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)
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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
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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
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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
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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
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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
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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
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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)
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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
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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
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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
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Structures
Fabrications
Castings
Integral 4-post ROPS
777F frame
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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