777F

Caterpillar

®

_{777F Mining Truck}

Name

Venue

Date

Overview

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 Model Year Introuced 770 2004 772 1971 773 1970 775 1992 777 1975 785 1984 789 1986 793 1991 795 2008 797 1998

Update Yearly

6

Field Population

Truck

Model

Total

Units

Fleet

Hours

Highest Hour Unit

(As of Decem ber 2008)

777

10000+

350 million

116,000

785

2900+

108 million

139,700

789

2200+

91 million

116,703

793

2700+

100 million

106,891

797

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)

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)

9

Future Mining Truck Market Segmentation

100mt – 390mt Short Tons Metric Tons 860E (AC) 75171 (DC) SF32601 (DC) SF31904 (DC) 730E (DC) 793D 75600 (AC) 797B 797F 795F-AC 785C 100 109 118 127 136 145 154 163 172 181 191 200 209 218 227 236 245 254 263 272 281 290 299 308 318 327 336 345 354 363 372 381 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250 260 270 280 290 300 310 320 330 340 350 360 370 380 390 400 410 420 Unit Rig MT5500AC T282B (AC) 789C

HD 1500-7 830E-AC 930E-4 (AC) 930E-4SE (AC) EH3500-ACII EH5000ACII MT6300AC MT4400AC MT3700AC MT3300AC TI274 (AC) 960E (AC) 7513 Series (DC) 7530 Series (DC) 793F 785D 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 BH100 DP905 TR100 SRT95* 777D 72 77 82 86 90 95 100 104 109 80 85 90 95 100 105 110 115 120

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

Product Development, Manufacturing & Distribution

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

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

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

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

Specifications

22

777F Dimensions

9830 mm 32.3 ft 6391 mm 20.9 ft 4697 mm 15.4 ft 5423 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 ft 5223 mm 17.1 ft 5185 mm 17.0 ft

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

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

Features & Benefits

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

De

gradat

ion

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

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)

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

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)

T ransm is s ion O utput T orque Cl utc h Po w 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

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

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

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

R

epo

rt

ing

KPIs/ Graphing Business Intelligence Reports

Assignment Health Production Monitoring Machine Tracking Material Tracking Machine Guidance

MineStar…

GPS Infrastructure: Satellites, Repeaters, Base Station

Administration/ Management Production Engineering and Geology Safety Maintenance Processing

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

55

Impact & wear protection that maximizes body life & performance

F

A

C

L

T

ragmentation

brasion

ohesion

oading

ool

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

Sustainability

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

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

.

63

Sustainable Development & Strategic Areas of Improvement

>

Enterprise SD 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

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)

Equipping Your 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

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

Productivity

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

Serviceability

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

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

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

Product Support

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

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

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.

89

Percentage Commonality in Parts Numbers

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

Questions

Caterpillar® 777F

Mining Truck

Media Support

www.cat.com

www.safety.cat.com

www.catreman.cat.com

www.catminer.cat.com

Mining Truck Bodies Body Maintenance Ground Rules

Product Development Video

Specalog AEHQ5749-01

Payload Management Guidelines AEXQ0250-02 Off-Highway Truck Safety Brochure AEXQ3070 777F vs 777D Production Study TEXR0438 Cat OHT Engine Compression Brake TEKQ0599 777F vs. 777F w/ Cat Engine Compression Brake TEXR0455 Visibility Package for Cat 777F, 775F, 773F, 772 & 770 OHT TEKQ0680 Cat Rubber Body System for Off-Highway Trucks TEKQ0598 777F vs. Komatsu HD785-5, Hitachi EH1700 and Terex TR100 TEJB9250-01