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777D ®

Off-Highway Truck

Engine
Engine Model Cat® 3508B EUI
Gross Power 746 kW 1,000 hp
Flywheel Power 699 kW 938 hp
Weights
Gross Machine Weight 163 293 kg 360,000 lb
Operating Specifications
SAE (2:1) Capacity 60.1 m3 78.6 yd3
Nominal Payload Capacity 90.9 tonnes 100 tons
777D Off-Highway Truck
Engineered for performance, designed for comfort, built to last.

Power Train - Engine Power Train - Transmission Engine/Power Train Integration


The Cat 3508B EUI engine delivers The Cat seven-speed power shift The Cat Data Link electronically
the power and reliability necessary transmission, matched with the 3508B combines engine, transmission, brake
to perform in the most demanding electronic unit injection engine, provides and operational information to optimize
applications. Designed for efficient consistent power and efficiency over a overall truck performance. Stored
operation, the 3508B offers excellent wide operating speed range for peak diagnostic data can be accessed via the
fuel efficiency, lower emissions, power train performance. pg. 5 Electronic Technician (ET) to improve
reduced engine noise and lower troubleshooting and reduce downtime.
operating costs. pg. 4 pg. 6

Truck Body Systems Matched Systems


A variety of Caterpillar designed and For full truck payloads with minimum
built truck bodies ensure optimal loading time, an efficient loading/
performance and reliability in tough hauling system starts with a perfect
hauling applications. Cat dealers can match. Cat dealers can help build an
help build an optimum hauling system optimum system solution to maximize
to maximize truck payloads and extend payloads, minimize loading time, and
body and truck wear life. pg. 14 lower operating costs. pg. 16

Top Performance.
Developed specifically for mining, quarrying
and construction applications, the 777D
keeps material moving at high volume to
lower your cost-per ton.

Reliable, Durable Operation.


Rugged construction and easy maintenance
procedures ensure long life with low
operating costs.

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Brake System Structures Operator’s Station
®
Cat front/rear oil-cooled, multiple disc Caterpillar truck frames are built to The ergonomic cab is designed for
brakes offer exceptional, fade-resistant resist twisting in the most severe, high operator comfort and ease of operation.
braking and retarding for maximum impact applications. Mild steel provides Controls and gauges are positioned
performance and productivity in all haul flexibility, durability and resistance to within easy reach for optimum
road conditions. Optional Automatic impact loads. Castings and forgings in efficiency and total machine control.
Retarder Control and Traction Control high stress areas provide exceptional An advanced monitoring system keeps
Systems provide optimum braking strength and durability for long life. the 777D running at peak productivity.
efficiency. pg. 8 pg. 10 pg. 12

Serviceability Customer Support


The 777D is designed for quick and Caterpillar dealers provide unmatched
easy servicing. Simplified service and product support, anywhere in the world.
maintenance features reduce downtime, With industry-best parts availability
allowing the machine to spend less time and a wide range of maintenance and
being serviced and more time on the service options, Cat dealers have what
haul roads. pg. 17 it takes to keep your hauling machines
productive. pg. 18

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Power Train - Engine
The Cat 3508B engine is built for power, reliability and efficiency for superior performance
in the toughest applications.

Two-Piece Piston Design. Two-piece


articulated pistons with a deep bowl,
1 Electronic Unit Injection low volume crevice design enhances
2 Two-Piece Pistons
3 Separate Circuit
combustion efficiency, improves fuel
Aftercooler efficiency and lowers emissions.
4 Valve Rotators
3 5 Oil Cooler
Electronic Unit Injection (EUI). The
6 Self-Aligning electronically controlled unit injection
Roller Followers fuel system senses operating conditions
7 Steel-Backed Copper and regulates fuel delivery for optimum
Bonded Bearings fuel efficiency. The proven high-pressure
4 1 fuel system provides improved response
times and more efficient fuel burn with
2 6 lower emissions and less smoke.
Electronic Control Module (ECM). ECM
utilizes advanced engine management
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software to monitor, control and protect
the engine utilizing self-diagnosing
7 electronic sensors. The computerized
system senses operating conditions and
power requirements and adjusts engine
for peak performance and most efficient
operation and at all times.
Separate Circuit Aftercooler. Allows
the aftercooler circuit to operate cooler
than jacket water temperature for a
denser air charge and greater combustion.
Engine Protection. Computerized
Engine. The Cat 3508B EUI twin Starting System. Features a direct-electric, system electronically protects the
turbocharged and aftercooled diesel 24-volt starting system with a 100-amp engine during cold starts, high altitude
engine delivers high power and alternator and four 190-amp-hour, low operation, air filter plugging, and high
reliability in the world’s most maintenance, high output, 12-volt exhaust temperature.
demanding applications. The 3508B batteries for dependable starting. Oil Renewal System (optional). Oil
is an 8-cylinder, four-stroke design renewal system meters and injects used
Altitude Compensation. Designed for
that uses long, effective power strokes engine oil from the crankcase to the
maximum operating efficiencies at
for more complete fuel combustion engine's fuel return line, extending oil
altitudes under 2228 m (7,500 ft).
and optimum efficiency. change intervals and increasing machine
High Torque Rise. The 23 percent torque availability and productivity.
Fuel Efficiency. The 3508B EUI has
rise provides unequalled lugging force
2% improved specific fuel consumption Exhaust Diverter (optional). Unique
during acceleration, on steep grades and
over the former 3508 EUI engine. muffler/exhaust design transfers heat
in rough underfoot conditions. Torque
EPA Compliant. The 3508B engine is rise effectively matches transmission to the truck body to keep materials from
compliant with U.S. Environmental shift points for maximum efficiency sticking in cold climates. When in the
Protection Agency Tier I emissions and fast cycle times. lowered position, the diverter routes the
standards. exhaust through the body; when raised,
Enhanced Life. High displacement, low exhaust is diverted through the muffler.
rpm rating and conservative horsepower
ratings mean more time on the haul
roads and less time in the shop.

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Power Train - Transmission
Cat power train delivers more power to the ground for greater productivity and lower
operating costs.

1) Transmission. The Cat seven-speed


planetary power shift transmission is
matched with the direct-injection 3508B
diesel engine to deliver constant power
over a wide range of operating speeds.
Robust Design. Designed for the
higher horsepower of the 3508B
engine, the proven planetary power
shift transmission is built tough for
long life between overhauls.
Long Life. A dedicated oil tank and
circuit provides cooler, cleaner oil
for maximum performance and longer
component life.
Transmission Chassis Control (TCC).
TCC uses electronically transferred
engine rpm data to execute shifts at
preset points for optimum performance,
efficiency and clutch life.
2) Lock-Up Torque Converter. Combines
maximum rimpull and the cushioned
shifting of torque converter drive with
the efficiency and performance of
direct drive. Engages at approximately
6.4 km/h (4 mph), delivering more
power to the wheels.
Lock-Up Clutch. Quickly releases and
re-engages to reduce power train torque
loads for smoother shifting, long life
Axles. Full floating axles are shot Steering System. Hydraulic steering
and a more comfortable ride.
peened to relieve internal stresses and control system is designed for
Smooth Shifting. Individual clutch increase durability. Rolled splines also exceptional smoothness and precise
modulation provides smooth clutch provide increased service life. control. A separate circuit prevents
engagements to optimize performance cross contamination for long life.
Wheels and Rims. Cast rear wheels and
and extend clutch life.
Cat center-mount rims are mounted using
3) Final Drives. Cat final drives work as studs and nuts to minimize maintenance
a system with the planetary power shift and maximize durability.
transmission to deliver maximum power
to the ground. Built to withstand the
forces of high torque and impact loads,
double reduction final drives provide
high torque multiplication (19.16:1) 2
to further reduce drive train stress. 3

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Engine/Power Train Integration
Electronically combines critical power train components to work more intelligently to
optimize overall truck performance.

1 Electronic Technician
1
2 CAT Data Link
3 Sensors
4 Engine Control Module (ECM)
7 5 Transmission Chassis Control (TCC)
6 Automatic Retarder Control (ARC)
6 Traction Control System (TCS)
Integrated Brake Control (IBC)
2
7 Electronic Monitoring System
(EMS III) Display
8 Transmission
9 Oil-Cooled Brakes

3 4

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9 9

Cat Data Link. Electronically integrates Transmission Chassis Control (TCC). • Controlled Throttle Shifting. Regulates
machine computer systems to optimize TCC uses electronically transferred engine rpm during shifting to reduce
overall power train performance, engine rpm data to execute shifts at power train stress and clutch wear
increase reliability and component life, preset points for optimum performance by controlling engine speed, torque
and reduce operating costs. efficiency and clutch life. converter lock-up and transmission
clutch engagement for smoother shifts
Economy Mode. Using the Electronic The transmission chassis controller
and longer component life.
Technician (Cat ET) service tool, provides integrated functionality, to
the mechanic can reduce the engine the following electronic controls: • Directional Shift Management.
setting to 920 gross horsepower to Regulates engine speed during directional
match loader/crusher availability shifts to prevent damage caused by high
and conserve fuel. speed directional changes.

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• Neutral Coast Inhibitor. Prevents • Reverse Shift Inhibitor. Protects the Diagnostic Capability. Critical data
transmission from shifting to neutral engine from abrupt directional changes from the electronic engine and
at speeds above 6.5 km/h (4 mph) to by slowing down the engine before transmission controls, including
protect the transmission from operating shifting the transmission into reverse. transmission shifting, engine speed
with insufficient lubrication. and fuel consumption, provides service
technicians with enhanced diagnostic
• Body-up Shift Limiter. Prevents the
capability to reduce downtime and
transmission from shifting above a
operating costs.
pre-programmed gear without the
body fully lowered. Electronic Monitoring System (EMS III).
EMS III allows the operator to view
• Body-up Reverse Neutralizer.
requested information and utilizes a
Automatically shifts the transmission
three-category warning system to alert
to neutral if the hoist lever is activated
the operator of abnormal machine
while transmission is shifted in reverse.
conditions. Data can be downloaded via
• Overspeed Protection. The transmission the Electronic Technician (ET) service
control electronically senses engine tool for quick diagnosis and repair.
conditions and automatically up-shifts
Optional Attachments. Caterpillar
one gear to prevent overspeeding.
offers optional braking controls that
If overspeeding occurs in top gear, Electronic Technician (ET). Cat ET service are electronically integrated with the
the lock-up clutch is disengaged. tool provides service technicians with Cat Data Link to enhance retarding,
• Programmable Top Gear. Transmission easy access to stored diagnostic data traction and braking performance:
top gear maximum can be set using the through the Cat Data Link to simplify
problem diagnosis and increase machine • Automatic Retarder Control (ARC).
Cat ET service tool to help the operator
availability. Optional ARC electronically controls
maintain speed limits.
retarding on grade to maintain optimum
• Downshift Inhibitor. Prevents engine • Cat ET displays the status of all engine rpm and oil cooling.
overspeeding by keeping the transmission engine parameters, including throttle
position, timing and fuel flow. • Traction Control System (TCS).
from downshifting until engine speed
Optional TCS electronically monitors
reaches the downshift point. • Cat ET replaces 13 mechanical tools and controls rear wheel slippage for
• Economy Shift Mode. Modifies engine to perform functions like cylinder greater traction in poor underfoot
maps, resulting in greater fuel economy. cutout checks, injector solenoid tests conditions.
and timing calibration.
• Integrated Braking Control (IBC).
Optional IBC integrates Automatic
Retarder Control and Traction Control
into one system for optimum performance
and efficiency.

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Brake System
Reliable braking with superior control gives the operator the confidence to focus
on productivity.

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 (optional).
Multiple disc, spring-applied,
hydraulically-released, dry brakes
available for front wheel braking only.
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
Integrated Braking System. The Cat Front/Rear Oil-Cooled Multiple Disc brake is applied to all four wheels for
oil-cooled braking system delivers Brakes. Caterpillar four-wheel, forced superior parking capability on all grades
reliable performance and control in oil-cooled, multiple disc service brakes up to 15 percent.
the most extreme haul road conditions. are continuously cooled by water-to-oil
The integrated system combines the heat exchangers for exceptional, non-fade
service, secondary, parking brake and braking and retarding performance.
retarding functions in the same robust 1 Parking/Secondary Piston
system for optimum braking efficiency. 2 Service/Retarding Piston
2 3 Friction Discs
4 Steel Plates
1 5 Actuating Springs
6 Cooling Oil In
7 Cooling Oil Out

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3

5 6

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IBC

ARC 1 Service Brake Sensor TCS


1 2 2 Engine Sensor
3 ARC
4 ARC Switch
5 Brakes
6 Service Brakes 6
7 Axle Speed Sensor
8 TCS 7

8
3
7

5 6

Automatic Retarder Control (ARC) • Fuel Efficiency. During retarding Traction Control System (TCS) (optional).
(optional). ARC electronically controls applications the engine ECM does not TCS electronically monitors and
braking on grade to maintain engine at inject fuel into the cylinders for controls rear wheel slippage for
approximately 1900 RPM (adjustable additional fuel economy. greater traction and enhanced truck
from 1850-1950 RPM in increments performance in poor underfoot
Four Corner Retarding. Four corner
of 10). ARC is deactivated when the conditions. If slippage exceeds a set
retarding with 60/40 percent split
operator applies the brakes or throttle. limit, the oil-cooled disc brakes engage
(rear/front) in braking effort provides
to slow the spinning wheel. Torque is
ARC Benefits. superior control in slippery conditions.
then automatically transferred to the
Balanced front to rear brake torque
• Engine Overspeed Protection. wheel with better traction.
provides exceptional braking performance
Automatically activates ARC when
and minimizes wheel lock-up, especially • Differential Action. Normal differential
engine speed exceeds factory preset
during retarding. action provides superior maneuvering
levels, regardless of operator inputs,
and control in slippery conditions.
to avoid potentially damaging engine ARC Operating Efficiency Advantages.
overspeeds. • System Back-Up. Should sensors
fail, normal differential action is
• Ease of Operation. ARC increases
still available to maintain steering
operating ease, resulting in greater
Engine Speed (rpm)

* and control.
operator confidence with less fatigue.
Integrated Braking Control (IBC)
• Faster Speeds. ARC allows the
(optional). IBC combines Automatic
operator to maintain optimum engine
Retarder Control (ARC) and Traction
speeds for faster downhill hauls and
Control System (TCS) into one integrated
greater productivity.
brake control system for optimum
• Superior Control. Automatic brake 0 10 20 30 40 50 60 70 efficiency, performance and reliability.
Time (Seconds)
modulation offers a smoother ride and
Cat Data Link. All control modules
better control in slippery conditions, Automatic Retarder Control
(Maintains Engine rpm between 2160-2300) communicate via the Cat Data Link and
allowing the operating to concentrate
Manual Retarder Control work together as an integrated system
on driving. (Wide Variation in Engine rpm)
to maximize production efficiency and
* Optimum Engine rpm
extend component life.

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Structures
Rugged Cat structures are the backbone of the 777D off-highway truck’s durability.

Integral Four-Post ROPS Cab. Resiliently


mounted to the main frame to reduce
vibration and sound, the integral ROPS
structure is designed as an extension
of the truck frame. The ROPS/FOPS
structure provides “five sided protection”
for the operator.
Steering and Suspension System.
Cat integrated steering and suspension
system is designed for precise steering,
excellent maneuverability with minimal
tire wear, and superior ride control to
optimize operator comfort all shift long.
Steering System. A twin double-acting
cylinder steering system is designed
to deliver precise control under all
Box-Section Design. The 777D frame Castings. Castings have large radii with loading and underfoot conditions.
uses a box-section design, incorporating internal reinforcing ribs to dissipate stress The steering system is separate from
two forgings and 22 castings in high in areas of high stress concentration. the main hydraulic system to prevent
stress areas with deep penetrating and Castings move welds to lower stress cross-contamination and overheating
continuous wrap-around welds to resist areas for greater frame life. from other sources.
damage from twisting loads without
Serviceability. The open box-section Supplemental Steering. Main hydraulic
adding extra weight.
frame design allows easy access to steering system is backed by a battery
Steel Structures. Mild steel used power train components, reducing powered supplemental steering system
throughout frame provides flexibility, overall removal and installation time, which uses pressure accumulators and
durability and resistance to impact and lowering overall repair costs. The allows up to three 90 degree turns in case
loads, even in cold climates, and raised and pinned body allows excellent of engine failure. System automatically
allows for easy field repairs. access to the transmission. engages when needed.

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Superior Control. Automatic brake
modulation offers a smoother ride and
better control in slippery conditions,
allowing the operator to concentrate
on driving.
Front Spindles and Wheels. Rigidly
mounted to the cylinder rods for reliable
operation and long life.
Maximum Tire Life. The steering system
is designed to maintain zero toe-in/toe-out
when tie-rods and front suspension
cylinders are properly adjusted to
minimize tire scuffing and maximize
tire life.
Suspension System. Designed to dissipate
haul road and loading impacts for longer
frame life and a more comfortable ride.

1 Nitrogen
1 2 Oil
3 Rebound
Chamber
2
4 Cylinder
Housing
3 5 Piston

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• Front. Front cylinders with preset Ride Control. Built-in rebound control
caster and camber are mounted to the and strategically located cab relative to
frame and serve as steering kingpins the front axle minimizes the effect of
for a tight turning radius with excellent pitch and bounce, resulting in a more
Cylinders. Four independent self- maneuverability and low maintenance. comfortable ride, higher productivity
contained, nitrogen/oil pneumatic, and less fatigue.
• Rear. Rear cylinders allow axle
variable-rebound suspension cylinders oscillation and absorb bending and
are designed to absorb shocks in the twisting stresses caused by uneven and
most severe applications. rough haul roads rather than transmitting
Durable Design. Rugged cylinders them to the main frame.
utilize large diameter bore and low
pressure nitrogen/oil design for long
life with minimal maintenance.

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Operator’s Station
Ergonomically designed for operator comfort, superior control and high productivity.

6) ROPS/FOPS Cab. Integral, sound-


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suppressed cab is resiliently mounted
to the mainframe to isolate the operator
from sound and vibration for a quiet,
secure and comfortable ride.
7) Operator Controls. Easy to reach
turn signal, high beam, windshield
wiper/washer, and retarder controls
6 are designed for optimum efficiency
5 and comfort.
8) Storage Compartment. Large
compartment located under the trainer
seat provides an uncluttered working
1 environment.
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3
9) Trainer Seat. Full-size, fully padded
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trainer seat features a backrest, wide
11 hip and shoulder room, and seat belt
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for secure travel.
10) Monitoring System. Electronic
4 Monitoring System (EMS III)
12 features easy-to-read displays for
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precise machine status information.
Data can be downloaded via the
14 2 Electronic Technician (Cat ET)
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service tool for quick diagnosis
and repair.
• Gauge Cluster maintains a constant
display of vital machine functions,
including: coolant temperature, oil
Ergonomic Layout. The 777D operator 3) Steering Column. Sport wheel with
temperature, brake air pressure, and
station is ergonomically designed for tilt and telescopic steering provides
fuel level.
total machine control in a comfortable, a comfortable driving position and
productive environment. All controls, greater control. • Speedometer/Tachometer Module
levers switches and gauges are positioned monitors three systems: engine speed,
4) Transmission Console. Ergonomic
to maximize productivity and minimize ground speed and actual gear.
gear shift lever with backlit gear
operator fatigue.
indicators optimize efficiency. • Message Center displays messages
1) Dash. Wrap-around dash puts all requested by operator and advises
5) Viewing Area. Designed for excellent
controls within each reach of the operator. operator of abnormal machine
all-around visibility and clear sight lines
Backlit displays enhance visibility. conditions.
to the haul road, the large viewing area
2) Air Suspension Seat. Ergonomically enables the operator to maneuver with
designed, fully adjustable Cat Comfort confidence for greater productivity.
Air Suspension Seat with adjustable
armrests provides optimal driving
comfort. A wide, retractable seat belt
provides a secure, comfortable restraint.

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11) Heating/Air Conditioning.
Electronically controlled four-speed
fan and nine vents deliver temperature-
controlled air circulation for a
comfortable working environment
in any climate. A/C is optional.
12) Foot Pedals. Ergonomically designed
for comfort. Secondary brake pedal is
conveniently located on the floor for
easy operator control.
13) Operator Window. Powered operator
window offers simple operation and an
unobstructed view. 15) Truck Production Management • System is accurate within ±5%
System (TPMS) (optional). TPMS under normal loading conditions
provides valuable payload and cycle over a normal shift.
time data to improve productivity.
Radio Ready. Cab is prewired with
• Utilizes strut pressure sensors and power converter, speakers, wiring
on-board microprocessor to harness, antenna and provision for
determine payload weight. add-on communication systems.
• Delivers consistent, accurate Product Link Ready. Optional Product
payloads and improves efficiency Link system provides a two-way
by minimizing overloading and communication flow of vital machine
underloading. data and location information between
the dealer and the customer. Product
• External lights signal loading tool
Link provides updates on service meter
operator when payload is reached.
hours, machine condition, machine
• On-board computer stores up to location as well as integrated mapping/
14) Hoist Levers. Four-position electronic
1,400 cycles for analysis of payload route planning.
hoist system with fingertip control
weight, cycle times, distances, and
provides low impact body-down
actual cycle dates and times.
snubbing. Mounted next to the
operator’s seat for ease of operation.
Payload Weight Distribution
Percentage of Total Loads

Payload Weight (Tons)

Recommended Payload Range With Production Management

Inefficient Payload Ranges Without Production Management

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

Body/Chassis Integration. Caterpillar


truck bodies are designed and matched
with the integrated chassis system for
optimum structural reliability, durability
and long life.
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 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
Cat Truck Bodies. Caterpillar offers Body Selection. Selection of the right support.
three specific body styles to help body depends on material and haul road • Full-Length Stringers create strength
customers obtain the lowest conditions. The better the match of body and rigidity throughout the bed.
cost-per-ton hauling solution. to application, the greater the efficiency.
Your Cat dealer can help you select the • Box Section Beams offer increased
• Dual-Slope durability in the floor, sidewall, top
right body system for your site specific
• Flat Floor (custom) application. rail, corner, and cab canopy areas.

• Mine Specific Design (MSD) • Wide Body Design provides


(custom) complete coverage of tires,
eliminating the need for rock
deflectors.

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1) Dual-Slope Body. The advanced dual- 2) Flat Floor Body (custom). The flat
slope body design with V-shaped floor floor design with slight incline delivers
increases load retention, maintains a excellent payload capacity, high dump
low center of gravity, reduces shock clearances and smooth, controlled
loading, and maintains optimum load dumping. 3) Mine Specific Design (MSD) Body
distribution on steep inclines and in • Flat floor design provides consistent (custom). The MSD body is based on
challenging haul road conditions. wear characteristics on body tail. the flat floor design and is customized
• Reinforced, rolled steel top rail to maximize payload potential and
• 12 degree forward body slope minimize cost-per-ton. Each MSD body
increases body strength and protects provides good load retention
the body from damage caused by design begins with a detailed mine site
on better maintained haul roads. profile to develop a body suitable for a
the loading tool or falling material
• 400 Brinell steel on surfaces mine’s individual needs.
• 8 degree “V” reduces shock loading provides excellent wear.
and centers the load. Body Liners. A variety of liner options
• Maintains a load height of are available to save weight and help
• 10 degree forward body slope and 4571 mm (15 ft) to match extend the body system’s life. Wear
18 degree ducktail slope helps retain a variety of loading tools. surfaces and liners are equipped to
loads on steep grades. handle tough impact loads while
• 60.6 m3 (78.7 yd3) capacity allows resisting abrasion. Wear plates
• Maintains a load height of 4380 mm operators to achieve rated payload
(14 ft 3 in) for faster, more confident deliver long life in high wear areas.
in 2900 lb/BCY material.
loading.
• 60.1 m3 (78.6 yd3) capacity allows
operators to achieve rated payload
in 2900 lb/BCY material.

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Matched Systems
An efficient loading/hauling system starts with a perfect match.

Efficient Combination. The 777D is Tire Options. Choose from a range of Loader Match. Designed to work as an
designed to deliver full payloads and tire options to match specific underfoot optimum pass/match system, the 777D
fast cycle times. When properly matched, conditions, haul road conditions and is best sized to match the following
Cat trucks and loading tools create an hauling distances to maximize Caterpillar loading tools:
efficient combination to maximize performance and extend tire life.
Wheel Loaders
volume of material moved at the
Systems Approach. The Caterpillar • 990 II — 6 pass/match
lowest operating cost.
systems approach means increased • 992G — 4 pass/match
Machine Configuration Options. efficiencies through common design.
Mass Excavators
Choose from various truck Cat haul trucks, loaders and excavators
• 5110B ME — 6-7 pass/match
configuration options to match use common engines, parts and operator
• 5130B ME — 5 pass/match
specific site and hauling conditions. environments which add up to more
• 5230B ME — 3-4 pass/match
uptime, greater productivity and lower
Body Options. Choose from a full line
maintenance costs. Front Shovels
of standard and custom body designs
• 5130B FS — 4-5 pass/match
and wear protection based on material,
• 5230B FS — 3-4 pass/match
loading tools and site conditions.

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Serviceability
Less time spent on maintenance means more more time on the haul roads.

Servicing Ease. Easy access to daily


service points simplifies servicing
and reduces time spent on regular
maintenance procedures. Enhanced
serviceability and extended service
intervals are designed to increase
machine availability and productivity.
Maintenance Platform. Provides access
to engine, air filters, steering hydraulic
tank and battery compartment.
In-Frame Access. Permits easy access
to major components for easy servicing
and removal.
Ground-Level Access. Allows
convenient servicing to tanks, filters,
drains, battery disconnect and engine
shutdown.
Engine Prelube (optional). Engine
prelubrication provides engine oil
pressure prior to engine cranking.
Reduces engine dry and cold start wear
and reduces engine component wear.
Automatically fills engine oil filters
and galleries, and ensures components
are lubed prior to cranking.
Fast Fill Service Center (optional).
Wiggins fast fill service center features
high speed fuel and oil exchange.
Oil Renewal System (ORS) (optional). Air Filters. Radial seal air filters are On-Board Diagnostic Systems. EMS III
Extends oil change intervals and reduces easy to change, reducing time required continuously checks all critical machine
waste oil handling by continuously for air filter maintenance. functions and components, and helps
burning oil from the engine oil pan locate faults quickly for faster repair.
Sealed Electrical Connectors. Electrical
through normal engine operation. Electronic control system enables
connectors are sealed to lock out dust
Make-up oil must be continually quick diagnosis of engine conditions
and moisture. Harnesses are braided for
added to compensate for oil burned. and effective maintenance and repairs
protection. Wires are color coded for
utilizing the Electronic Technician (ET)
Scheduled Oil Sampling. S•O•SSM easy diagnosis and repair.
service tool.
sampling valves speed sampling Spin-on Filters. Spin-on filters for fuel
and analysis reliability. and oil systems reduce changing time
Pressure Test Points. Disconnect and help assure clean, tight seals.
valves are conveniently located
throughout the hydraulic systems
for easy pressure testing.

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Customer Support
Caterpillar dealers have what it takes to keep haul trucks productive.

Financing. Your dealer is an expert at


arranging affordable financing options
for all Caterpillar products.
Product Support. You will find nearly
all parts at your dealer parts counter.
Cat dealers use a worldwide computer
network to locate in-stock parts to
minimize machine downtime. Save
money with Cat Reman parts. Receive
the same warranty and reliability as
new products at a savings of 40 to 70%.
Literature Support. Operation and
maintenance manuals are easy to use,
helping you get the full value of your
equipment investment.
Customer Support Agreements.
Cat dealers offer a variety of product
support agreements, and work with
customers to develop a plan that meets
specific needs. Plans can cover the
entire machine, including attachments,
to help protect your investments.
Operation. Improving operating
techniques can boost your profits.
Your Cat dealer has training videotapes,
literature and other ideas to help you
increase productivity.
Replacement. Repair, rebuild or replace?
Your Cat dealer can help you evaluate
Machine Selection. Make detailed Purchase. Look past initial price.
the cost involved so you can make the
comparisons of the machines under Consider the financing options
right choice.
consideration before purchase. Cat available, as well as day-to-day
dealers can estimate component life, operating costs. This is also the time www.CAT.com. For more complete
preventive maintenance cost, and the to look at dealer services that can be information on Cat products, dealer
true cost of lost production. included in the cost of the machine to services, and industry solutions, visit
lower equipment owning and operating us on the web at www.CAT.com.
costs over the long run.

18
Engine Brakes

Engine Model Cat 3508B EUI Brake surface - front 2787 cm2 432 in2
102 116 cm 15,828 in2
2
Gross Power 746 kW 1,000 hp Brake surface - rear
Flywheel Power 699 kW 938 hp • Meets ISO 3450:1996 standards up to 163 293 kg (360,000 lb)
Net Power - Cat 699 kW 938 hp gross operating weight.
Net Power - ISO 9249 699 kW 938 hp
Net Power - SAE J1349 (6/95) 699 kW 938 hp
Net Power - EEC 80/1269 699 kW 938 hp Service Refill Capacities
Max. Torque 4713 N m
• 3,476 lb ft
Fuel Tank 1137 L 300 gal
Torque rise 23 %
Cooling System 325 L 86 gal
Bore 170 mm 6.7 in
Crankcase 124 L 33 gal
Stroke 190 mm 7.5 in
Differentials and final drives 329 L 87 gal
Displacement 34.5 L 2,105 in3
Steering tank 57 L 15 gal
• Net power advertised is the power available at rated speed Steering system 84 L 22 gal
of 1750 rpm, measured at the flywheel when the engine is (includes tank)
equipped with fan, air cleaner, muffler and alternator.
Brake/hoist hydraulic tank 220 L 58 gal
• Ratings based on standard air conditions of 25° C (77° F) and
Brake/hoist system 415 L 110 gal
99 kPa (29.32 Hg) dry barometer. Power based on fuel having
(includes tank)
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 30° C (86° F). Torque converter/ 81 L 21.5 gal
transmission sump
• No engine derating required up to 2288 m (7,500 ft) altitude.
Torque converter/transmission 138 L 36.5 gal
• Complaint with U.S. Environmental Protection Agency Tier I system (includes sump)
emissions standards.

Body Hoists
Transmission
Pump flow - high idle 405.5 L/min 119 gal/min
Forward 1 10.5 kph 6.5 mph
Relief valve setting - raise 18 962 kPa 2,750 psi
Forward 2 14.3 kph 8.9 mph
Relief valve setting - lower 18 950 kPa 3,450 psi
Forward 3 19.3 kph 12 mph
Body raise time @ high idle 15 Seconds
Forward 4 26 kph 16.2 mph
Body lower time float 13 Seconds
Forward 5 34.9 kph 21.9 mph
Body power down @ high idle 13 Seconds
Forward 6 46.6 kph 29.4 mph
Forward 7 60.4 kph 39.9 mph
Reverse 11.9 kph 7.4 mph
Suspension
• Maximum travel speeds with standard 27.00-R49 tires.
Effective cylinder stroke - front 318 mm 12.5 in
Effective cylinder stroke - rear 165 mm 6.5 in
Final Drive Rear axle oscillation 5.4º

Differential ratio 2.74:1


Planetary ratio 7.00:1 Approximate Weights - Dual-slope
Total reduction ratio 19.16:1
• Planetary, full-floating. Empty vehicle 61 296 kg 141,749 lb
Chassis 45 518 kg 106,964 lb
Body 15 778 kg 34,785 lb

777D Off-Highway Truck specifications 19


Approximate Weights - Dual-slope Lined Tires

Empty vehicle 66 764 kg 153,804 lb Standard 27.00-R49 (E4) Tire


Chassis 45 518 kg 106,964 lb • Productive capabilities of the 777D truck are such that,
Body 21 246 kg 46,840 lb under certain job conditions, TKPH (TMPH) capabilities of
standard or optional tires could be exceeded and, therefore,
limit production.
Approximate Weights - Flat Floor • Caterpillar recommends the customer evaluate all job
conditions and consult the tire manufacturer for proper
Empty vehicle 61 788 kg 142,723 lb tire selection.
Chassis 45 518 kg 106,964 lb
Body 16 270 kg 35,759 lb
ROPS

Standards SAE J1040 MAY94,


Approximate Weights - Flat Floor Lined
ISO 3471:1997
Empty vehicle 67 286 kg 154,954 lb • ROPS (Rollover Protective Structure) for cab offered by
Chassis 45 518 kg 106,964 lb Caterpillar meets SAE J1040 MAY94 and ISO 3471:1997
Body 21 768 kg 47,990 lb Level II ROPS criteria.

Sound
Approximate Weight Distribution - DS/FF
Standards ANSI/SAE J1166 MAY90,
Front axle - empty 47%
SAE J88 JUN96
Front axle - loaded 33%
Rear axle - empty 53% • The operator sound exposure Leq (equivalent sound
pressure level) measured according to work cycle
Rear axle - loaded 67%
procedures specified in ANSI/SAE J1166 MAY90 is 78 dB(A)
for cab offered by Caterpillar, when properly installed and
maintained and tested with doors and windows closed.
Capacity - Dual-slope - 100% fill factor • The exterior sound pressure level for the standard machine
3 3
measured at a distance of 15 m (49 f) according to the test
Struck 42.1 m 55 yd procedures specified in SAE J88 JUN86, mid-gear moving
Heaped 2:1 (SAE) 60.1 m3 78.6 yd3 operation is 90 dB(A).
• Hearing protection may be needed when operating with
an open operator station and cab (when not properly
Capacity - Flat Floor - 100% fill factor maintained or doors/windows open) for extended periods
or in a noisy environment.
Struck 42 m3 54.6 yd3
Heaped 2:1 (SAE) 60.2 m3 78.7 yd3
Steering

Weights Standards SAE J1511 OCT90,


ISO 5010:1992 (E)
Gross Machine Weight 163 293 kg 360,000 lb • Turning diameter on front wheel track with standard tires:
25.3 m (83 ft).
• Machine clearance turning circle: 28.4 m (93 ft 2 in).
Operating Specifications • Steering angle, left or right: 31.8 degrees.
SAE (2:1) Capacity 60.1 m3 78.6 yd3 • Separate hydraulic system prevents cross contamination.
Nominal Payload Capacity 90.9 tonnes 100 tons

20 777D Off-Highway Truck specifications


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 Flat Floor Dual Slope Flat Floor


1 Height to Top of 4472 mm 14 ft 8 in 4472 mm 14 ft 8 in 11 Operating Width 6105 mm 20 ft 6105 mm 20 ft
ROPS - Full 12 Centerline Front 4173 mm 13 ft 8 in 4173 mm 13 ft 8 in
1 Height to Top of 4567 mm 15 ft 4567 mm 15 ft Tire Width
ROPS - Empty 13 Overall Front Tire Width 4961 mm 16 ft 3 in 4961 mm 16 ft 3 in
2 Overall Body Length 9525 mm 31 ft 3 in 9581 mm 31 ft 5 in 14 Engine Guard 700 mm 2 ft 4 in 700 mm 2 ft 4 in
3 Inside Body Length 7234 mm 23 ft 9 in 6797 mm 22 ft 3 in Clearance - Empty
4 Overall Length 9780 mm 32 ft 1 in 9780 mm 32 ft 1 in 15 Overall Canopy Width 6048 mm 19 ft 10 in 6099 mm 20 ft
5 Wheelbase 4570 mm 15 ft 4570 mm 15 ft 16 Outside Body Width 5524 mm 18 ft 2 in 5524 mm 18 ft 2 in
6 Rear Axle to Tail 3020 mm 9 ft 11 in 2968 mm 9 ft 9 in 17 Inside Body Width 5200 mm 17 ft 1 in 5200 mm 17 ft 1 in
7 Dump Clearance - 1164 mm 3 ft 10 in 1128 mm 3 ft 8 in 18 Front Canopy Height - 5147 mm 16 ft 10 in 5185 mm 17 ft
Empty Empty
7 Dump Clearance - 1062 mm 3 ft 6 in 1026 mm 3 ft 4 in 18 Front Canopy Height - 5045 mm 16 ft 6 in 5083 mm 16 ft 8 in
Loaded Loaded
8 Loading Height - 4380 mm 14 ft 4 in 4571 mm 15 ft 19 Rear Axle 750 mm 2 ft 6 in 750 mm 2 ft 6 in
Empty Clearance - Empty
9 Inside Body 1898 mm 6 ft 3 in 1959 mm 6 ft 5 in 20 Centerline Rear Dual 3576 mm 11 ft 9 in 3576 mm 11 ft 9 in
Depth - Max Tire Width
10 Overall Height - 10 059 mm 33 ft 10 094 mm 33 ft 1 in 21 Overall Rear Dual 5262 mm 17 ft 3 in 5262 mm 17 ft 3 in
Body Raised Tire Width

777D Off-Highway Truck specifications 21


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


161 000 kg (355,000 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

22 777D Off-Highway Truck specifications


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.)

777D Off-Highway Truck specifications 23


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.)

24 777D Off-Highway Truck specifications


Retarding Performance

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

Typical Field Empty Weight


Gross Machine Operating Weight
161 000 kg (355,000 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

777D Off-Highway Truck specifications 25


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 (front/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
Heater/Defroster, 7570 kCal (38,000 Btu) Stop and Tail Lights, LED
Hoist Lever, finger tip-actuated Mirrors, right/left
Horn, air Reservoirs (separate)
Insulated and Sound-Suppressed Brake/Converter/Hoist
Power Port, 24-volt Steering
Product Link Ready Transmission/Torque Converter
Radio Ready, 5-amp converter, speakers, antenna, wiring Rims, 19.5 x 49
Seat, Caterpillar Comfort, full air suspension Rock Ejectors
Seat Belts, 75 mm (3 in) wide retractable Service Platform, bolt-on
Seat, Passenger Supplemental Steering, automatic
Steering Wheel, tilt, padded, telescopic Tires, 24.00-35, radial
Storage Compartment Tow Hooks, front
Sun Visor Tow Pin, rear
Tinted Glass Transmission
Window, electric (operator) 7-Speed Automatic Power Shift, electronic control
Coolant, Extended Life, –35° C (–30° F) Body-up Shift Limiter
Crankcase Guard Controlled Throttle Shifting
Driveline Guard Directional Shift Management
Electrical System, 24-volt Downshift/Reverse Shift Inhibitor
Engine Economy Shift Mode
Cat 3508B Electronic Unit Injection Engine Overspeed Protection
8-Cylinder Diesel Reverse Neutralizer During Dumping
Turbocharged Neutral Coast Inhibitor
Aftercooled Neutral Start Switch
Air Cleaner with Precleaner (2) Programmable Top Gear Selection
Automatic Cold Mode Idle Control Vandalism Protection Locks
Electric Start Windshield Wipers and Washer, electric intermittent
Engine Shutdown Switch, ground level
Starting Aid, Ether
Filters, Spin-on

26 777D Off-Highway Truck specifications


Optional Equipment
With approximate changes in operating weights.
Optional equipment may vary. Consult your Caterpillar Dealer for specifics.
kg lb kg lb
Air Conditioning 90 198 Muffler 175 385
Automatic Retarder Control (ARC), dry/wet 5.9 13 Muffler/Exhaust Diverter 188 415
Body Liners1 Oil Change System, high speed, Wiggins 2.3 5
Dual Slope 5493 12,110 Starting System3, low temperature 170 375
Flat Floor 5584 12,231 Starting Aid, heater, engine coolant, 120V/240V 2.3 5
Engine Prelubrication 44 98 Traction Control System (TCS) 50 110
Integrated Braking Control2 (IBC), dry/wet 56 123 Truck Production Management System 45 100

1
Minimum yield strength 9207 bar/900 mPa (13,000 psi). 16 mm (0.63 in) floor, 8 mm (0.31 in) front and sidewalls.
2
Combines Traction Control System (TCS) and Automatic Retarder Control (ARC) into one system.
3
Includes two additional batteries and extra starting motor.

Weight/Payload Calculation*
(Example)

Dual Slope Dual Slope w/Liner Flat Floor Flat Floor w/Liner
CHASSIS kg lb kg lb kg lb kg lb
Empty Chassis Weight + 10% fuel 48 518 106,964 48 518 106,964 48 518 106,964 48 518 106,964
Fuel Correction
(90% × 300 × 7.1 lb/gal) 870 1,917 870 1,917 870 1,917 870 1,917
Optional Attachments Weight
Debris Allowance
(4% of chassis weight) +1941 +4,279 +1941 +4,279 +1941 +4,279 +1941 +4,279
Total Chassis Weight 51 329 113,160 51 329 113,160 51 329 113,160 51 329 113,160
BODY
Body Weight 15 778 34,785 15 785 34,800 16 220 35,759 16 220 35,759
Body Attachment Weights 5461 12,040 5548 12,231
Total Body Weight +15 778 +34,785 +21 246 +46,840 +16 220 +35,759 +21 768 +47,990

Total Empty Operating Weight 67 107 147,945 72 575 160,000 67 549 148,919 73 079 161,150

Target Payload +96 186 +212,055 +90 718 +200,000 +95 744 +211,081 +90 196 +198,850

Gross Machine Operating Weight 163 293 360,000 163 293 360,000 163 293 360,000 163 293 360,000

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

777D Off-Highway Truck specifications 27


777D Off-Highway Truck

For more complete information on Cat products, dealer services,


and industry solutions, visit us on the web at www.CAT.com

© 2003 Caterpillar
Printed in U.S.A.

AEHQ5140-02 (6-03) Materials and specifications are subject to change without notice.
Featured machines in photos may include additional equipment.
Replaces AEHQ5140-01 See your Caterpillar dealer for available options.

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