Caterpillar® 777F Mining Truck

Name

Venue

Date

OverviewCaterpillar® 777F Mining Truck

3

Safety Reminders

3

Emergency Contacts

Fire

•Building: <Phone #>

•Municipal: <Phone #>

Medical

•Building: <Phone #>

•Municipal: <Phone #>

First Responders

•Room <Identify>

•Building <Location and name>

Emergency Information

Alarm Description

• Evacuate

• Take cover

• All clear

Unique Hazards

•Room

•Floor/Building

Emergency Procedures

•Equipment locations

•Evacuation routes

4

Meeting Agenda

4

• History• Product Development Manufacturing & Distribution• Specifications• Features & Benefits• Safety Health & Environment• Equipping Your Truck• Productivity• Serviceability• Product Support

5

Mining Truck Evolution

5

•Over 50,000 construction and mining trucks (769-797) delivered since 1963

•Over 18,000 large mining trucks (777-797) delivered since 1980

Caterpillar’s mining truck experience dates back over 40 years and includes the world’s largest truck

Cat ModelYear

Introuced

770 2004772 1971773 1970775 1992777 1975785 1984789 1986793 1991795 2008797 1998

Update Yearly

6

Field Population

Truck Model

Total Units

Fleet Hours

Highest Hour Unit(As of December 2008)

777 10000+ 350 million 116,000785 2900+ 108 million 139,700789 2200+ 91 million 116,703793 2700+ 100 million 106,891797 350+ 6.6 million 74,000

Update Bi-Yearly

7

Large Mining Truck Worldwide Fleet

Over 18,900 Shipments* (as of Feb. 31st 2009)

38%

North America

20%

Latin America

28%

Asia Pacific,

Indonesia &

Australia

14%

Europe, Africa & Middle

East

*Shipments leaving factory (Percentages reflect 777,785, 789, 793,797, distribution)

Update Bi-Yearly

8

777 Worldwide Fleet

Over 10,000 Shipments

34%

North America

10%

Latin America

26%

Asia Pacific,

Indonesia &

Australia

30%

Europe, Africa & Middle

East

(Percentages reflect 777 distribution since 1980)Update Bi-Yearly

9

Future Mining Truck Market Segmentation

100mt – 390mt

Short TonsMetric Tons

860E (AC)

75171 (DC)

SF32601 (DC)SF31904 (DC)

730E (DC)

793D

75600 (AC)

797B

797F

795F-AC785C

100 109 118 127 154 172 209 218 227 236 245 254 272263 281 290 299 308 318 327136 163 191145 181 200 354336 345 372363 381

110 120 130 140 170 190 230 240 250 260 270 280 300290 310 320 330 340 350 360150 180 210160 200 220 390370 380 410400 420

Unit Rig

MT5500AC

T282B (AC)

789C

HD 1500-7 930E-4 (AC)830E-AC

930E-4SE (AC)

EH3500-ACII EH5000ACII

MT6300ACMT4400ACMT3700ACMT3300AC

TI274 (AC)

960E (AC)

7513 Series (DC) 7530 Series (DC)

793F785D

830E (DC)

7514 Electric (DC)

EH4500-2 (AC)

SF33900 (AC)

10

Future Mining Truck Market Segmentation

90mt Segment

Short Tons

Metric Tons

HD785-5

777F

DP905

TR100

HD785-7

EH1700-3

HD985-5**

* Pre Production ** Japan Only

7757

BH85-1 BH90 BH100DP905

TR100

SRT95*

777D

72 77 82 86 100 10990 10495

80 85 90 95 110 120100 115105

11

777 History

• Cat ® 777 – 1974 – 1985– Over 1,750 sold

• B-Series – 1985 – 1992– Over 1,800 sold

• C-Series – 1992 – 1996– Over 1,040 sold

• D-Series – 1996 – 2006 – Over 3,800 sold

• F-Series– 2006 – Present– Over 1,500 sold

The 777 has continuously evolved to remain the leader in its class

Product Development, Manufacturing & DistributionCaterpillar® 777F Mining Truck

13

6 Sigma & CPS

6 Sigma CPI• Changes processes to enhance product quality• Maintains quality during production and when

product is in the field • Keeps all accountable to deliver a superior

product at all levels

Caterpillar Production System (CPS)• 6 Sigma based method for relentless

improvement• Focuses on 3 processes:

– Core– Governing – Enabling

A methodology that improves product quality, processes throughout the company, and customer satisfaction

14

Design & Engineering

• New Product Introduction (NPI) process

• Concurrent Product and Process Design (CPPD)

• 6 Sigma methodology improves processes and product quality

• Collaborates with Cat design and manufacturing resources worldwide

The 777F was developed by the truck engineering group in Decatur, Illinois using the latest design technologies and

methodologies

15

Research & Testing

• Largest and most sophisticated research and development facility in the industry

• State-of-the-art laboratories, testing facilities, and simulators

• Interacts with design teams at each product facility

Innovation begins at the Caterpillar Technical Center in Mossville, Illinois

… and hits the ground at the Tucson Proving Grounds

•Complete machine cooling evaluations

•On-machine structural evaluations

•Complete machine sound evaluations

•Brake, steering, visibility & government standards

•Performance & machine productivity comparisons

•Machine endurance & reliability evaluations

16

Manufacturing & Assembly

• Close tolerance machining centers• Automated material handling

systems• Extensive welder training• Nondestructive weld testing• Highly trained, experienced

assemblers

From machine shop to assembly line, the 777F and its components are produced using the latest machining technology and a highly

skilled workforce

17

Manufacturing Quality Assurance

• Engineered using computer- generated stress modeling

• Steel castings used in high stress locations

• Rollover fixtures ensure all welding is done horizontally, not overhead

• Ultrasonic weld inspection of all frames

• Caterpillar build cell quality certification

• Precise coordinate measuring• Contamination control, for the entire

process• Laser hardened wheel spindles

Quality control practices have long been built into the Caterpillar manufacturing process, from machining to assembly

18

Distribution & Support

• Caterpillar’s Global Distribution network maintains over 20 parts centers worldwide

• Dealer branch facilities, service trucks, trained technicians, and operator training programs provide customers with full-scale customer support

• Cat Product Support Center offers global training for dealer service technicians

• Global Mining’s Field Assembly Group commissions 793s around the world

When Cat products reach the field, they are supported by an advanced network of parts distribution facilities, dealer service

centers, and technical training facilities

19

777F Component Sources

Caterpillar designs and manufactures all major components of the 777F

C32 Manufactured in Griffin, GA

Bodies also manufactured in Australia & South Africa

20

Completely Caterpillar

• Complete design control over entire truck

• Single-point accountability • Enables Cat to optimize the truck

as a whole rather than by individual component

• Ensures compliance with the high quality standards expected

• Reduces confusion for warranty issues

Design and manufacturing control ensures that the 777F operates as a complete and balanced unit

March 2009 – Decatur Plant

SpecificationsCaterpillar® 777F Mining Truck

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777F Dimensions

9830 mm

32.3 ft6391 mm

20.9 ft

4697 mm

15.4 ft5423 mm

17.8 ft

6081 mm

19.9 ft

912 mm

3.0 ft

5170 mm

17.0 ft

6494 mm

21.3 ft

10 528 mm

34.5 ft

4564 mm

15.0 ft

3031 mm

10.0 ft

912 mm

3.0 ft

1066 mm

3.5 ft

4428 mm

14.5 ft

10 364 mm

34.0 ft

4050 mm

13.3 ft

936 mm

3.1 ft

3576 mm

11.7 ft5223 mm

17.1 ft

5185 mm

17.0 ft

Shown with standard, dual-slope body

23

777 Specifications

Maximum GMW – kg (lb) 163 293 (360,000) 163 293

(360,000)

146 966 (324,000)

Chassis weight1 – kg (lb) 48 870 (107,740) 49 380 (108,860) 45 850 (101,090) Engine model C32 ACERT® 3508B EUI 3508B EUI

Number of cylinders 12 8 8

Displacement – L (in3) 32.1 (1,959) 34.5 (2,105) 34.5 (2,105)

Gross power – kW (hp) 758 (1,016) 746 (1,000) 686 (920)

Flywheel power – kW (hp) 700 (938) 699 (937) 649 (870)

Rated speed – rpm 1,750 1,750 1,750

Engine derates above altitude2 – m (ft) 3658 (12,000) 2288 (7,500) 2 288 (7,500)

Transmission speeds 7 7 7

Top speed, loaded – km/h (mph) 64.5 (40.1) 64.2 (39.9) 64.2 (39.9)

1 Approximate clean chassis with full fuel, hoist, body mounting group and tires. Excludes body weight. Dependent on optional attachments.

2 Approximate altitude only. Changes with barometric pressure variations. Derate above this altitude is 1% per 1kPa

Nominal payload: 90.9 tonnes (100

tons)777F 777D

777C

(77.1 tonnes / 85 tons)

24

777 Specifications

Brake discs per side1 – front 12 12 12

Brake surface, front – cm2 (in2) 40 225 (6,235) 40 225 (6,235) 40 225 (6,235)

Brake discs per side – rear 15 15 12

Brake surface, rear – cm2 (in2) 102 116 (15,828) 102 116 (15,828) 80 400 (12,462)

Front brake disc outside diameter–

mm (in)540 (21.5) 540 (21.5) 540 (21.5)

Rear brake disc outside diameter–

mm (in)715 (28.2) 715 (28.2) 715 (28.2)

Total brake area – cm2 (in2) 142 341 (22,063) 142 341 (22,063) 120 625 (18,697)

Fuel tank capacity – L (gal) 1137 (300) 1137 (300) 946 (250)

Optional fuel tank – L (gal) 1325 (350) 1325 (350) N/A

777F 777D 777C

Oil cooled brakes optional on 777C.

Features & BenefitsCaterpillar® 777F Mining Truck

26

Features & Benefits

• Frame & structures• Steering & suspension• Power train• Cooling system• Brakes & retarding• Operator station• System integration• Body & liners • Tires & rims

The 777F is the premier machine in its class, designed and built by

Caterpillar using components and systems that have evolved through

years of rugged mining applications

27

777F Frame

• Engineered using computer-generated stress modeling

• Forgings and castings used in high stress locations

• Rollover fixtures ensure all welding is done horizontally, not overhead

• All critical welds are ultrasonically tested• High strength low alloy (mild) steel is

highly durable, easy to weld

Caterpillar ®

frames are designed to deliver long service life in rugged

mining applications

28

Structures

Fabrications

Castings

Integral 4-post ROPS

777F frame

29

Integrated Steering & Suspension

• Four-corner independent, nitrogen- over-oil cylinders offer superior performance and ease of service

• Front & rear struts have built-in rebound control to improve ride

• Front cylinders act as axle mounting group

• Turning radius designed to minimize tire wear

Designed by Cat for excellent maneuverability, safe operation, lower operating

costs, and a comfortable ride

Nitrogen

Rebound

Chamber

Cylinder

Housing

Piston

30

Front Axle Steering Components

• Separate steering hydraulic system prevents cross contamination

• Secondary steering meets ISO 5010 up to 120% of target payload

• Twin double-acting cylinders• Steering arm pin retention plate

provides redundant pin retention• Front suspension cylinders serve

as kingpins• Serviceable bracket assembly on

steering box casting saves time at rebuild

• Two tie-rods allow optimum steering geometry

The 777F front suspension is a field proven design with dual tie-rods for optimum steering geometry to help extend

tire life

31

Cat C32 ACERT ™ Technology Engine

• V12 with 700 kW (938 hp) flywheel output and displacement of 32.1 L (1,959 in 3 )

• Compliant with U.S. EPA Tier 2 / EU Stage II emissions regulations.

• Fuel consumption improved over 3508B.• 25% less expensive to rebuild than the Cat

3508B it replaces • Mechanical Electronic Unit Injection (MEUI)

with a record of high reliability in the field

• Overhead cam, crossflow head design • Twin turbochargers with air to air after cooling

(ATAAC) for higher operating efficiency in all conditions

• Enhanced diagnostics with Caterpillar Electronic Technician (Cat ET)

The new C32 is a highly responsive, fuel efficient, and environmentally friendly engine that uses proven ACERT™ Technology

32

Oil supply from crankcase

Oil sent to tank via fuel return line

Oil metered via electronic controls

Oil Renewal System (ORS)

• Eliminates regular oil changes and oil disposal costs

• Improves average engine oil quality• Lessens environmental impact• Decreases service downtime• Exclusive integrated

Caterpillar controls

ORS meters used crankcase oil into the fuel system to be burned, replaced

by new oil as the system is regularly topped off

33

Because ORS constantly replaces old oil with new, the quality level remains consistent and free of the quality degradation experienced in oil during

a

typical 500-hour life cycle

Superior Engine Oil Quality with ORS

Oil Degradation vs Time

Oil

Deg

rad

ati

on

Hours

0 1000 2000 3000 4000 5000

Non-ORS

ORS

34

ACERT ™ Technology

• Advanced electronic control includes fuel mapping to optimize performance based on work parameters

• Precision microburst fuel delivery from mechanically actuated, electronic unit injectors (MEUI)

• Refined air management uses twin turbochargers and air-to-air after-cooling (ATAAC)

• ACERT ™ Technology serves as the platform for meeting future emissions standards

• 500-hour engine service intervals reduce service downtime and operating costs

Cat engines with ACERT Technology are field proven with millions of

on-highway and off-road hours, providing lower emissions and

optimum performance without using EGR

35

Engine Comparisons:C32 ACERT™ Technology vs. 3508B

777F 777D

Engine C32 ACERT® 3508B EUI

Gross power 758 kW (1,016 hp) 746 kW (1,000 hp)

Flywheel power 700 kW (938 hp) 699 kW (937 hp)

Displacement 32.1 L (1,959 in3 ) 34.5 L (2,105 in3)

Cylinder configuration V-12 V-8

36

Power Train Integration

1. Engine Control Module

2. Sensors

3. Electronic Unit Injector (EUI)

4. Automatic Retarder Control (ARC) and Traction Control System (TCS)

5. Transmission Chassis Control (TCC)

6. Transmission

7. Wheel Sensor

8. Brakes

9. Cat Data Link

10.Cat Messenger 1

2

3

4

5

6

7

8 9

Cat Data Link electronically connects the engine and transmission controls

to optimize overall power train performance, reliability and component life

10

37

Lock-up clutch

Input

Torque

converter output

Flow of power

Flow of oil

Torque converter drive mode

Lock-up Torque Converter

• Multiplies torque for high rimpull.• Lock-up reduces fluid power losses

and increased power train efficiency• High reliability from proven design

components • High converter performance over

broad range of speeds.• Lock-up clutch engages at 6.4 km/h

(4.0 mph)

Combines the advantages of direct drive and converter drive to achieve high component reliability and maximum output

performance

38

Controlled Throttle Shift

• Regulates engine rpm during shifts• Reduces torque spikes and extends

transmission life• Smoother ride and less spillage • Lowers operator fatigue • Possible only through electronic

integration of components

Reduces driveline torque stress for smoother shifts, extended component

life and improved operator comfort

Controlled Throttle Shift (CTS)

Tra

nsm

issi

on O

utpu

t Tor

que

Clu

tch

Pow

er

Time

Shift without CTS

Shift with CTS

Shift with CTS

Shift without CTS

39

Precise Transmission Control

• Microprocessor controls hydraulics for smoother clutch transition during shifts

• Reduces torque spikes and extends transmission life

• Possible only through electronic integration of components

• Together with Controlled Throttle Shifting provides:– Smoother ride and less spillage – Lower operator fatigue

Electronically controlled individual clutch modulation reduces driveline

torque stress for smoother shifts, extended component life and

improved operator comfort

40

Seven-Speed Planetary Transmission

• Torque converter lock-up in first gear• Electronic Clutch Pressure Control

(ECPC) system provides smoother speed and directional shifts than 777D

• Downshift inhibitor prevents engine overspeed

• Clutch packs mounted outside of gear sets for ease of service

• Directional shift management automatically reduces engine throttle before shifting

Large diameter clutch packs are controlled to provide smooth shifting and

to limit clutch energy input for extended component life

41

Rear Wheel Group

• Spindle now splined for rear brakes, reducing rebuild time over previous bolted design

• Laser-hardened spindle in the wheel bearing journal area

• Integrated wheel and hub reduces removal and installation time

• More bolts at the spindle to rear axle housing joint for increased strength

• Wheel groups are interchangeable side to side

Heavy duty components and ease of service combine to deliver long life and

reduced downtime in the most rugged conditions

42

Next Generation Modular Radiator (NGMR)

• Square wave fin design provides greater surface area and higher heat rejection than the previous folded core radiator

• Efficient, single-pass parallel flow design• Brazed construction offers stronger joints

and improved leak prevention• Poly-V accessory drive self-adjusts

belt tension• Larger fin spacing permits easier cleaning.

NGMR offers higher heat rejection than previous model; modular design permits easy removal of single core without removing entire

radiator

NGMR – copper

square wave fin

Conventional steel flat fin

43

Rockford Fan

• Replaces direct drive fan arrangement with on-demand Rockford clutch fan arrangement.

• Provides cooling airflow only when necessary.

• Reduces chance of overcooling in low ambient conditions.

• Provides more efficient operation by reducing fan speed when full fan speed is not required.

Optional variable speed Rockford Fan prevents overcooling and provides more efficient operation.

44

Brakes and Retarding

• Full hydraulic actuation• Forced oil cooling for fade

resistance and low wear• Spring applied, hydraulic

released secondary/parking brake for added safety

• Braking & retarding on all four wheels

• Redundant systems

• Sealed from contaminants

Oil-cooled multiple disc brakes on all four wheels provide exceptional braking and retarding

45

Engine Compression Brake

• Increases retarding capability - up to 35% higher downhill travel speeds.

• Automatically actuated with Automatic Retarder Control (ARC).

• Reduced wear on braking components used in retarding applications.

Optional Caterpillar Compression Brake is increases downhill travel speeds and reduces demands on braking system

46

Operator Station

• Resiliently mounted cab with ROPS/FOPS • Twice the glass area of the 777D• Operator sound level reduced to 76 dB(A).• Lighted stairway replaces previous ladder• Messenger LCD display provides real-time

machine operation, service and diagnostic data

• Optional VIMS™ System display monitors over 250 machine functions and payload data

• Tilt and telescoping steering wheel• Improved heat and A/C circulation• Trainer seat• Optional WAVS rear vision camera with

178 mm (7 in) LCD color monitor in cab

All-new 777F operator workstation is designed for maximum operator comfort, control, convenience, and safety

47

Cat Comfort Seat

• High-back seat supports head and neck• Ride zone indicator adjusts seat

suspension to operator’s weight• Adjustable rake lower cushion• Washable seat cover• Dual retractor lap and shoulder belt system• Adjustable shoulder belt has six vertical

height settings for optimum fit

The Caterpillar Comfort Seat with three-point operator restraint is the most durable and supportive seat available for Cat

Mining Trucks

Ride zone indicator

Three-point restraint

48

Information Systems

Cat Messenger (standard)• Machine totals – service hours,

fuel usage• System pressures and temperatures• Service modes – limits and ranges

VIMS System Advisor (optional) • Expanded level of information• Monitors over 250 machine functions

and health data• Acting on VIMS System data has

proven to extend component life, reduce downtime and costs

The Cat Messenger system and optional VIMS ™

System Advisor provide various levels of real-time performance and

operating data

VIMS System Advisor display

Cat Messenger display

49

Road Analysis Control (RAC)

• Existing suspension cylinder pressure sensors measure pitch & bias of truck, and frame rack (twist)

• System identifies haul road problem areas to avoid and correct

• Transmits real time data and GPS locations to haul road maintenance via radio, if equipped

• Improved haul roads help optimize truck component life, fuel consumption, and safety

RAC monitors and logs haul road severity to increase truck life and

reduce cost per ton

50

MineStar™ System –Integrated Mine Information

Radio Network

Re

po

rtin

g

KPIs/

Graphing

Business

Intelligence

Reports

Assignment HealthProduction

Monitoring

Machine

Tracking

Material

Tracking

Machine

Guidance

MineStar…

GPS Infrastructure: Satellites, Repeaters, Base Station

Administration/ ManagementProduction

Engineering

and Geology

SafetyMaintenanceProcessing

Data Flow

51

777F Bodies

Available in 3 sizes:

•Dual Slope

–60-80 m

3 (78-105 yd

3 )

•X Body

–64-81 m

3 (83-105 yd

3 )

•Coal Body

–89-126 m

3 (116-165 yd

3 )

Highlights

•Load retention

•Liner options

•Durability

•Low maintenance

52

Dual Slope Body

• Excellent load retention• Interior surfaces made of 400 BHN steel

for superior wear and impact resistance• Stringer rails and box section ribs provide

exceptional body strength and rigidity• Optional 16 mm steel floor liner includes

front wall, sidewall, and canopy transition liners

• Optional 102 mm impact absorbing rubber liner dissipates energy in hard rock applications

The 777 dual slope truck body has proven itself at some of the toughest sites in the world for its performance, durability, and low

maintenance

53

X Body

• Excellent load retention• Body surfaces made of 400 BHN and 450 BHN

steel for superior wear and impact resistance• Multiple volume and liner options to match

application needs.• Mine-site specific recommendations

available.• Less tail wear compared to dual slope.• Increased base body volume for better

payload capability in typical applications.• Control metering when dumping into

crushers.• Increased head clearance for easier ingress

and egress.

The 777 X body maintains durability while offering the following advantages over the dual slope

54

Coal or High Volume Applications

• Attain target payload in coal• Maintain proper center of gravity• Maximize payload (less weight than other

modified body options – i.e. tailgates)• Minimize maintenance (eliminates cost &

downtime associated with tailgates)• Covers combined applications with the

addition of mine specific liner options• Available: 777, 785, 789, 793, & 795

54

Gateless Coal Body

55

Impact & wear protection that maximizes body life & performance

F

A

C

L

T

ragmentation

brasion

ohesion

oading

ool

Mine Specific Design (F.A.C.LT)

56

FACLT & Body Liner Segmentation

L 1 L 1

L 1 L 2 L 2

L 3

L 3

L 4 L 4

L 5 L 5

L 6 L 6

L 7 L 7 L 8 L 8

L 9 L 9

L 10 L 10

L 11 L 11

L 12 L 12

L 13

L 14

L 15

L 15 L 15

57

Caterpillar Body Liner Options - Types

Smooth Plate for cohesive

materials

Rock Box

for dry and non-cohesive

materials

Zipper Grid

For semi-cohesive materials

Mechanically Attached Wear

Plate System (MAWPS)

semi-cohesive to non-cohesive materials

58

777F Rims

Competitive rim

offset flange with wedges

Caterpillar rim

center mount with studs

Cat center mount rim offers reduced stress and longer life than offset

flange designs; stud mounted rim stays torqued while wedge mounted

design requires constant attention

59

Extended Tire Life

• Gross weight distribution is ideally 33/67 front-to-rear axle

• Traction Control System attachment reduces tire slippage and wear

• Steering geometry and turning radius are designed to minimize tire scrub

The Cat 777F is designed specifically to extend tire life and reduce costs

SustainabilityCaterpillar® 777F Mining Truck

61

Sustainable Development at Caterpillar

• Our vision is a world in which all people’s basic requirements – for shelter, clean water, effective sanitation and reliable power – are not only met but provided in a way that sustains our environment.

• Our mission is to enable economic growth through infrastructure and energy development and to provide solutions that protect people and preserve the planet.

• Our strategy is to provide work environments, products, services and solutions that make wise use of the world's natural resources and reduce harmful impacts on people and nature. This means we

leverage assets including technology and innovation to:

–Promote and protect individual safety

–Provide employment, education, and training

–Minimize the use of energy, materials, and water

–Maximize recycling (remanufacturing)

–Minimize harmful emissions (e.g. air, noise, etc), water discharges, waste and use of hazardous substances

–Optimize the use of renewable resources

62

“Our commitment to being a leader

in sustainable development will

keep us focused on what really

matters—making the intelligent

choices that will drive the growth of

our business and help create a more

sustainable world.”

--Jim Owens, Caterpillar

Chairman and CEO .

Executive Summary

63

Sustainable Development & Strategic Areas of Improvement

> Enterprise SD Goals…

Caterpillar Goals

64

Sustainable Development & Strategic Areas of Improvement

> Enterprise SD “Customer” Goals…

Customer Goals

65

Standard Safety Features

Standard Features• 4-post ROPS• Oil-cooled brakes for fade-resistant

operation• Ground level engine shutdown switch and

machine lockouts for added safety• Three-point operator restraint• Lighted stairway and wider railed cab

access • Heated mirrors• Toe boards help prevent objects from

accidentally being kicked off the deck• Window cleaning platforms around the cab

10/10/20 Overload Policy applies

The 777F offers the latest safety features for the protection of the operator

and mine employees

66

Optional Safety Features

• Payload Monitoring (TPMS or VIMS) to help manage payloads.

• High intensity discharge (HID) lighting in high beams improves night time visibility

• Extended life disc brakes provide longer service life and increased heat resistance than standard brakes

• WAVS rear vision camera and 178 mm (7 in) color LCD monitor in cab

• Perimeter Visibility Package provides perimeter visibility around the machine.

• Wheel Chocks for chocking machine when parked.

The 777F offers optional features to enhance safety in specific

operating environments

67

Ecology Drains

• Ecology drains are standard equipment and located throughout the 777F – Engine – Transmission– Torque converter– Hydraulic tank– Fuel tank– Radiator

• On-board QuickEVAC™ system simplifies the engine oil change process by evacuating the engine sump and purging the oil filters to minimize oil spills

Easily accessible drain plugs are installed in components to provide an environmentally safe and effective method to drain fluids

68

•No Risk to Environment

•Resurfacing Method

•Thermal Spray

•Gases combined with fine metal powder and sprayed three times the speed of sound onto rod surface. Ground to like new

polish.

•Extends life 3 times longer

•Better Wear Resistance

•Reduces Repair time

•Increases quality with life

•Reduced Seal Leakage

AST- Advanced Surface Technology

Increasing availability, reliability, and durability AST lowers operating costs on the machine

69

Customer Testament

• Bunbury Boring Co. (Brian Linaker) : “…achieving

400% greater life [than chrome] in harsh abrasive application….”

•DrillCorp (Arron Tink): “….in extremely salty conditions…the chrome will lift and peel, and rams leak after 6 months…HVOF is

still running after 30 months….”

•Barloworld: “1.5” more than chrome

•Empire: “3 times +” more than chrome

•Trakindo: “200%” more than chrome

•WesTrac: “50% +” more than chrome

Overall Machine Value

•HVOF Eliminates 2-3 Rebuilds (Life of the Truck)

–$$ = 32(hrs) x 2.5 x Customer Profit/Hr

–Time to Change all Struts & Hoist Cylinder

•32 hrs

–Customer Profit/Hr= $2,000 – $80,000

–Customer Profit Gain (Life of the Truck)

• $160,000 to $6.4 million

Equipping Your TruckCaterpillar® 777F Mining Truck

71

777F Standard Equipment

ELECTRICAL

•Alarm, backup

•Alternator, 95 ampere

•Auxiliary jump start receptacle

•Batteries, maintenance-free, 12V (4),

•190 amp-hour

•Electrical system, 25 AMP, 24V to 12V

•converter

•Lighting system:

•Backup light (halogen)

•Directional signals/hazard warning,

•(front & rear LED)

•Headlights, (halogen) with dimmer

•Operator access courtesy lights

•Side profile lights

•Stop/tail lights (LED)

•MINESTAR ready

PRODUCT LINK COMMUNICATIONS

•Product Link Ready (Level 1)

GUARDS

•Engine crankcase

•Driveline

•Fan and A/C

POWERTRAIN

•Caterpillar C32 engine with ACERT

Technology :

-12 cylinder diesel

-Air-To-Air Aftercooler (ATAAC)

-Air cleaner with precleaner (2)

-Automatic cold mode idle control

-Electric priming pump

-Electric cold weather start (two

starters and four batteries)

-Ether starting aid

POWERTRAIN

-Exhaust, body heat

-Fuel filter/water separator

-QuickEvac

-Turbocharger (2)

•Braking system:

-Automatic Retarder Control (ARC)

(utilizes oil-cooled, multiple disc brakes)

-Brake release motor (towing)

-Manual retarder (utilizes

oilcooled,multiple disc brakes)

-Oil-cooled, multiple disc (front/rear)

-Parking

-Secondary

-Service

72

777F Standard Equipment

POWERTRAIN (continued)

•Transmission:

-7 speed automatic powershift with

electronic clutch pressure control

-Body Up Shift Inhibitor

-Controlled throttle shifting

-Directional shift management

-Downshift inhibitor

-Neutral start switch

-Neutral coast inhibitor

OTHER STANDARD EQUIPMENT

•Body mounting group

•Body safety pin (secures body in up

•position)

•Body down indicator

•CD ROM parts book

•Center mounted rims

•Direct drive fan

•Fuel tank (1136 liter / 300 gallons)

•Ground level battery disconnect

•Ground level engine shutdown

•Ground level grease fittings

•Reservoirs (separate):

-Brake/converter/hoist

-Steering

-Transmission/torque converter

•Rims 19.5 x 49

•Rock ejectors

SUSPENSION SYSTEMS

•Suspension, rear (EU Compliant)

•Supplemental steering (automatic)

•Tie down eyes

•Tow hooks(front)/Tow pin (rear)

•Vandalism protection locks

•Wiggins fast fuel

ANTIFREEZE

•Extended Life Coolant to -35C(-30F)

ProductivityCaterpillar® 777F Mining Truck

74

90

%

10/10/20 Overload Policy

• No more than 10% of loads above 110%• No loads above 120%• The average payload shall not exceed the target

No loads should be above 120% of the target payload

90% of loads should fall into this range

No more than 10% of loads should exceed 110% of the target

payload

75

777F Performance

• 2 - 4% increase in fuel economy• All hydraulic, oil-cooled brakes and

Automatic Retarder Control enable faster downhill hauls

• Optional compression brake provides up to up to 35% higher downhill travel speed.

• Improved high altitude operation – zero derate to 3658 m (12,000 ft) compared to 2288 m (7,500 ft)

• Meets U.S. EPA Tier 2/Stage II emissions regulations

• 500-hour service interval keeps the 777F on the job longer

• New cab improves operator comfort and efficiency

The 777F with C32 ACERT™ Technology provides improved performance and fuel economy over the previous 777D with 3508B engine

ServiceabilityCaterpillar® 777F Mining Truck

77

ITEM 777F 777D Savings per 2000 hours

% Savings 777F

Grease $76.72 $96.88 $20.16 21%

Filters 2,647.52 3,120.36 472.84 15%

Oil/Coolant 3,558.70 4,673.53 1,114.83 24%

Labor 1,972.75 2,490.58 517.83 21%

Preventive maintenance cost 8,255.69 10,381.35 2,125.66 20%

PM cost per hour $4.13 $5.19 $1.06 20%

Eight fewer grease fittings and 500-hour oil change and filter intervals

lower the 777F PM costs by 20% over the previous 777D

Preventive Maintenance Savings

78

1

5 2 6

1

3

4

Right Side Inspection

1. Front and rear tires – Check inflation; inspect inside of tire for damage or wear; remove large rocks from treads; check front wheel cover for bolts that are loose or missing

2. Right steering cylinder, tie rod, and front suspension cylinder

3. Power train – Check oil level sight gauge for transmission, look for leaks or damage

4. Fuel tank – Check that filler cap is properly installed; check fuel level sight gauge; look for leaks or damage

5. Right hoist cylinder – Look for leaks, cracking, or marks on chrome

6. Frame and body – Inspect for cracks or damage

79

1

6

8

5

4 9

2

7

5

3

2

9

1

Front Inspection

1. Ground level controls – Make sure switch covers are secure

2. Front operating lights – Check for damage

3. Radiator – Check for leaks; remove any debris

4. Engine – Check for oil and coolant leaks; check oil sump dipstick

5. Ladders and platform – Make sure that the ladders and hand rails are secure

6. Check the coolant level

7. Check steering system hydraulic oil level sight gauge

8. Make sure that all of the windows are clean; make sure that the operator's vision is not impaired by dust, mud, or other foreign materials

9. Adjust the mirrors for proper vision

80

1

6

2

1

5

3

4

Left Side Inspection

1. Front and rear tires – Check inflation; inspect inside of tire for damage or wear; remove large rocks from treads; check front wheel cover for bolts that are loose or missing

2. Left steering cylinder, tie rod, and front suspension cylinder

3. Power train – Check oil level sight gauge in torque converter sump (see Note below); check for leaks at torque converter and transmission

4. Hydraulic tank, hoist and brake oil – Check that filler cap is properly installed; check oil level sight gauge; look for leaks or damage

5. Left hoist cylinder – Look for leaks, cracking, or marks on chrome

6. Frame and body – Inspect for cracks or damage

Note: The torque converter sump oil level is checked with the body

down and the engine off. There are two sight gauges. Use the lower

gauge if the oil is cold. Use the upper gauge if the oil is at operating

temperature.

81

Rear Inspection

2

1

3

2

1. Inspect lights for damage

2. Check suspension cylinders

3. Clean WAVS camera lens (if equipped)

Product SupportCaterpillar® 777F Mining Truck

83

Dealer Support

Parts and Component

Support

Equipment Management

Services

Repair and Maintenance

Process Engineering

We offer a dealer network and support system that is unparalleled by any competitor Cat dealers continue to support the

customer through the entire life of the machine on every angle

84

Caterpillar Global Factory Support

• 23 parts distribution centers

• 13 training centers

• 107 manufacturing facilities

85

Caterpillar Global Dealer Network

180

locally owned businesses

1,916

dealer branch stores

93,000

employees supporting you

$7.8 billion

in assets

50+ years

average tenure

More than our top 3 competitors combined

86

Parts & Service Support Worldwide

• Preventive maintenance programs• Diagnostic programs, such as Scheduled

Oil Sampling and Technical Analysis• Rebuild and Reman options• Operator training• Customer support agreements

Cat dealers offer a wide range of parts and service plans that will maximize uptime and return on your investment

87

Caterpillar Certified Rebuild (CCR)

• Inspection• Disassembly• Reconditioning• Engineering updates• Power train testing• Reassembly• Performance testing• Repainting• New serial number/warranty• Customer evaluation

The CCR program offers a like-new machine with a renewed warranty and serial number, all at a much lower cost than a

comparable new machine

88

Off Highway Truck Reman Components

• Engines• Engine Components• Final Drives• Torque Converter• Transmission• Electric Drive Components• Drivetrain Components

– Wheel assemblies, Spindles, Carriers, Clutch Plates

• Hydraulics– Piston Motors, Gear Pumps,

Rods / Cylinders• Electronic Components

– Starters, Alternators, ECU’s• Price 40 – 70% below new parts

We offer the following Reman components from 777-797 to decrease down time, reduce cost, and increase quality.

More information at catreman.cat.com

89

Percentage Commonality in Parts Numbers

Update As Models Release

90

777F Reduces Cost per Ton

Safety

•Key safety features you are used to on Cat trucks (oil cooled brakes,

ROPS/FOPS, 10/10/20)

•Plus new enhanced safety features contribute to further lowering your

costs

Production

•Improved operator efficiency and comfort

•Higher down hill speeds

Utilization

•Traction control allows continued operation in poor underfoot conditions

Owning Cost

•Long economic life

•Higher resale value than competition. Even though a customer may not

resell their truck, the high resale is indicative of the remaining value in

older Cat trucks

•25% lower engine rebuild cost

Maintenance Cost Per Hour

•Improvements throughout the truck (Engine, Transmission, Wheel groups,

brakes, frame, electrics and electronics)

•VIMS System capability allows diagnostics

and prognostics to extend service life

of components

•500 hr service intervals

•20% lower maintenance cost per hour based on grease, filters, oil/coolant and

labor

Tire Cost Per Hour

•Weight distribution and low Empty

Machine Weight (EMW)

• Steering geometry

Operator Efficiency

•Operator station comfort and ergonomics

•Operator confidence in braking and retarding optimizes downhill speed

Fuel Cost Per Ton

•Engine fuel efficiency improved by 2-4%

QuestionsCaterpillar® 777F Mining Truck

Caterpillar® 777F Mining Truck

Media Support

www.cat.comwww.safety.cat.comwww.catreman.cat.comwww.catminer.cat.com

Mining Truck BodiesBody MaintenanceGround RulesProduct Development Video

Specalog AEHQ5749-01

Payload Management Guidelines AEXQ0250-02Off-Highway Truck Safety Brochure AEXQ3070777F vs 777D Production Study TEXR0438Cat OHT Engine Compression Brake TEKQ0599777F vs. 777F w/ Cat Engine Compression Brake TEXR0455Visibility Package for Cat 777F, 775F, 773F, 772 & 770 OHT TEKQ0680Cat Rubber Body System for Off-Highway Trucks TEKQ0598777F vs. Komatsu HD785-5, Hitachi EH1700 and Terex TR100 TEJB9250-01