777D^Non-Current

Engine

The Cat 3508B EUI twin turbocharged and aftercooled diesel engine delivers high power and reliability in the world's most demanding applications. The 3508B is an 8-cylinder, four-stroke design that uses long, effective power strokes for more complete fuel combustion and optimum efficiency.

Fuel Efficiency

The 3508B EUI has 2% improved specific fuel consumption over the former 3508 EUI engine.

EPA Compliant

The 3508B engine is compliant with U.S. Environmental Protection Agency Tier I emissions standards.

Starting System

Features a direct-electric, 24-volt starting system with a 100-amp alternator and four 190-amp-hour, low maintenance, high output, 12-volt batteries for dependable starting.

Altitude Compensation

Designed for maximum operating efficiencies at altitudes under 2228 m (7,500 ft).

High Torque Rise

The 23 percent torque rise provides unequalled lugging force during acceleration, on steep grades and in rough underfoot conditions. Torque rise effectively matches transmission shift points for maximum efficiency and fast cycle times.

Enhanced Life

High displacement, low rpm rating and conservative horsepower ratings mean more time on the haul roads and less time in the shop.

Two-Piece Piston Design

Two-piece articulated pistons with a deep bowl, low volume crevice design enhances combustion efficiency, improves fuel efficiency and lowers emissions.

Electronic Unit Injection (EUI)

The electronically controlled unit injection fuel system senses operating conditions and regulates fuel delivery for optimum fuel efficiency. The proven high-pressure fuel system provides improved response times and more efficient fuel burn with lower emissions and less smoke.

Electronic Control Module (ECM)

ECM utilizes advanced engine management software to monitor, control and protect the engine utilizing self-diagnosing 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 system electronically protects the engine during cold starts, high altitude operation, air filter plugging, and high exhaust temperature.

Oil Renewal System (optional)

Oil renewal system meters and injects used engine oil from the crankcase to the engine's fuel return line, extending oil change intervals and increasing machine availability and productivity.

Exhaust Diverter (optional)

Unique muffler/exhaust design transfers heat to the truck body to keep materials from sticking in cold climates. When in the lowered position, the diverter routes the exhaust through the body; when raised, exhaust is diverted through the muffler.

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.

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.

3) Final Drives

Cat final drives work as a system with the planetary power shift 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) to further reduce drive train stress.

Axles

Full floating axles are shot peened to relieve internal stresses and increase durability. Rolled splines also provide increased service life.

Wheels and Rims

Cast rear wheels and Cat center-mount rims are mounted using studs and nuts to minimize maintenance and maximize durability.

Steering System

Hydraulic steering control system is designed for exceptional smoothness and precise control. A separate circuit prevents cross contamination for long life.

Cat Data Link

Electronically integrates machine computer systems to optimize overall power train performance, increase reliability and component life, and reduce operating costs.

Economy Mode

Using the Electronic Technician (Cat ET) service tool, the mechanic can reduce the engine setting to 920 gross horsepower to match loader/crusher availability and conserve fuel.

Transmission Chassis Control (TCC)

TCC uses electronically transferred engine rpm data to execute shifts at preset points for optimum performance efficiency and clutch life. The transmission chassis controller provides integrated functionality, to the following electronic controls:

Electronic Technician (ET)

Cat ET service tool provides service technicians with easy access to stored diagnostic data through the Cat Data Link to simplify problem diagnosis and increase machine availability.
• Cat ET displays the status of all engine parameters, including throttle position, timing and fuel flow.
• Cat ET replaces 13 mechanical tools to perform functions like cylinder cutout checks, injector solenoid tests and timing calibration.

Electronic Monitoring System (EMS III)

EMS III allows the operator to view requested information and utilizes a three-category warning system to alert the operator of abnormal machine conditions. Data can be downloaded via the Electronic Technician (ET) service tool for quick diagnosis and repair.

Optional Attachments

Caterpillar offers optional braking controls that are electronically integrated with the Cat Data Link to enhance retarding, traction and braking performance:

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.

Front/Rear Oil-Cooled Multiple Disc Brakes

Caterpillar four-wheel, forced oil-cooled, multiple disc service brakes are continuously cooled by water-to-oil heat exchangers for exceptional, non-fade braking and retarding performance.

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.

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 brake is applied to all four wheels for superior parking capability on all grades up to 15 percent.

Automatic Retarder Control (ARC) (optional)

ARC electronically controls braking on grade to maintain engine at approximately 1900 RPM (adjustable from 1850-1950 RPM in increments of 10). ARC is deactivated when the operator applies the brakes or throttle.

Traction Control System (TCS) (optional)

TCS electronically monitors and controls rear wheel slippage for greater traction and enhanced truck performance in poor underfoot conditions. If slippage exceeds a set limit, the oil-cooled disc brakes engage to slow the spinning wheel. Torque is then automatically transferred to the wheel with better traction.

Integrated Braking Control (IBC) (optional)

IBC combines Automatic Retarder Control (ARC) and Traction Control System (TCS) into one integrated brake control system for optimum efficiency, performance and reliability.

Cat Data Link

All control modules communicate via the Cat Data Link and work together as an integrated system to maximize production efficiency and extend component life.

Box-Section Design

The 777D frame uses a box-section design, incorporating two forgings and 22 castings in high stress areas with deep penetrating and continuous wrap-around welds to resist damage from twisting loads without adding extra weight.

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 loading and underfoot conditions. The steering system is separate from the main hydraulic system to prevent cross-contamination and overheating from other sources.

Suspension System

Designed to dissipate haul road and loading impacts for longer frame life and a more comfortable ride.

Ride Control

Built-in rebound control and strategically located cab relative to the front axle minimizes the effect of pitch and bounce, resulting in a more comfortable ride, higher productivity and less fatigue.

Ergonomic Layout

The 777D operator station is ergonomically designed for total machine control in a comfortable and productive environment. All controls, levers switches and gauges are positioned to maximize productivity and minimize operator fatigue.

1) Dash

Wrap-around dash puts all controls within each reach of the operator. Backlit displays enhance visibility.

2) Air Suspension Seat

Ergonomically designed, fully adjustable Cat Comfort Air Suspension Seat with adjustable armrests provides optimal driving comfort. A wide, retractable seat belt provides a secure, comfortable restraint.

3) Steering Column

Sport wheel with tilt and telescopic steering provides a comfortable driving position and greater control.

4) Transmission Console

Ergonomic gear shift lever with backlit gear indicators optimize efficiency.

5) Viewing Area

Designed for excellent all-around visibility and clear sight lines to the haul road, the large viewing area enables the operator to maneuver with confidence for greater productivity.

6) ROPS/FOPS Cab

Integral, sound-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 are designed for optimum efficiency and comfort.

8) Storage Compartment

Large compartment located under the trainer seat provides an uncluttered working environment.

9) Trainer Seat

Full-size, fully padded trainer seat features a backrest, wide hip and shoulder room, and seat belt for secure travel.

10) Monitoring System

Electronic Monitoring System (EMS III) features easy-to-read displays for precise machine status information. Data can be downloaded via the Electronic Technician (Cat ET) service tool for quick diagnosis and repair.
• Gauge Cluster maintains a constant display of vital machine functions, including: coolant temperature, oil temperature, brake air pressure, and fuel level.
• Speedometer/Tachometer Module monitors three systems: engine speed, ground speed and actual gear.
• Message Center displays messages requested by operator and advises operator of abnormal machine conditions.

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.

14) Hoist Levers

Four-position electronic hoist system with fingertip control provides low impact body-down snubbing. Mounted next to the operator's seat for ease of operation.

15) Truck Production Management System (TPMS) (optional)

TPMS provides valuable payload and cycle time data to improve productivity.
• Utilizes strut pressure sensors and on-board microprocessor to determine payload weight.
• Delivers consistent, accurate payloads and improves efficiency by minimizing overloading and underloading.
• External lights signal loading tool operator when payload is reached.
• On-board computer stores up to 1,400 cycles for analysis of payload weight, cycle times, distances, and actual cycle dates and times.
• System is accurate within ±5% under normal loading conditions over a normal shift.

Radio Ready

Cab is prewired with power converter, speakers, wiring harness, antenna and provision for add-on communication systems.

Product Link Ready

Optional Product Link system provides a two-way communication flow of vital machine data and location information between the dealer and the customer. Product Link provides updates on service meter hours, machine condition, machine location as well as integrated mapping/route planning.

Cat Truck Bodies

Caterpillar offers three specific body styles to help customers obtain the lowest cost-per-ton hauling solution.
• Dual-Slope
• Flat Floor (custom)
• Mine Specific Design (MSD) (custom)

Body Selection

Selection of the right body depends on material and haul road conditions. The better the match of body to application, the greater the efficiency. Your Cat dealer can help you select the right body system for your site specific application.

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 support.
• Full-Length Stringers create strength and rigidity throughout the bed.
• Box Section Beams offer increased durability 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.

1) 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 m3 (78.6 yd3) capacity allows operators to achieve rated payload in 2900 lb/BCY material.

2) Flat Floor Body (custom)

The flat floor design with slight incline delivers excellent payload capacity, high dump clearances and smooth, controlled dumping.
• Flat floor design provides consistent wear characteristics on body tail.
• 12 degree forward body slope provides good load retention on better maintained haul roads.
• 400 Brinell steel on surfaces provides excellent wear.
• Maintains a load height of 4571 mm (15 ft) to match a variety of loading tools.
• 60.6 m3 (78.7 yd3) capacity allows operators to achieve rated payload in 2900 lb/BCY material.

3) Mine Specific Design (MSD) Body (custom)

The MSD body is based on the flat floor design and is customized to maximize payload potential and minimize cost-per-ton. Each MSD body design begins with a detailed mine site profile to develop a body suitable for a mine's individual needs.

Body Liners

A variety of liner options are available to save weight and help extend the body system's life. Wear surfaces and liners are equipped to handle tough impact loads while resisting abrasion. Wear plates deliver long life in high wear areas.

Efficient Combination

The 777D is designed to deliver full payloads and fast cycle times. When properly matched, Cat trucks and loading tools create an efficient combination to maximize volume of material moved at the lowest operating cost.

Machine Configuration Options

Choose from various truck configuration options to match specific site and hauling conditions.

Body Options

Choose from a full line of standard and custom body designs and wear protection based on material, loading tools and site conditions.

Tire Options

Choose from a range of tire options to match specific underfoot conditions, haul road conditions and hauling distances to maximize performance and extend tire life.

Systems Approach

The Caterpillar systems approach means increased efficiencies through common design. Cat haul trucks, loaders and excavators use common engines, parts and operator environments which add up to more uptime, greater productivity and lower maintenance costs.

Loader Match

Designed to work as an optimum pass/match system, the 777D is best sized to match the following Caterpillar loading tools: Wheel Loaders
• 990 II — 6 pass/match
• 992G — 4 pass/match Mass Excavators
• 5110B ME — 6-7 pass/match
• 5130B ME — 5 pass/match
• 5230B ME — 3-4 pass/match Front Shovels
• 5130B FS — 4-5 pass/match
• 5230B FS — 3-4 pass/match

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)

Extends oil change intervals and reduces waste oil handling by continuously burning oil from the engine oil pan through normal engine operation. Make-up oil must be continually added to compensate for oil burned.

Scheduled Oil Sampling

S•O•SSM sampling valves speed sampling and analysis reliability.

Pressure Test Points

Disconnect valves are conveniently located throughout the hydraulic systems for easy pressure testing.

Air Filters

Radial seal air filters are easy to change, reducing time required for air filter maintenance.

Sealed Electrical Connectors

Electrical connectors are sealed to lock out dust and moisture. Harnesses are braided for protection. Wires are color coded for easy diagnosis and repair.

Spin-on Filters

Spin-on filters for fuel and oil systems reduce changing time and help assure clean, tight seals.

On-Board Diagnostic Systems

EMS III continuously checks all critical machine functions and components, and helps locate faults quickly for faster repair. Electronic control system enables quick diagnosis of engine conditions and effective maintenance and repairs utilizing the Electronic Technician (ET) service tool.

Machine Selection

Make detailed comparisons of the machines under consideration before purchase. Cat dealers can estimate component life, preventive maintenance cost, and the true cost of lost production.

Purchase

Look past initial price. Consider the financing options available, as well as day-to-day operating costs. This is also the time to look at dealer services that can be included in the cost of the machine to lower equipment owning and operating costs over the long run.

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 the cost involved so you can make the right choice.

www.CAT.com

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