponding
payload capability. The body has an SAE 2.1
capacity of 60.1 m3 (78.6 yd3). The body design
allows the 992G to effectively load the 777D.
The body is designed to provide a 100 ton
(91 tonne) payload based on 1720 kg/BCM
material at an 87 percent fill factor.

16 Cat 777D Off-Highway Trucks July 2007

 Truck Body Systems

Body Liners. Liner options are available to

save weight and help extend the system’s life.
Liner material is a 400 BHN through hardened
9140 kg/cm2 (130,000 psi) yield strength steel,
which provides excellent impact and wear resistance.

Canopy. The canopy, along with Arm guard,

has excellent coverage to protect the cowlings
and cabin.

Dual Slope Body. The advanced dual-slope

body design with V-shaped floor increases load
retention, maintains a low center of gravity,
reduces shock loading, and maintains optimum
load distribution on steep inclines and in
challenging haul road conditions.

• Reinforced, rolled steel top rail increases body

strength and protects the body from damage
caused by the loading tool or falling material

• 8 degree “V” reduces shock loading and centers

the load.

• 10 degree forward body slope and 18 degree

ducktail slope helps retain loads on steep grades.

• Maintains a load height of 4380 mm (14 ft 3 in)

for faster, more confident loading.

• 60.1 m\dS3\dnS (78.6 yd\dS3\dnS) capacity

allows operators to achieve rated payload in
2,900 lb/BCY material.

July 2007 Cat 777D Off-Highway Trucks 17

Operator’s Station
Operator’s Station. Ergonomically designed for operator comfort, superior control and high productivity.
Ergonomic Layout. Caterpillar has been the
industry leader in cab design using a four
post Rollover Protective Structure (ROPS)
structure which provides superior protection
compared to other designs. With the new 777D
cab, Caterpillar sets another industry standard
for cab design – this time for ergonomics and
operator comfort. The cab body has been widened
160 mm (6.3 inches), providing for a 14 percent
increase in overall spaciousness (+15 ft3) and
ten percent more glass area. The interior has
been changed to the dawn gray color scheme for
improved aesthetics and to enhance the feeling
of spaciousness. The controls and layout provide
greater operator comfort and convenience with a
more automotive feel, yet maintain Caterpillar’s
high standards for function and durability.
18 Cat 777D Off-Highway Trucks
Operator and Trainer Seats. The 777D is equipped
with the standard Caterpillar Air Suspended seat,
which provides increased operator comfort and
increased durability. The seat offers 76 mm (3 inch)
height adjustment with 176 mm (7 inch) total
travel and an additional right side arm rest.
The comfortable trainer’s seat provides ample
space between the transmission console and
the door to the trainer. The wide seat, has a
retractable seat belt and is Polyester type fabric
covered. The seat cushion tilts forward for access
to the storage compartment below.
Center Console. The transmission gear lever
provides a better grip and feel for the operator.
The gear numbers are backlit for improved
visibility in low light operation and the console
cover provide a good view of gear selection.
The console cover has been designed for easy
modification to mount a CB or two way radio.
A cup holder is mounted on the right side of the
transmission console.
Doors and Instrument Panel. The ABS plastic dash
board and door panels provide a more modern look
and make cleaning easier. The instrument panel
is designed to provide outstanding ergonomics.
The controls are now all located within easy reach
of the operator. Controls are clearly labeled and
lighted for nighttime operation.
Steering Column. A three-spoke “Sport,” padded
steering wheel provides a comfortable grip.
The adjustable steering column is treated with
a non-metallic cover.
Ventilation System. The cab features improved
ducting and a four-speed fan, which creates
greater airflow control for operator comfort.
A total of nine vents are used to direct airflow
throughout the cab.
July 2007

HVAC System (Optional). The air conditioner
is conveniently located at the front of the cab.
This provides improved serviceability and increased
cab storage space. The automotive style heating
and air conditioning controls are located on the
dash panel within easy reach of the operator.
Storage Space. Large storage space is provided
in the cab making it convenient to store a parts
and service manual, lunch box, thermos and other
personal items. A tie down strap is also included.
A storage “pocket” is located in the right side
door and more storage is located below the
EMS display.
Radio Ready Roof and Headliner. The roof and
headliner are designed to accommodate a radio.
Wiring and speakers are standard and installation
of the radio is the only requirement. The headliner
provides mounting for the TPMS display (if
equipped). The dome light is located toward the
center of the cab to provide better lighting for the
operator.
Body-Up and Reverse Gear Indicators. An indicator
light on the dash notifies the operator when the body
is up. There also is a light to notify the operator
when the transmission is in reverse.
Instrumentation. The Caterpillar Electronic
Monitoring System (EMS) is standard equipment.
See the EMS section for further details.
Other.
• A 12 volt/5 amp power port is located behind
the operator’s seat next to the fuse panel.
The port provides a power supply for a laptop
computer. This port is a handy feature when
using the laptop for the Electronic Technician
(ET) or downloading information from
the TPMS.
July 2007 Cat 777D Off-Highway Trucks
Operator’s Station
• A 24 volt cigarette lighter is located on the
dash to the left of the steering wheel and there
also is an ashtray.
• The hoist lever is designed for easier operator
reach.
• The air valves and numerous electrical
components in the rear of cab are assembled
on removable panels for ease of assembly and
maintenance.
• Paddle-type door handles on the outside of the
cab doors are mounted flush with the cab door.
• The removable center console cover allows
easier “reworking” to accommodate a
communications radio.
Caterpillar Electronic Monitoring System (EMS).
The 777D will incorporate the new Caterpillar
Electronic Monitoring System (EMS) that
continuously watches machine systems. The system
is a flexible, modular monitoring system, which
includes a message center module, a speedometer/
tachometer module, a four gauge module, various
switches and sensors, an action lamp and an
action alarm.
The message center module is the heart of the EMS
system because it receives information from the
switches, sensors and other electronic controls on
the machine via the Cat Data Link. The message
center module processes all of this information
and activates various outputs. These outputs could
be in the display portion of the message center
module, gauge cluster module, speedometer/
tachometer module, action lamp and/or action
alarm. The display components show the operator
the condition of the systems and each system’s
diagnostic information.
19
Operator’s Station
Message Center Module Display. The outputs in
the message center module display are alert indicators
and the message area. The alert indicators notify
the operator of abnormal machine conditions.
The message center module uses the status of the
switch inputs, sender inputs and/or sensor inputs
to determine when an abnormal condition is
present. Then the message center module flashes
the appropriate alert indicator. The pictograph
symbol of the flashing alert indicator identifies
the responsible machine system. When an alert
indicator flashes, an abnormal condition exists.
The system has three alert levels:
• Level one alerts the operator to an abnormal
machine condition by a gauge in the red zone
and/or a flashing alert indicator.
• Level two will cause the master alert indicator
to light in addition to the message center alert
indicator. A level two warning indicates that
immediate operator action is necessary.
• Level three adds an alert buzzer, indicating
that immediate machine shutdown is necessary.
Ten Alert Indicator Lights.
• Engine oil pressure
• Battery charging system
20 Cat 777D Off-Highway Trucks
• Primary steering flow
• Check engine indicator
• Parking brake
• Service engine
• Engine coolant flow
• Torque converter oil temperature
• Inlet air restriction
• Transmission oil filter restriction
Message Area. The message area contains a row
of six digits, a decimal point between certain
digits, six text symbols (units of measure),
an “x10” (times 10) symbol and a service
meter symbol that are used to show machine
system conditions and other service and setup
information. The type of information shown
on the screen depends on the message center
operating mode.
There are seven different EMS modes of
operation.
Normal Mode. The default (Normal Mode) is
accessible to the operator on the dash display.
The Normal Mode has five different functions
available through a dashboard-mounted rocker
switch:
• Service Meter. The message module keeps track
of the total number of hours the machine has
operated.
July 2007
 Operator’s Station

• Odometer. This mode will display on the six-
digit readout the total distance the machine has
traveled. The units indicator will show MILES
or KM depending on the units of measure.
• Digital Tachometer. This displays the engine
speed in RPM on the six digit display.
• Load Counter. This displays the number of loads
since last reset by the operator. The system counts
the number of times the body has been raised and
is resettable.
• Digital Scrolling. Service personnel or the
operator can view the faults that the message
center has detected. Faults from other machine
systems (ECM, TCC, etc.) that are attached to the
Cat Data Link are shown in this mode. The faults
remain stored for future reference.
Log Mode. When in Log Mode, each of the gauges
in the four-gauge cluster will display the highest
or lowest recorded condition and the speedometer
and tachometer will display the highest recorded
values. Alert indicators will light when an
abnormal condition exists.
Units Mode. This is used to toggle between U.S.
and Metric units of measure.
Permanent Load Counter. This mode displays
the total number of times the body is raised.
Unlike the Load Counter in Normal Mode,
this can not be reset.

Other modes. The other modes are used primarily

for servicing and are accessed through toggle
switches to the right rear of the operator seat.

The other modes include:

• Harness Code Mode. This displays the

recognized machine model.

Numeric Readout Mode. This mode provides

a numerical display to supplement the gauge Gauge Cluster Module. The four gauges show
indicator (i.e. actual temperature will be displayed system air pressure, fuel level, engine coolant
compared to an indicator position on the gauge). temperature and brake oil temperature.

Service Mode. This allows service personnel to

see and to troubleshoot the faults that the message
center has detected. Faults can be placed on hold
or cleared in this mode.

July 2007 Cat 777D Off-Highway Trucks 21

Operator’s Station

Speedometer/Tachometer Module. The speed is

displayed in the three digit display area. The gear
readout consists of two digits, which show the
actual transmission gear engaged. The left digit
shows the actual gear, such as 1, 2, etc. The right
digit shows the direction selected: F, N, or R.
The Tachometer shows engine speed in rpm.

22 Cat 777D Off-Highway Trucks July 2007


Truck Production Management System (TPMS)
(Optional). The Caterpillar Truck Production
Management System (TPMS) is available on
777D as an optional attachment. This system is
a site management tool that measures, displays
and records load, dump, haul and idle times,
haul and return distances, and machine payloads.
Up to 1,400 cycles can be downloaded into a
spreadsheet format.
The payload information is available to the
truck operator via a display located in the cab.
In addition, the loader operator is signaled via a
lighting system mounted on the left and right sides
of the machine. This system signals the operator
when one more pass is required. Operation
management can download all information with
a personal computer using a serial port located
behind the operator’s seat.
Automatic Retarder Control (ARC). Sensors
measure engine speed and an electronic control
modulates the braking system to maintain
engine speed at a predetermined engine rpm.
ARC provides more uniform brake application
and faster average downhill speeds compared
to manual retarding. While ARC modulates the
brakes, the operator may also apply additional
braking force using either the manual retarder or
the service brake pedal. When the operator applies
the throttle, ARC is overridden. An auto resume
feature reactivates the control.
July 2007 Cat 777D Off-Highway Trucks
Attachments/Custom Products
The ARC system has been updated to include
automatic engine speed protection, ET service
tool communication capability and improved
communication with the TCC. The automatic
engine overspeed feature will activate even if
the operator has his foot on the accelerator or
the system turned “off”. If engine rpm exceeds
a pre-set limit above the normal control range
of the ARC system, ARC will automatically
activate, reducing the possibility of an engine
overspeed condition occurring.
See Feature Module AEDK0075 for more
information.
Traction Control System (TCS). The Traction Control
System (TCS) uses the rear parking/secondary
brakes (spring engaged and hydraulically released)
to decrease the revolutions of a spinning wheel.
The TCS allows the tire with better underfoot
conditions to receive an increased amount of torque.
The system is controlled by the Brake ECM.
The Brake ECM monitors the drive wheels
through three input signals: one at each drive axle,
and one at the transmission output shaft. When a
spinning drive wheel is detected, the Brake ECM
sends a signal to the selector and proportional
valves which ENGAGE the brake of the affected
wheel. When the condition has improved and the
ratio between the right and left axles returns to
1:1, the Brake ECM sends a signal to RELEASE
the brake.
Integrated Brake Control. IBC is a combination
of TCS and ARC.
Serial Number. The Serial number prefix for the
new 777D Truck is FKR.
23
Technical Specifications

Engine Transmission
Engine Model Cat® 3508B EUI Forward 1 10.5 km/h 6.5 mph
Gross Power – SAE J1995 746 kW 1,000 hp Forward 2 14.3 km/h 8.9 mph
Net Power – SAE J1349 699 kW 938 hp Forward 3 19.3 km/h 12 mph
Net Power – Cat 699 kW 938 hp Forward 4 26 km/h 16.2 mph
Flywheel Power 699 kW 938 hp Forward 5 34.9 km/h 21.9 mph
Net Power – ISO 9249 699 kW 938 hp Forward 6 46.6 km/h 29.4 mph
Net Power – 80/1269/EEC 699 kW 938 hp Forward 7 60.4 km/h 39.9 mph
Peak Torque 4713 N·m 3,476 lb ft Reverse 11.9 km/h 7.4 mph
Torque Rise 23%
• Maximum travel speeds with standard 27.00-R49 tires.
Bore 170 mm 6.7 in
Stroke 190 mm 7.5 in
Displacement 34.5 L 2,105 in3 Final Drives
• Net power advertised is the power available at rated Differential Ratio 2.74:1
speed of 1,750 rpm, measured at the flywheel when the Planetary Ratio 7.00:1
engine is equipped with fan, air cleaner, muffler and
Total Reduction Ratio 19.16:1
alternator.
• Ratings based on standard air conditions of 25° C (77° F) • Planetary, full-floating.
and 99 kPa (29.32 Hg) dry barometer. Power based on
fuel having API gravity of 35 at 16° C (60° F) and an LHV
of 42,780 kJ/kg (18,390 BTU/lb) when engine used at Brakes
30° C (86° F).
• No engine derating required up to 2288 m (7,500 ft) Brake Surface – Front 2787 cm2 432 in2
altitude. Brake Surface – Rear 102 116 cm2 15,828 in2
• Meets U.S. Environmental Protection Agency Tier I
emissions standards.
• Meets ISO 3450:1996 standards up to 163 293 kg
(360,000 lb) gross operating weight.

Weights – Approximate
Body Hoists
Target Gross Machine 163 360 kg 360,143 lb
Operating Weight Pump Flow – High Idle 498 L/min 131.5 gal/min
Operating Weight – empty 64 670 kg 142,573 lb Relief Valve Setting – Raise 18 962 kPa 2,750 psi
Relief Valve Setting – Lower 18 950 kPa 3,450 psi
Body Raise Time – High Idle 15 Seconds
Operating Specifications Body Lower Time – Float 13 Seconds
Body Power Down – High Idle 13 Seconds
Nominal Payload Capacity 90.4 tonnes 100 tons
Body Capacity – Struck 42.1 m3 55.06 yd3
Body Capacity – SAE 2:1 60.1 m3 78.6 yd3 Capacity – Dual Slope – 100% fill factor
• Refer to the Caterpillar 10/10/20 Payload Guidelines. Struck 42.1 m3 55 yd3
Heaped 2:1 (SAE) 60.1 m3 78.6 yd3

24 Cat 777D Off-Highway Trucks July 2007

 Technical Specifications

Weight Distributions – Approximate ROPS

Front Axle – Empty 47% ROPS/FOPS Standards SAE J1040 MAY94,
Front Axle – Loaded 33% ISO 3471:1997
Rear Axle – Empty 53%
• ROPS (Rollover Protective Structure) for cab offered by
Rear Axle – Loaded 67% Caterpillar meets SAE J1040 MAY94 and ISO 3471:1997
Level II ROPS criteria.

Suspension
Sound
Effective Cylinder Stroke 318 mm 12.5 in
– Front Sound Standards ANSI/SAE J1166 MAY90,
SAE J88 JUN96
Effective Cylinder Stroke 165 mm 6.5 in
– Rear • The operator sound exposure Leq (equivalent sound
Rear Axle Oscillation 5.4 Degrees pressure level) measured according to work cycle
procedures specified in ANSI/SAE J1166 MAY90 is
78 dB(A) for cab offered by Caterpillar, when properly
Approximate Weights – Dual Slope installed and maintained and tested with doors and
windows closed.
Empty vehicle 64 670 kg 142,573 lb • The exterior sound pressure level for the standard
Chassis 46 600 kg 107,144 lb machine measured at a distance of 15 m (49 ft) according
Body 16 070 kg 35,428 lb to the test procedures specified in SAE J88 JUN86, mid-
gear moving operation is 90 dB(A).
• Hearing protection may be needed when operating with
an open operator station and cab (when not properly
Service Refill Capacities maintained or doors/windows open) for extended
periods or in a noisy environment.
Fuel Tank 1137 L 300 gal
Cooling System 268 L 71 gal
Crankcase 125 L 33 gal Steering
Differentials and Final Drives 306 L 81 gal
Steering Standards SAE J1511 OCT90,
Steering Tank 40 L 11 gal
ISO 5010:1992 (E)
Torque Converter/Brake/ 220 L 58 gal
Hoist Hydraulic Tank • Turning diameter on front wheel track with standard
Torque Converter/ 81 L 21.5 gal tires: 25.3 m (83 ft).
Transmission System • Machine clearance turning circle: 28.4 m (93 ft 2 in).
• Steering angle, left or right: 30.5 degrees.
• Separate hydraulic system prevents cross
Tires contamination.

Standard Tire 27.00-R49 (E4) Tire

• Productive capabilities of the 777D truck are such that,

under certain job conditions, TKPH (TMPH) capabilities
of standard or optional tires could be exceeded and,
therefore, limit production.
• Caterpillar recommends the customer evaluate all job
conditions and consult the tire manufacturer for proper
tire selection.

July 2007 Cat 777D Off-Highway Trucks 25

Dimensions
All dimensions are approximate. (Shown with dual slope body)

11

3
10
9 14

12
49.4
13
18°
15
1
8 16
17

5 6

4
18

19

20
21

Dual Slope Dual Slope

1 Height to Top of ROPS – Full 4472 mm 14 ft 8 in 11 Operating Width 6105 mm 20 ft
1 Height to Top of ROPS – Empty 4567 mm 15 ft 12 Centerline Front Tire Width 4173 mm 13 ft 8 in
2 Overall Body Length 9525 mm 31 ft 3 in 13 Overall Front Tire Width 4961 mm 16 ft 3 in
3 Inside Body Length 7234 mm 23 ft 9 in 14 Engine Guard Clearance – Empty 700 mm 2 ft 4 in
4 Overall Length 9780 mm 32 ft 1 in 15 Overall Canopy Width 6048 mm 19 ft 10 in
5 Wheelbase 4570 mm 15 ft 16 Outside Body Width 5524 mm 18 ft 2 in
6 Rear Axle to Tail 3020 mm 9 ft 11 in 17 Inside Body Width 5200 mm 17 ft 1 in
7 Dump Clearance – Empty 1164 mm 3 ft 10 in 18 Front Canopy Height – Empty 5147 mm 16 ft 10 in
7 Dump Clearance – Loaded 1062 mm 3 ft 6 in 18 Front Canopy Height – Loaded 5045 mm 16 ft 6 in
8 Loading Height – Empty 4380 mm 14 ft 4 in 19 Rear Axle Clearance – Empty 750 mm 2 ft 6 in
9 Inside Body Depth – Max 1898 mm 6 ft 3 in 20 Centerline Rear Dual Tire Width 3576 mm 11 ft 9 in
10 Overall Height – Body Raised 10 059 mm 33 ft 21 Overall Rear Dual Tire Width 5262 mm 17 ft 3 in

26 Cat 777D Off-Highway Trucks July 2007

Gradeability/Speed/Rimpull

To determine gradeability performance: Read from gross horizontally to the curve with the highest obtainable gear, then
weight down to the percent of total resistance. Total resistance down to maximum speed. Usable rimpull will depend upon
equals actual percent grade plus 1% for each 10 kg/t (20 lb/ton) traction available and weight on drive wheels.
of rolling resistance. From this weight-resistance point, read

Typical Field Empty Weight

163 360 kg (360,143 lb) Load
Gross Weight
20 30 40 50 60 80 100 150 200 kg x 1000

50 100 150 200 250 300 400 500 lb x 1000

kg x lb x
1000 1000
50 120
100 1st Gear E L
40 30% 20%
30 70
1st Gear 15%
20 50 12%
2nd Gear 10%

EFFECTIVE GRADE (Favorable)

30 3rd Gear 8%
4th Gear 6%
10
20
5th Gear 4%
RIMPULL

5 6th Gear
10
7th Gear 2%
3
5
2

3
1
2

0.50
1
0.30 Torque Converter Drive
Direct Drive
0.5
0 5 10 15 20 25 30 35 40 45 50 mph

0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 km/h
SPEED

July 2007 Cat 777D Off-Highway Trucks 27

Retarding Performance

Gross Weight
0 50 100 150 200 250 300 350 400 450 lb x 1000

0 30 60 90 120 150 180 210 kg x 1000

30%
25%

20%

EFFECTIVE GRADE (Favorable)

1st Gear 15%
2nd Gear

3rd Gear 10%

4th Gear
5th Gear
6th Gear 7th Gear 5%

0 10 20 30 40 50 60 70 80 km/h

0 5 10 15 20 25 30 35 40 45 50 mph
SPEED
Grade Distance — 450 m (1500 ft.)

Gross Weight
0 50 100 150 200 250 300 350 400 450 lb x 1000

0 30 60 90 120 150 180 210 kg x 1000

30%
25%

20%
EFFECTIVE GRADE (Favorable)

1st Gear 15%

2nd Gear
3rd Gear
10%
4th Gear
5th Gear
6th Gear
7th Gear
5%

0 10 20 30 40 50 60 70 80 km/h

0 5 10 15 20 25 30 35 40 45 50 mph
SPEED
Grade Distance — 600 m (2000 ft.)

28 Cat 777D Off-Highway Trucks July 2007

Retarding Performance

Gross Weight
0 50 100 150 200 250 300 350 400 450 lb x 1000

0 30 60 90 120 150 180 210 kg x 1000

30%
25%

20%

EFFECTIVE GRADE (Favorable)

1st Gear 15%

2nd Gear
10%
3rd Gear
4th Gear
5th Gear
6th Gear 7th Gear 5%

0 10 20 30 40 50 60 70 80 km/h

0 5 10 15 20 25 30 35 40 45 50 mph
SPEED
Grade Distance — 900 m (3000 ft.)

Gross Weight
0 50 100 150 200 250 300 350 400 450 lb x 1000

0 30 60 90 120 150 180 210 kg x 1000

30%
25%

20%
EFFECTIVE GRADE (Favorable)

15%
1st Gear
2nd Gear
10%
3rd Gear
4th Gear
5th Gear
6th Gear 5%
7th Gear

0 10 20 30 40 50 60 70 80 km/h

0 5 10 15 20 25 30 35 40 45 50 mph
SPEED
Grade Distance — 1500 m (5000 ft.)

July 2007 Cat 777D Off-Highway Trucks 29

Retarding Performance

To determine retarding performance: Add lengths of all
downhill segments and, using this total, refer to proper
retarding chart. Read from gross weight down to the percent
effective grade. Effective grade equals actual % grade minus
1% for each 10 kg/t (20 lb/ton) of rolling resistance. From this
weight-effective grade point, read horizontally to the curve
with the highest obtainable gear, then down to maximum
descent speed brakes can properly handle without exceeding
cooling capacity. The following charts are based on these
conditions: 32° C (90° F) ambient temperature, at sea level,
with 27.00-R49 tires.
NOTE: Select the proper gear to maintain engine rpm at the highest
possible level, without overspeeding the engine. If cooling oil
overheats, reduce ground speed to allow transmission to shift to
the next lower speed range.

Typical Field Empty Weight

Gross Machine Operating Weight
163 360 kg (360,143 lb)

Gross Weight
0 50 100 150 200 250 300 350 400 450 lb x 1000

0 30 60 90 120 150 180 210 kg x 1000

30%
25%

20%

EFFECTIVE GRADE (Favorable)

15%
1st Gear

2nd Gear
10%
3rd Gear

4th Gear

5th Gear 5%
6th Gear 7th Gear

0 10 20 30 40 50 60 70 80 km/h

0 5 10 15 20 25 30 35 40 45 50 mph
SPEED
Continuous Grade Length

30 Cat 777D Off-Highway Trucks July 2007

Standard Equipment
Standard equipment may vary. Consult your Caterpillar dealer for details.

Air Line Dryer Gauges

Alternator (100-amp) Actual Gear Indicator
Alarm, Back-up Air Cleaner Service Indicator
Batteries, 190-amp hour, 12-volt (4) Air Pressure
Battery Disconnect Switch, ground level Body Down Indicator
Body Mounting Group Brake Oil Temperature
Body Safety Pins Coolant Temperature
Body Up Reverse Inhibitor Engine Overspeed Indicator
Braking System Fuel Level
Brake Disconnect Switch, front Hour Meter
Brake Heat Exchanger Load Counter, automatic
Brake Release Motor for Towing Odometer
Oil-Cooled Multiple Disc Brakes (rear) Speedometer
Parking Brake Tachometer
Retarder Lighting System
Secondary Brake Auxiliary Jump Start Receptacle
Cab, ROPS Back-up Lights
Coat Hook Directional Signals and Hazard Warning, LED
Diagnostic Connector Port, 24-volt Dome/Courtesy Light
Electronic Monitoring System III Headlights, Halogen, with dimmer
Hoist Lever, finger tip-actuated Stop and Tail Lights, LED
Horn, air Mirrors, right/left
Insulated and Sound-Suppressed Reservoirs (separate)
Power Port, 24-volt Brake/Converter/Hoist
Product Link Ready Steering
Radio Ready, 5-amp converter, speakers, antenna, wiring Transmission/Torque Converter
Seat, Caterpillar Comfort, full air suspension Rims, 19.5 2 49
Seat Belts, 75 mm (3 in) wide retractable Rock Ejectors
Seat, Passenger Service Platform, bolt-on
Steering Wheel, tilt, padded, telescopic Supplemental Steering, automatic
Storage Compartment Tires, 27.00-R49, radial
Sun Visor Tow Hooks, front
Tinted Glass Tow Pin, rear
Window, electric (operator) Transmission
Coolant, Extended Life, –35° C (–30° F) 7-Speed Automatic Power Shift, electronic control
Crankcase Guard Body-up Shift Limiter
Drive line Guard Controlled Throttle Shifting
Electrical System, 24-volt Directional Shift Management
Engine Downshift/Reverse Shift Inhibitor
Cat 3508B Electronic Unit Injection Economy Shift Mode
8-Cylinder Diesel Engine Overspeed Protection
Turbocharged Reverse Neutralizer During Dumping
Aftercooled Neutral Coast Inhibitor
Air Cleaner with Precleaner (2) Neutral Start Switch
Automatic Cold Mode Idle Control Programmable Top Gear Selection
Electric Start Vandalism Protection Locks
Engine Shutdown Switch, ground level Windshield Wipers and Washer, electric intermittent
Starting Aid, Ether
Filters, Spin-on

July 2007 Cat 777D Off-Highway Trucks 31

Optional Equipment
Optional equipment may vary. Consult your Caterpillar dealer for details.

Air Conditioning Lubrication Group – Automatic

Automatic Retarder Control (ARC), dry Muffler
Body Tail End Liner Muffler/Exhaust Diverter
Dual Slope Wiggins Service Center
Fuel Fast Fill Adapter
Fuel Tank
Integrated Braking Control (IBC), dry
Combines Traction Control System (TCS) and Automatic
Retarder Control (ARC) into one system.

Weight/Payload Calculation*
(Example)

Dual Slope Dual Slope w/Liner

CHASSIS kg lb kg lb
Empty Chassis Weight + 10% fuel 48 600 107,144 48 600 107,144
Fuel Correction (90% × 300 × 7.1 lb/gal) 870 1,918 870 1,918
Optional Attachments Weight Debris Allowance
(4% of chassis weight) +1944 +4,286 +1944 +4,286
Total Chassis Weight 51 414 113,347 51 414 113,347
BODY
Body Weight 16 070 35,428 16 070 35,428
Body Attachment Weights 5 432 11,975
Total Body Weight +16 070 +35,428 +21 502 +47,403

Total Empty Operating Weight 67 484 148,775 72 916 160,751

Target Payload +95 876 +211,368 +90 444 +199,393

Gross Machine Operating Weight 163 360 360,143 163 360 360,143

* Refer to Caterpillar’s 10/10/20 Payload Policy for Quarry and Construction Trucks.

32 Cat 777D Off-Highway Trucks July 2007

 Notes

July 2007 Cat 777D Off-Highway Trucks 33

Notes

34 Cat 777D Off-Highway Trucks July 2007

 Notes

July 2007 Cat 777D Off-Highway Trucks 35

For more complete information on Cat products, dealer services, and industry solutions, visit us
on the web at www.cat.com

TEJB9288 (07-2007)
© 2007 Caterpillar Inc.
All rights reserved
Printed in the U.S.A.

Materials and specifications are subject to change without notice. Featured machines in may
include additional equipment. See your Caterpillar dealer for available options.
CAT, CATERPILLAR, their respective logos, “Caterpillar Yellow” and the POWER EDGE trade
dress, as well as corporate and product identity used herein, are trademarks of Caterpillar and
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