Cat 777D

®

777DOff-Highway Truck

Maximum GrossMachine Weight 161 000 kg 355,000 lbs.

SAE 2:1 Capacity 60.1 m3 78.6 yd3

Payload Capacity 90.9 mt 100 tons

Cat® 3508B EUI EngineGross Power 746 kW 1000 HPFlywheel power 699 kW 938 HP

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Engine & Power Train IntegrationThe Caterpillar Data Link electronicallycombines engine, transmission andbrake information to optimize overalltruck performance. The ElectronicTechnician (ET) gives access to storeddiagnostic data, significantly reducingdowntime. pg. 6-7

Oil-cooled Rear Disc BrakesCaterpillar forced oil-cooled, multipledisc brakes are continuously cooled forexceptional, non-fade braking andretarding. The optional AutomaticRetarder Control, Traction ControlSystem (TCS) and Front Oil CooledBrakes enhance truck performance andincrease productivity. pg. 8

777D Off-Highway TruckEngineered for performance, designed for comfort, built to last.

Power TrainThe power train is designed and builtby Caterpillar, starting with the hightorque rise, electronic Caterpillar®

3508B diesel engine, through the seven-speed power shift transmission. Thisassures the highest standards forquality, performance and efficiency.Matched power train components resultin less shifting, faster speeds and greaterreliability. pg. 4-5

Top performance.A truck for high production and low cost-per-tonhauling in off-highway applications.

Reliable, durable operation.Rugged construction and easy maintenanceguarantee long life with low operating costs.

StructuresCaterpillar truck frames are built toresist the most severe twisting, highimpact applications. Mild steel providesflexibility, durability and resistance toimpact loads even in cold climates. Theframe incorporates 22 castings and 2forgings in high stress areas, providingtwo-and-one-half to three times thestrength of equivalent sized fabricatedstructures. pg. 10

Operator’s StationThe 777D operator’s station isergonomically designed for totalmachine control in a comfortable andproductive environment. All controls,levers, switches and gauges arepositioned to maximize productivity.The cab includes a large storagecompartment, air suspension seat andadvanced electronic monitoring system.pg. 12-13

Steering & SuspensionFront cylinders serve as steeringkingpins for tight turning radius andbuilt in camber and caster. Largediameter, low pressure suspensioncylinders provide long life and lowoperating and rebuild cost.pg. 15

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EngineThe eight-cylinder, turbocharged and aftercooled 3508B engine with EUI fuel system is builtfor power, reliability and economy, and meets all worldwide emissions standards.

The Cat 3508B diesel engine is a four-stroke design and uses long, effectivepower strokes for more complete fuelcombustion and optimum efficiency.The 3508B is designed with highdisplacement and a low speed rating forlong hours of service betweenscheduled overhauls and loweroperating costs.

The 23% torque rise provides highlugging force during acceleration andless down-shifting on grade or in roughunderfoot conditions. The torque curveeffectively matches the transmissionshift points to provide maximumefficiency and faster cycle times.

Unmatched Combustion Efficiency:1 Electronic Unit Injection (EUI) is a

proven high-pressure, direct injectionfuel system. This systemelectronically monitors operator andsensor inputs to optimize engineperformance.

2 Deep crater piston and low crevicevolume provide a more efficientcombustion. (see bottom right photo)

3 Separate Circuit Aftercooling (SCAC)allows the aftercooler circuit tooperate cooler than the jacket watertemperature for denser air charge andimproved combustion.

� Streamlined air system improvescombustion system efficiency anddecreases exhaust temperatures.

� 3508B EUI has 2% improved specificfuel consumption over the former3508 EUI.

� Reduced NOx and particulate levels.

Proven reliability and durability byelectronically protecting the engineduring:� Cold starts� High altitude operation� Operation with plugged air filters

Easier maintenance and repair throughmonitoring key functions and loggingcritical indicators. Electronic diagnosticaccess is possible with a single tool, theElectronic Technician (ET).

4 Valve rotators

5 Oil cooler

6 Self-aligning roller followers

7 Steel-backed copper bondedbearings

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The Cat seven-speed power shifttransmission, matched with the direct-injection Cat 3508B diesel engine,provides constant power over a wideoperating speed range for maximumefficiency.

1 The lock-up torque convertercombines the maximum rimpull andcushioned shifting of torque converterdrive with the efficiency andperformance of direct drive.

� It locks up at approximately 6.4 km/h(4.0 mph) for superior power trainefficiency by delivering more powerto the wheels.

� The lock-up clutch will quicklyrelease and re-engage during shifts tomaintain power wind-up andmaximum power train efficiency forsmooth shifting, improvedtransmission life and increasedoperator comfort.

� Provides maximum rimpull of53 300 kg (117,500 lb) to providehigh gradeability and fastacceleration.

2 The seven-speed, planetary powershift transmission utilizes amodulating pressure valve to regulateclutch pressure rise and fall to easeclutch engagement. This reducesshock loads on power traincomponents.

� Large diameter clutches and robustplanetary gears and bearings.

� Patented rotating clutch pressure sealsminimize drag losses and improvereliability.

� Separate transmission, hydraulic andsteering oil reservoirs prevent crosscontamination.

� 35% gear splits between all gearsmatch Cat engine design for optimumuse of engine power with minimizedshifting and torque converter use.

3 Final drive and differential torquemultiplication of 19.16:1 furtherreduces stress on the drive train.

Drive shaft. The transmission ismounted directly to the rear axlehousing, so the 777D requires only onedrive shaft and one set of U-joints

Full floating axles are shot peened torelieve internal stresses and increasedurability. Rolled splines also provideincreased service life.

Removable final drives and wheelgroups improve serviceability fordecreased downtime.

Cast rear wheels and Cat center-mountrims are mounted using studs and nuts(not wedge-mounts) to minimizemaintenance and provide outstandingdurability.

Power TrainCompletely designed and manufactured by Caterpillar to assure maximum efficiency, highquality, long service life and low operating costs.

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Engine/Power Train IntegrationCombining the electronic Engine Control Module (ECM) with the Caterpillar Transmission Chassis Controller (TCC) allows critical power train components to work more intelligently.

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The Caterpillar exclusive electronicintegration optimizes overall powertrain performance, reliability andcomponent life for reduced power trainoperating costs.

The CAT Data Link electronicallyintegrates the machine’s computersystems, which allows communicationsand provides the following benefits:� Controlled Throttle Shifting – Engine

RPM is regulated during a shift toreduce driveline stress for smoothershifts and longer component life.

� 920 GHP Option – The mechanic canselect a 920 ghp engine setting usingthe Electronic Technician (ET). Thisallows matching to crusher andloader limitations with possible fuelsavings.

� Directional Shift Management –Regulates engine speed duringdirectional shifts to prevent damagecaused by high speed directionalchanges.

� Neutral Coast Inhibitor – Helpsprevent the transmission fromshifting to neutral at speeds above 6.4 km/h (4.0 mph).

� Body Up Shift Inhibitor – Helpsprevent the transmission fromshifting above a pre-programmedgear without the body fully lowered.

Improved Diagnostics/Serviceability.The electronic engine and transmissioncontrols provide enhanced diagnosticcapability. The ability to store bothactive and intermittent indicators willsimplify problem diagnosis and totalrepair time, resulting in improvedmechanical availability and loweroperating cost.� Access to diagnostic data is made

easy through the use of a singleservice tool - ET.

� ET accesses data stored in the engineand transmission controls via the CatData Link. Information on engineboost pressure, fuel consumption,engine speed and transmission shiftdata can be retrieved by ET.

� ET is also a powerful diagnostic tool.It replaces 13 mechanical tools toperform functions like cylinder cut-out checks, injector solenoid test andtiming calibration.

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� Traction Control System (TCS)improves performance in poorunderfoot conditions byelectronically monitoring andcontrolling wheel slippage.

� Integrated Brake Controller (IBC)combines ARC and TCS, reducingthe number of electronic componentsand electrical lines.

1 Electronic Technician

2 Cat Data Link

3 Sensors

4 Engine Control Module

5 Transmission Chassis Controller

6 Automatic Retarder Control

Traction Control System

Integrated Brake Control

7 Electronic Monitoring

System (EMS II)

8 Transmission

9 Oil-Cooled Brakes

Electronic Monitoring System (EMS II)allows the operator to view requestedinformation and utilizes a three-category warning system to alert theoperator to abnormal machineconditions.

Caterpillar offers optional attachmentsthat integrate with the CAT Data LinkSystem.� Automatic Retarder Control (ARC)

works with the other electroniccomponents to automatically controlretarding on grade while maintainingsafe engine rpm.

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Oil-cooled Disc BrakesReliable braking lets the operator concentrate on the work.

Caterpillar forced oil-cooled, multipledisc brakes are continuously cooled forexceptional, non-fade braking andretarding. The optional AutomaticRetarder Control and Traction ControlSystem utilize the oil-cooled brakes toenhance truck performance and increaseproductivity.

Oil-cooled disc brakes are designed andbuilt for reliable, adjustment-freeoperation providing superiorperformance and service life incomparison to shoe-type and dry-discsystems.

An oil film prevents direct contactbetween the discs. This absorbs thebraking forces by shearing oil andcarries heat away, extending brake life.

A Caterpillar patented, two-pistondesign combines the service, secondary,parking brake and retarding functions.� The primary piston is hydraulically

actuated and provides both serviceand retarding functions.

� The secondary piston is spring-applied and is held in the disengagedposition by hydraulic pressure.

� In the event hydraulic systempressure drops below a certain level,the spring-applied secondary pistonwill automatically apply the brakes.

Front oil cooled brakes (standard) seephoto below� Provides superior braking and

handling in slippery underfootconditions.

� Splits braking requirements between two axles to improve traction.

� Longer downhill hauls benefit fromreduced rebuild frequency.

The retarding system has an intermittentrating of 1864 kW (2500 hp) and acontinuous rating of 895 kW (1200 hp).� When retarding, the engine runs

against compression and fuel input iscut off; enhancing the efficiency ofthe machine.

� Retarding forces are absorbed at thewheels so there are no drive linestresses associated with a drive lineretarding system.

1 Parking/Secondary Piston

2 Service/Retarding Piston

3 Friction Discs

4 Steel Plates

5 Actuating Springs

6 Cooling Oil In

7 Cooling Oil Out

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ARC Production Advantages

*

10Time (Seconds)

20 30 40 50 60

Automatic Retarder Control(Maintains Engine RPM between 1850-1950)

Manual Retarder Control(Wide Variation in Engine RPM)

* Optimum Engine RPMEngi

ne S

peed

(RPM

)

700

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Automatic Retarder Control/ARC (Optional)Electronically controls braking on grades for improved engine and brake component life.

Traction Control System (TCS) (Optional)Electronically controls wheel slippage for improved performance.

The Automatic Retarder Control (ARC)electronically controls braking on gradeto maintain approximately 1900 engineRPM (engine RPM is adjustable from1850-1950 RPM in increments of 10RPM). ARC is deactivated when theservice brakes or throttle are applied.An auto resume feature reactivates thecontrol.

Engine overspeed protection. ARC willautomatically activate when enginespeed exceeds factory preset levels,regardless of other operator inputs,including when the system is turned“off”, to help protect the engine fromoverspeed damage.

ARC results in...� Increased operator efficiency with

faster downhill speeds. Bymaintaining consistently higherengine speeds, overall truck speedwill be higher than a manuallycontrolled truck.

� Excellent controllability and reducedoperator effort. Automatic brakemodulation provides a smoother ride,better control in slippery conditionsand allows the operator to focus moreon truck operation.

Monitors wheel slip. If wheel slipexceeds the set limit, the oil-cooled discbrakes are automatically applied to slowthe spinning wheel.

Provides operator awareness throughan in-dash indicator, signifying TCS isengaged.

Utilizes normal differential action toprovide superior maneuvering in poorunderfoot conditions.� Reduces tire scuffing when compared

to positive lock differentials used onother systems.

Divides torque equally to reduce stresscreated on final drives and axles whentorque is transferred to one side.

Back-up design should the sensors fail,normal differential action is stillavailable to maintain control andsteering.

� Improved component life fromreduced torque and temperaturefluctuations in the brake system.

� Faster troubleshooting and diagnosiswith self-diagnostic capability and theability to communicate with ETthrough the Cat Data Link.

NOTE: Caterpillar offers Integrated Braking Control (IBC) (optional), combining ARC and TCS into one electronic control.

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StructuresThe backbone of the Cat truck.

The 777D frame uses a box-sectiondesign, incorporating 22 castings inhigh-stress areas, with deep-penetratingand continuous wrap-around welding.Mild steel is used throughout.

� Mild steel provides flexibility,durability, and resistance to impactloads even in cold climates.

1 Castings have large radii withinternal reinforcing ribs to dissipatestress. Castings move welds tolower stress areas and provide twoto three times the strength ofequivalent-sized fabricatedstructures.

The 777D frame provides for ease ofserviceability.

� The box-section frame allows simpleaccess to power train components.This “open design” reduces overallremoval and installation time,lowering repair costs.

� Transmission access is excellentunder the raised and pinned body.

� Repairs can be made without pre-heating in ambient temperaturesabove 16° C (60° F) using readilyavailable welding supplies.

2 The Rollover Protection Structure(ROPS) attaches securely to fourcastings welded into the frame.

The suspension system is designed todissipate haul road and loading impactsfor extended frame life.

� Four, independent, variable-rebound,suspension cylinders absorb shocks.

� Rear cylinders allow axle oscillationand absorb the bending and twistingstresses.

� Front cylinders, mounted to theframe, serve as steering kingpins,providing excellent maneuverabilityand reduced maintenance. Caster andcamber are preset.

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Truck BodyRugged, durable body is built to perform well in the toughest mining applications.

The 777D canopy extends to the front ofthe truck for excellent radiator and cowlprotection.

The 777D 78.6 yd3 (60.1 m3) body providesthe capacity to achieve rated payload in2,900 lb/BCY material and maintainexcellent load retention.

Body design maintains a low loadheight [4288 mm (14' 1")] to allow faster,more confident wheel loader operation.

Dual-Slope floor design has excellentloading and hauling characteristics:

� 8° “V” bottom for better loadcentering and reduced shock load.

� 10° forward body slope and 18°ducktail help eliminate spillage onthe grade.

� Five-sided beams join sidewall andfloor junctions to resist impactloading and sustained haulingstresses.

� Added impact resistance from boxsection beams in floor, sidewalls, toprail, corner and cab canopy areas.

� Two-stage dump cylinders for fastdump and body return times. Fewerseals for less chance of leakage.

Body width provides completecoverage of the tires without the needfor rock deflectors.

Liner (option) material is 400 Bhn,through-hardened, 130,000 psiminimum yield strength steel. Thismaterial has excellent wearcharacteristics and impact resistance.

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The 777D operator station is ratedhighly by operators. Everything neededfor top performance is at the operator’sfinger tips.

1 The wraparound dash panel isprovided in an easy line-of-sightarrangement, using LED backlitrocker switches.

2 The Caterpillar Comfort AirSuspension seat is standard. Theseat is fully adjustable and includesan adjustable right-hand armrest.

3 Tilt/telescoping steering wheelwith ergonomic grip improvescomfort and control.

� New steering system reducesoperator effort by 55 percent.

� Enhanced turn signal lever withhigh beam actuator and electricwindshield wiper controls.

� Ergonomically designed retarderlever.

4 Transmission console has LEDbacklit gear numbers andergonomic shift knob.

5 Exceptional all-around visibilityreduces fatigue and improvesproductivity.

6 Integral, sound-suppressedROPS/FOPS Cab is resilientlymounted, providing a quiet,protected work environment.

� Radio-ready cab with speakers,wiring harness, antenna andmounting bracket.

7 Front brake cut-out switchincreases front brake componentlife.

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Operator StationControl ease and comfort maximizes productivity.

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8 Large storage compartment0.10 m3 (3.5 ft3) is located under thetrainer’s seat.

9 Trainer’s seat with increasedhip/shoulder room, back rest, andretractable seat belt.

10 Electronic Monitoring System(EMS-II) provides critical data. Thesystem features three separatedisplays:

� A four-gauge cluster with coolanttemperature, oil temperature,brake air pressure, fuel level.

� Tachometer, digitalspeedometer/actual gearindicator.

� Message center module.

11 A standard heater and optional airconditioner with four-speed fan andnine vents.

12 Ergonomically designed foot pedalsfor increased operator comfort.

� Secondary brake moved to floor.

13 Electric power window forsimplified operation.

14 Electrohydraulic hoist lever isfinger tip actuated and provideslow-impact, body-down snubbing.

15 Truck Production ManagementSystem (TPMS) (optional) providespayload and cycle time data.

� Cat developed technologyutilizes strut pressure sensors andan on-board microprocessor todetermine payload weight.

� Accurate under normal loadingconditions to within ±5 percentover a normal operating shift.

� Delivers consistent accuratepayloads and improves efficiencyby minimizing overloading andunderloading.

- On-board computer stores1,400 cycles for furtheranalysis of: payload weight,cycle segment times, cyclesegment distances and actualclock time and date of eachcycle.

- External lights signal loadingtool operator when payload isreached.

- Internal troubleshooting andfault recording for easiermaintenance.

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� Internal troubleshooting and faultrecording for easier maintenance.

Accurate under normal loadingconditions to within ± 5% over a normaloperating shift.

TPMS gets consistent, accuratepayloads by minimizing overloadingand underloading. It maximizes longterm production and machine liferesulting in lower cost per ton.

Engine Prelubrication reduces enginewear by automatically building oilpressure before cranking over theengine.� Automatically fills engine oil filters,

oil galleries and ensures componentssuch as the crank, cam, turbochargersand rockers have lubrication prior toengine cranking.

� Minimizes wear on enginecomponents caused by dry or coldstarts. Also allows fast, easy refill ofoil into filters and galleries followingroutine oil changes.

Attachment OptionsAllow you to customize the 777D for your specific application.

Exhaust Diverter provides an exhaustmuffler and diverter valve arrangement. � Muffler/exhaust design allows truck

body heating to occur with the bodylowered and constant soundsuppression with the body raised.

Truck Production Management System(TPMS) enhances truck and loadereffectiveness for improved fleetproductivity and reduced operating andmaintenance costs.

Cat developed technology utilizes strutpressure sensors and an on-boardmicroprocessor to determine payloadweight accurately.

Maximizes truck production whileavoiding future costs and downtimerelated to overloading. Maximizes yourlong-term investment through betterload control and cycle data.� External lights on both sides of truck

signal loading tool operator whenproper load is reached.

� On-board computer stores 1400cycles for further analysis; payloadweight, cycle segment times, cyclesegment distances and actual clocktime and date of each cycle.

� In standard operation, the exhaustdiverter routes exhaust through thebody. While the body is raised, thediverter directs exhaust through themuffler.

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Variable flow hydraulic steering systemis completely separate from mainhydraulics.

Four independent, variable-reboundsuspension cylinders provide excellentride characteristics.

Rear cylinders allow axle oscillation.Bending and twisting stresses areabsorbed rather than transmitted to themain frame.

Supplemental steering. Batterypowered system automatically engageswhen needed.

Durable, simple design utilizing largediameter bore and low pressurenitrogen/oil. This design provides longlife and low operating and rebuild cost.

Front cylinders mount to frame. Serve assteering kingpins for tight turningradius, good maneuverability andreduced operating cost.

Front spindles and wheels are rigidlymounted to the cylinder rods.� Tire wear is minimized, lowering

costs.� Decreased maintenance costs by

eliminating camber and casteradjustment.

Nitrogen

Reboundchamber

Cylinderhousing

Piston

Steering and SuspensionRugged suspension and steering systems perform on rough haul roads and uneven terrain, shift-after-shift,day-after-day.

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Ground-level access providesconvenient servicing to all tanks(except steering), filters, all lube pointsand compartment draining.

The maintenance platform providesaccess to engine oil level, air filters,steering hydraulic tank and batterycompartment.

On-board diagnostics with EMS-IIprovides the machine operator with athree-category warning system andquick access to stored diagnostic data.

Off-board diagnostics with ET allowsservice technicians access to storeddiagnostics data reducing downtimeand lowering operating costs.� ET stores engine parameter

information such as timing, throttleposition, and fuel flow.

� Tranmissiom data is availablethrough ET via access to the CAT Data Link System.

A ground-level battery disconnectswitch facilitates safe, convenientservicing and maintenance.

Radial seal air filters are easy tochange, reducing air filter maintenancetimes.

Quick coupler pressure taps located inall hydraulic systems provide clear,quick pressure checks. S•O•S Oil andCoolant Sampling Valves make fluidsampling quick, clean and easy.

Sealed electrical connectors lock outdust and moisture. The color-coding forwires is standard for the entire Catproduct line.

Serviceability/Total Customer SupportWhen you buy a Caterpillar machine, you also get the Caterpillar total commitment tocustomer support.

Machine management service. Catdealers help manage your equipmentinvestments with:� Vehicle systems analysis to match

the right machine to the job.� Preventative maintenance programs.� S•O•S Fluid Analysis and Technical

Analysis programs.� Repair option analysis.� Training for operators and

mechanics.� TPMS data analysis.

Parts availability. The caterpillarworldwide computer network locatesparts instantly to minimize machinedowntime.

Literature support. Caterpillar manualsare easy to use and help provide the fullvalue of an equipment investment.

17777D Off-Highway Truck specifications

TransmissionCaterpillar seven-speed, electronicallycontrolled, automatic power shifttransmission.

Maximum travel speeds (standard

27.00 R49)

km/h MPH

Forward 1 10.5 6.5

2 14.3 8.9

3 19.3 12.0

4 26.0 16.2

5 34.9 21.9

6 46.6 29.4

7 60.4 39.9

Reverse 11.9 7.4

Features

� seven speeds forward and one reverse� reverse is torque converter driven� first gear has both torque converter

drive and direct drive� second through seventh gears are

direct drive� single-lever shift control provides

automatic shifting in all gears up tothe one selected by the control lever

� each shift is individually modulatedfor maximum smoothness

� separate hydraulic circuit with cooler� electronic control has built-in

diagnostics and facility code memory,event memory and programmablefeatures

� body up shift limiter� Controlled Throttle Shift (CTS)� Directional Shift Management� Neutral Coast Inhibitor

BrakesMeets the SAE J1473 OCT90, ISO 3450-1996 (E) standards up to 161 021 kg(355,000 lb) gross operating weight.

EngineFour-stroke cycle, eight cylinder 3508B twin-turbocharged and aftercooled dieselengine.

Ratings at 1750 RPM* kW HP

Gross power 746 1000

Net power 699 938

The following ratings apply at 1750RPM when tested under the specifiedstandard conditions for the specifiedstandard:

Gross power kW HP PS

ISO 3046-2 746 1000 —

Net powerCaterpillar 699 938 —

ISO 9249 699 938 —

EEC 80/1269 699 938 —

SAE J1349 (1/90) 699 938

DIN 70020 — — 972

Max torque:4713 Nm (3,476 lb-ft) @ 1300 rpm

Torque rise:23 percent

DimensionsBore 170 mm 6.7 in.Stroke 190 mm 7.5 in.Displacement 34.5 liters 2105 cu in.

*Power rating conditions

� based on standard air conditions of25°C (77°F) and 99 kPa (29.32 in Hg)dry barometer

� used 35°C API gravity fuel having anLHV of 42 780 kJ/kg (18,390 Btu/lb)when used at 30°C (86°F) [ref. a fueldensity of 838.9 g/L (7.001 lb/U.S.gal)]

� net power advertised is the poweravailable at the flywheel when theengine is equipped with fan, aircleaner, muffler and alternator

� no derating required up to 2288 m(7,500 ft) altitude

Features

� high pressure unit injection� full electronic control� two-piece piston with steel crown

(three rings) and thermally isolatedaluminum skirt

� copper-bonded crankshaft bearings� hardened crankshaft journals� two hard-faced inlet and exhaust

valves per cylinder, valve rotaters andhard alloy-steel seats

� self-aligning roller followers on camshaft

� dry-type radial seal air cleaners withprimary and secondary elements andprecleaner

� direct-electric 24-volt starting systemwith 100-amp alternator and four 190-amp-hour, low-maintenance, high-output, 12-volt batteries

� optional air starting arrangementavailable

Final DrivesPlanetary, full-floating.

Ratios

Differential 2.74:1

Planetary 7.00:1

Total reduction 19.16:1

Features

� retarding system:continuous rating 895 kW (1200 HP)intermittent rating 1864 kW (2500 HP)

� secondary braking-spring applied, hydraulically released,oil cooled disc brakes-all brakes will activate as part of the secondary system

� parking brakes-spring-applied, hydraulically released-uses wet disc brakes in service system-toggle switch activated

� standard front oil-cooled-forced-oil-cooled-air-over-oil-actuated multiple diskbrakes

-improved control in slipperyconditions

Brake surface

front (opt.) 2787 cm2 (432 in2)

front (std.) 40 215 cm2 (6235 in2)

rear 102 116 cm2 (15,828 in2)

18 777D Off-Highway Truck specifications

FrameFull box-section with torque tubecrossmember.

Features

� integral front bumper� front box beams for suspension

cylinder and ROPS support.� box-section rear crossmember for

body and ROPS support withattachment points for maintenanceplatform and rear engine platformsupport

� castings are used to provide additionalstrength in critical stress areas

� mild-steel plates [290 MPa (42,000 psi)minimum yield strength] and castings[241 MPa (35,000 psi) minimum yieldstrength] provide:

- flexibility

- durability

- easy field maintenance

Exterior Sound RatingThis machine, in a standardconfiguration, when measured andoperated as per the prescribed modes inANSI/SAE J88 JUN86, has a 15 msound pressure level of 90dB(A) for themode that gives the highest level.

ROPSIntegral ROPS cab is standard.

� ROPS (Rollover Protection Structure)offered by Caterpillar for the machinemeets ROPS criteria SAE J1040MAY94, ISO 3471-1997

� When properly installed andmaintained, the cab offered byCaterpillar, when tested with doorsand windows closed as per work cycleprocedures specified in ANSI/SAEJ1166 MAY90, results in an operatorsound exposure Leq (equivalent soundlevel) of 78 dB(A)

� This operator A-weighted soundexposure level can be used inconjunction with OSHA, MSHA andEEC Occupational Noise ExposureCriteria

Body HoistsTwin, two-stage hydraulic cylindersmounted outside the main frame, doubleacting in second stage.

Features

� power raise in both stages and powerdown in first stage

� pump flow at high idle is 405.5 L/min (119 gpm).

� relief valve setting is 189.0 bar/18 962 kPa (2750 psi)

� body raise time (at high idle) is 15 seconds

� body lower time

- float 13 seconds

- power down at high idle 13 seconds

SteeringSeparate hydraulic system.

Features

� twin, double-acting cylinders� front suspension cylinders serve as

kingpins� automatically controlled, electric

supplemental steering system asstandard (meets SAE J1511 OCT90and ISO 5010-1992) (E)

� turning diameter on front wheel track.

- 25.3 m (83')� machine clearance turning circle

- 28.4 m (93'2")� steering angle (left or right) 31.8°� separate hydraulic system prevents

cross-contamination� lower steering wheel effort and

reduced steering wheel cycle timeswith a new variable-displacementpump

NOTE: The turning diameter andmachine clearance turning circledistances shown are measured in acontrolled environment and may differfrom actual field measurements.

Service Refill CapacitiesU.S.

L Gallons

Fuel tank 1137 300

Cooling system 325 86

Crankcase 124 33

Differentials and final drives 329 87

Steering Tank 57 15

Steering System(includes tank) 84 22

Brakes, Converter, Hoist,Hydraulic Tank 220 58

Brakes, Converter, Hoist System (includes tank) 415 110

Transmission Hydraulic tank 81 21.5

Transmission System(includes tank) 138 36.5

SuspensionIndependent, self-contained, oil-pneumatic suspension cylinder on eachwheel.

Effective cylinder stroke:

Front 318 mm 12.5"

Rear 165 mm 6.5"

Rear axle oscillation ±5.4°

19777D Off-Highway Truck specifications

Gradeability/Speed/Rimpull

To determine gradeability performance:Read from gross weight down to thepercent of total resistance. Totalresistance equals actual percent gradeplus 1% for each 10 kg/metric ton(20 lb./U.S. ton) of rolling resistance.From this weight-resistance point, readhorizontally to the curve with thehighest obtainable gear, then down tomaximum speed. Usable rimpull willdepend upon traction available andweight on drive wheels.

20

120100

70

50

30

20

10

5

3

2

1

0.50

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

mph

lb x 1000kg x 1000

lb x 1000

kg x 1000

5 10 15 20 25 30 35 40 45 50

0.30

0.50

1

2

3

5

10

20

30

4050

50 100 150 200 250 300 400 500

30 40 50 60 80 100 150 200

Gross Weight

Speed

Rim

pull

Tota

l Res

ista

nce

(Gra

de p

lus

Rolli

ng)

1st Gear E L

1st Gear

2nd Gear

3rd Gear4th Gear

5th Gear

6th Gear

7th Gear

30% 20%

15%12%10%8%6%

4%

2%

Torque Converter DriveDirect Drive

Empty Weight161 000 kg-Load (355,000 lbs)

0 50 100 150 200 300250 350 400 450 lb x 1000

0 30 60 90 120 150 180 210 kg x 1000

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

0 5 10 15 20 25 30 35 40 45 50 mph

Speed

Effe

ctiv

e Gr

ade

(Fav

orab

le)

Gross Weight

Continuous Grade Length

10%

5%

15%

20%

25%30%

5th Gear

4th Gear

3rd Gear

2nd Gear

1st Gear

6th Gear7th Gear

20 777D Off-Highway Truck specifications

To determine retarding performance: Add lengths of alldownhill segments and, using this total, refer to properretarding chart. Read from gross weight down to the percenteffective grade. Effective grade equals actual % grade minus1% for each 10 kg/metric ton (20 lb./U.S. ton) of rollingresistance. From this weight-effective grade point, readhorizontally to the curve with the highest obtainable gear, then

down to maximum descent speed brakes can properly handlewithout exceeding cooling capacity. The following charts arebased on these conditions: 32°C (90°F) ambient temperature,at sea level, with 27.00-R49 tires and a properly maintainedcooling system.

NOTE: Select the proper gear to maintain engine RPM atthe highest possible level, without overspeeding the engine.If cooling oil overheats, reduce ground speed to allowtransmission to shift to the next lower speed range.

Retarding Performance

Empty WeightOperating Weight161 000 kg (355,000 lbs)

21777D Off-Highway Truck specifications

Retarding Performance

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

0 30 60 90 120 150 180 210 kg x 1000

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

0 5 10 15 20 25 30 35 40 45 50 mphSpeed

Effe

ctiv

e Gr

ade

(Fav

orab

le)

Gross Weight

Grade Distance — 450m (1500 ft.)

10%

5%

15%

20%

25%30%

4th Gear3rd Gear

2nd Gear

1st Gear

6th Gear5th Gear

7th Gear

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

0 30 60 90 120 150 180 210 kg x 1000

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

0 5 10 15 20 25 30 35 40 45 50 mphSpeed

Effe

ctiv

e Gr

ade

(Fav

orab

le)

Gross Weight

Grade Distance — 600m (2000 ft.)

10%

5%

15%

20%

25%30%

5th Gear4th Gear

3rd Gear2nd Gear

1st Gear

6th Gear 7th Gear

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

0 30 60 90 120 150 180 210 kg x 1000

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

0 5 10 15 20 25 30 35 40 45 50 mphSpeed

Effe

ctiv

e Gr

ade

(Fav

orab

le)

Gross Weight

Grade Distance — 900m (3000 ft.)

10%

5%

15%

20%

25%30%

5th Gear4th Gear

3rd Gear

2nd Gear

1st Gear

6th Gear 7th Gear

0 50 100 150 200 300250 350 400 450 lb x 1000

0 30 60 90 120 150 180 210 kg x 1000

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

0 5 10 15 20 25 30 35 40 45 50 mph

Speed

Effe

ctiv

e Gr

ade

(Fav

orab

le)

Gross Weight

Grade Distance — 1500m (5000 ft.)

10%

5%

15%

20%

25%30%

5th Gear

1st Gear

7th Gear6th Gear

2nd Gear

3rd Gear4th Gear

22 777D Off-Highway Truck specifications

777D

777D777D

4193 mm(13'9")loaded

872 mm(2'10")empty

9569 mm(31'5")

6950 mm(22'10")

4567 mm(15')

empty

4472 mm(14'8")loaded

9780 mm(32'1")

4570 mm(15')

3045 mm(10')

4288 mm(14'1")empty18°

9950 mm(32'8")

1965 mm(6'5")

185 mm(7")

5028 mm(16'6")empty

4933 mm(16'2")loaded

5262 mm(17'3")

5200 mm(17'1")

5524 mm(18'2")

6048 mm(19'10")

4961 mm(16'3")

4173 mm(13'8")

6105 mm(20')

700 mm(2'4")empty

750 mm(2'6")empty

3576 mm(11'9")

49.4°

DimensionsAll dimensions are approximate.

Weights(approximate)

kg lb

Total empty 64 400 141,900Chassis with hoistand body mountinggroup 48 600 107,100

Body, empty 15 800 34,800

Weight distribution:Empty Loaded

Front Axle 47% 33%Rear Axle 53% 67%

BodyDual-slope main floor with "V" bottom.

Features

� 10° forward slope, dual slope designfor excellent load carryingcharacteristics

� 18° ducktail� exhaust heating is standard� load height (empty) 4288 mm (14'1")

CapacityDual slope - 100% fill factor.

m3 yd3

Struck 42.1 55.0

Heaped 3:1 54.4 71.1

Heaped 2:1 (SAE) 60.1 78.6

Heaped 1:1 76.8 100.5

Sidewall plate 10 mm 0.39"

Front plate 12 mm 0.47"

Bottom plate 20 mm 0.79"

Canopy plate 6 mm 0.25"

TiresStandard: 27.00-R49.

� productive capabilities of the 777DTruck are such that, under certain jobconditions, TKPH (TMPH)capabilities of standard or optionaltires could be exceeded and, therefore,limit production

� Caterpillar recommends the userevaluate all job conditions and consultthe tire manufacturer to make propertire selection

23777D Off-Highway Truck specifications

Standard EquipmentNote: Standard equipment may vary. Consult your Caterpillar dealer for specifics.

Air hornAir line dryerAlternator (100-amp)Back up alarmBattery disconnect switch, ground levelBody down indicatorBody mounting groupBody up reverse inhibitorBrakes:

Oil-disc (front/rear)ParkingSecondary

Brake (front) disconnect switchBrake heat exchangerBrake release motor, for towingCab, ROPS:

Insulated and sound-suppressedTinted glassRadio readySun visorCaterpillar Comfort Air

Suspension seatCrankcase guardDrive line guardElectric system, 24-voltElectronic Monitoring System

Electronic Unit Injector engineGauges:

Actual Gear IndicatorAir pressureBrake oil temperatureCoolant temperatureFuelHour meter, electricOdometerSpeedometerTachometer

Heater/defroster 7570 kCal(38,000 Btu)

Hoist lever, fingertip actuatedJump start receptacleLighting system:

Back up lightDome/courtesy lightHazard and directional signals, LEDHeadlights, Halogen, with

dimmerStop and tail lights, LED

Load counterMirrors, right and leftPrecleanerReservoirs (separate):

TransmissionConverter/brake/hoistSteering

RetarderRock ejectorsSeat belts, retractableSeat, passengerSound reduction switch, body upStarting, electricSteering, automatic supplemental,

electricSteering wheel, padded, tilt and

telescopicTires, 27.00-R49, Radial, 2 star (E-4)Transmission, electronically controlled

automatic power shift withdownshift/reverse shift inhibitor,neutralizer during dumping, neutralstart switch, engine overspeedprotection, directional shiftmanagement, programmable top gearand body-up shift limiter and controlthrottle shifting

Vandalism protection locksWindow, electric power (operator)Windshield wipers and washer, electric

intermittent

Optional EquipmentWith approximate changes in operating weights.Note: Optional equipment may vary. Consult your Caterpillar dealer for specifics.

kg lb

Air conditioning 90 198

Automatic Electronic Traction Aid 50 110

Automatic Retarder Control (ARC) 5.9 13

Engine Prelubrication 44 98

Fuel system, fast-fill (Wiggins) 2.3 5

Front Caliper Disc Brakes - 240 - 530

Heater, engine coolant 2.3 5

Body liners [9207 bar/900 mPa(130,000 psi), minimum yield strength]16 mm (.063") floor, 8 mm (0.31")front and sidewalls 5460 12,040

kg lb

Muffler/Exhaust Diverter 77 170

Oil change system, quick service 0.9 2

Starting system, low temperature,includes two additional batteriesand extra starting motor 170 375

Truck Production Management System 60 27

2424

777D Off-Highway Truck

Materials and specifications are subject to change without notice.

www.CAT.com© 1996, 2000 Caterpillar

Printed in U.S.A.AEHQ5140-02 (12-00)Replaces AEHQ5140-01