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For Dealer Sales PersonnelThis document supplements information in the Specalog. Marketingcontent will be available only on secured dealer extranets and byaccessing the PDF in the Electronic Sales Library.

Cat® 775FOff Highway Trucks

August 2006

Caterpillar® Product Information

Product Bulletin

®

TEJB9246 Cat 775F Off Highway Trucks August 20062

Table of Contents

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Marketing Strategy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Cat® C27 engine with ACERT™ Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4MEUI Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Electronic Clutch Pressure Control (ECPC) System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Operator Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Information Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Body Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Serviceability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Power Train – Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Power Train – Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Structures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Engine – Power Train Integration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Operator’s Station. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Serviceability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Information & Monitoring Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Truck Body Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Customer Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

August 2006 TEJB9246 Cat 775F Off Highway Trucks 3

Overview

Since its introduction, the Cat® 775 Off-Highway Truck has maintained leadership in its class. The newF-Series trucks build on that reputation by retaining the most valued features of the E-Series whileoffering enhanced features. These improvements and features provide improved performance, reliabilityand productivity – bringing a whole new level of value to Caterpillar® customers.


Marketing Strategy

Cat® C27 engine with ACERT™ Technology

The 775F features the new Cat® C27 engine with ACERT™ Technology, which will deliver the performance,reliability and durability customers have come to expect from Caterpillar. In the 775F, the C27 meetsU.S. EPA Tier 2 and European Union Stage II regulations. Through the added efficiencies of the ACERTTechnology, the C27 engine’s service intervals have increased from 250 hours to 500 hours. A newlydesigned block adds structural strength, while a reengineered cylinder head delivers improved airflow.

MEUI Fuel System

The C27 engine features the Caterpillar® MEUI Fuel System, combining the technical advancement ofelectronic control with the simplicity of direct mechanically controlled fuel injection. The system sensesoperating conditions and regulates fuel delivery for optimum fuel efficiency, improved response times,lower emissions and less smoke.

Electronic Clutch Pressure Control (ECPC) System

The F-Series seven-speed transmission provides a superior ride with smoother speed and directional shiftsthrough the use of the Electronic Clutch Pressure Control (ECPC) system. This proven transmission isbuilt for long life between overhauls, providing durability that is only known as Caterpillar.

Operator Station

The 775F boasts an all-new operator station, designed to provide superior operator comfort and control.This operator station has 100 percent more glass area, 18 percent more volume and over 7-inches increasedwidth than the 775E. A new ergonomic design and layout of controls provides increased productivityand reduced operator fatigue. This truck features the Caterpillar Comfort Seat, delivering improvedcomfort, support and durability to the operator. A lighted stairway access system allows the operator toeasily and safely enter and exit the truck. An optional HID lighting package provides superior nighttimevisibility. Also available is an optional camera system, which provides visibility to the rear of the truckthrough a 7-inch LCD color monitor in the cab.

Information Systems

Valuable machine information is now easily available to the operator or technician. The 775F comesstandard with Cat Messenger, providing real-time machine performance and diagnostic data. An optionalVIMS™ monitoring system offers extensive machine functions and payload data. These trucks are alsoMineStar™ information management system ready, which links machines in the field with business andoperating systems.


Marketing Strategy

Brake System

The same proven brake design found on the 775E is now all-hydraulic, providing superior reliability,response, control, serviceability and modulation. The parking brake is integrated into the gear selectorfor easy operation.

Body Systems

The new 775F offers a variety of application-specific body systems to provide versatility as well as thestrength, capacity and durability of its predecessor. Caterpillar will now offer dual slope and flat floorbody systems with three different steel liner packages and two rubber-lined packages.

Serviceability

Serviceability is faster and easier with the 775F. New 500-hour engine service intervals lower operatingcosts and reduces downtime. Newly configured electrical access allows for up to 50 percent fasterservicing. A new machine lockout switch allows maintenance and trouble-shooting while the engine isrunning. QuickEvac™ system, standard on all F-Series trucks, reduces engine oil service time by up to50 percent.


Power Train – Engine

Cat® C27 engine with ACERT™ Technology.With the C27 engine, Caterpillar optimizes engineperformance while meeting U.S. EPA Tier 2 andEuropean Union Stage II regulations in the 775F.ACERT™ Technology reduces emissions duringthe combustion process by using advancedtechnology in the air and fuel systems, inconjunction with integrated electronics. Caterpillarmeets emission regulations at the combustionsource, rather than recycling exhaust.

Engine Design. The Cat C27 engine uses ACERTTechnology and iron-specific features to deliverstrong performance and long-term durability.

Block. The C27 block features a new designthat provides higher structural strength throughincreased iron compaction and thicker walls.This new design supports the engine’s highercompression ratios and increases its power densityrelative to the 3412B.

Cylinder Head. A reengineered cylinder headdelivers dramatically improved airflow with aunique cross-flow design and new intake manifolds.The new cross flow air design routes air straightacross the head removing bends and turns thatcreate resistance to flow. By removing theresistance to flow, parasitic loads are reduced aspumping needs are lessened. The cylinder headis a one-piece, cast iron component with a newlydesigned graphite and steel composite head gasketthat seals the combustion chamber with betterrigidity and wear capability.

Overhead Cam. Two, single overhead cams(one per head) are driven by gears on the flywheelend of the engine. Placing the cam gears at theflywheel end significantly reduces noise andvibration. Caterpillar has also added two pendulumabsorbers, mounted at the front of the camshaftsto further reduce noise and vibration. Together,these two features are contributing to the long lifeand durability of this engine.

Pistons, Connecting Rods, Cylinder Liners.Changes to the pistons, rods, and liners have beenmade to support the higher cylinder pressuresand compression ratios associated with ACERTTechnology. The C27 engine has a 137.2 mm(5.4 in) bore, 152.4 mm (6 in) stroke and uses asingle-piece steel piston mated to a more robustconnecting rod to ensure long component life.The piston’s steel skirt increases its durability.The skirt also results in reduced thermal expansion,allowing a tighter piston fit and reduced linercavitations. The smaller overall piston surfacearea reduces friction and enhances fuel economy.Also, the tolerances between the pistons and thewet cylinder liners have been tightened tounprecedented levels.

Power Train – Engine. The Cat® C27 engine with ACERT™ Technology uses advanced enginetechnology to reduce emissions without after-treatment. The turbocharged, aftercooled 12-cylinderengine has higher horsepower and faster response for superior performance in demanding applications.


Power Train – Engine

Turbochargers. The two side-mountedturbochargers on the C27 engine are air-cooled,non-waste gated with a with a full aluminumwheel. The C27 engine also includes a newturbine housing and an additional spacer bearing.The addition of a spacer bearing eliminates snaprings and therefore reduces complexity andimproves shaft motion. These changes enablethe C27 engine to deliver longer life and lowermaintenance costs, and contribute to betterfuel economy.

EPA Compliant. The C27 engine is compliant withU.S. EPA Tier 2 and European Union Stage IIemissions regulations in the 775F, reducing NOx27.5 percent from 4.8 g/bhp-hr to 3.0 g/bhp-hrover the 3412E.

Single-Piece Piston Design. New single-pieceforged steel pistons with integrated forged steelskirt are more robust to withstand high engineheat and pressure, and enable enhanced combustionefficiency, improved fuel efficiency and loweremissions. Corrosion-resistant, stainless steeltop ring reduces ring, groove and liner wear forgreater reliability and longer life.

MEUI Fuel System. Fuel delivery, provided bythe MEUI mechanically actuated electronic unitinjection system, involves a high degree ofprecision. Precisely shaping the combustioncycle lowers combustion chamber temperatures,generating fewer emissions and optimizing fuelcombustion. The system senses operating conditionsand regulates fuel delivery for optimum fuelefficiency, improved response times, loweremissions and less smoke.

Electronic Control Module (ECM). ECM usesadvanced engine management software to monitor,control and protect the engine using self-diagnosingelectronic sensors. The computerized systemsenses operating conditions and power requirementsand adjusts the engine for peak performance andthe most efficient operation at all times.

Advanced Diesel Engine Management A4 EngineController. The ADEM™ A4 electronic controlmodule delivers optimum fuel performance.The engine management system provides flexiblefuel mapping, allowing the engine to respondquickly to varying application needs. It tracksengine and machine conditions while keepingthe engine operating at peak efficiency.

Next Generation Modular Radiator (NGMR).The new modular cooling system with a single-passflow core design uses brazed construction forstronger joints, better leak prevention and higherheat transfer. The simpler design of the single-passsystem, which replaces the two-pass flow foldedcore system of the 775E, enables coolant to enterone end of the core and flow out the opposite endfor more efficient ambient cooling capability andgreater durability.

Fan (optional). The 775F includes a direct-drivefan, standard, or an optional on-demand fan witha Rockford clutch. The optional fan providescooling airflow only when necessary resulting ina reduction in fuel consumption, over cooling andgenerated noise. Rockford’s unique variable speedtechnology enables the fan clutches to respond tochanges in the engine cooling demands by varyingthe fan speed. This allows the fan to slow downor speed up as necessary, utilizing less workinghorsepower from the engine and lowering fuelconsumption.


Power Train – Transmission

Mechanical Power Train. The Cat mechanicaldrive power train and power shift transmissionprovides unmatched operating efficiency andcontrol on steep grades, in poor underfootconditions, and on haul roads with highrolling resistance.

Transmission. Pairing the Caterpillar seven-speedplanetary power shift transmission with theC27 diesel engine with ACERT Technologydelivers constant power over a wide range ofoperating speeds.

• Transmission Chassis Control (TCC). TCC useselectronically transferred engine rpm data toexecute shifts at preset points for optimumperformance, efficiency and clutch life. The TCCprovides integrated functionality to controlledthrottle shifting, directional shift management,neutral coast inhibitor, body-up shift limiter andbody-up reverse neutralizer.

Lock-Up Torque Converter. Combines maximumrimpull and cushioned shifting of torque converterdrive with the efficiency and performance ofdirect drive. The torque converter includes: anadditional clutch plate to maintain power traincapability for higher horsepower and top speed,a new torque converter adapter that provides extralength to house the additional clutch plate andenables the converter components to be changedwithout having to change the housing, and a newsump oil level switch that serves as an emergencywarning if oil is lost. The lock-up torque converterengages at approximately 8 km/h (5 mph),delivering more power to the wheels.

• Lock-Up Clutch. Quickly releases and re-engagesto reduce power train torque loads for smoothershifting, long life and a more comfortable ride.

• ECPC (Electronic Clutch Pressure Control)System. ECPC modulates clutch engagementindividually, allowing for smoother speed anddirectional shifts. ECPC provides controls forboth the torque converter lock-up clutch and thetransmission clutches that are tailored to eachparticular upshift or downshift. This providesthe operator a superior ride and reduced fatigue.

Power Train – Transmission. The Cat seven-speed power shift transmission matched with the Cat C27engine with ACERT Technology provides constant power and efficiency over a wide operating speedrange for optimal power train performance.


Power Train – Transmission

The new contamination control system was designedfor ECPC systems. The design incorporates two,high capacity, 6-micron filters with sedimentcapacity increased by more than 35 percent(compared to the 20-micron filter on the 775EICM system) and a Post Clutch Valve Main Relief(PCVMR) system. In the PCVMR system themain relief valve is located at the end of theECPC valves’ oil supply, reducing debris build-upby supplying a constant oil flow past theECPC valves. Another ECPC advantage is theincorporation of external pressure taps to improvemaintenance. These pressure taps provide easyexternal access to pressure readings on the lube,main relief valve, and the seven transmissionclutches. Without accessing the inside of thetransmission, these pressure taps reduce theopportunity for contamination.

Final Drives. Cat final drives work as a systemwith the planetary power shift transmission todeliver maximum power to the ground. Built towithstand the forces of high torque and impactloads, double reduction final drives provide hightorque multiplication to further reduce drivetrain stress.

• Steering System. Hydraulic steering controlsystem is designed for exceptional smoothnessand precise control. A separate circuit preventscross contamination for long life.

• Battery Powered Supplemental Steering.A battery powered supplemental steering systemuses pressure accumulators and allows up tothree 90 degree turns in case of engine failure.

• Wheels and Rims. Cast rear wheels andCat center-mount rims are mounted using studsand nuts to minimize maintenance and maximizedurability.


Structures

Box-Section Design. The 775F frame uses abox-section design, incorporating two forgingsand 19 castings in high-stress areas with deeppenetrating and continuous wrap-around weldsto resist damage from twisting loads withoutadding extra weight.

• Steel Structures. Mild steel used throughoutthe frame provides flexibility, durability andresistance to impact loads, even in cold climates,and allows for easy field repairs.

• Castings. Castings have large radii with internalreinforcing ribs to dissipate stress in areas of highstress concentration. Castings move welds tolower stress areas for greater frame life.

Integral Four-Post ROPS Cab. Resiliently mountedto the main frame with all-new cab mounts thatreduce vibration and sound, the integral ROPSis designed as an extension of the truck frame.The ROPS/FOPS structure provides “five-sidedprotection” for the operator.

Suspension System. Designed to dissipate haul-road and loading impacts for longer frame life anda more comfortable ride.

• Cylinders. Four independent self-contained,oil pneumatic, variable-rebound suspensioncylinders are designed to absorb shocks in themost severe applications.

• Durable Design. Rugged cylinders use a largediameter bore and low pressure nitrogen/oildesign for long life with minimal maintenance.

– Front. Front cylinders with preset caster andcamber are mounted to the frame and serve assteering kingpins for a tight turning radius withexcellent maneuverability and low maintenance.

– Rear. Rear cylinders allow axle oscillationand absorb bending and twisting stresses causedby uneven and rough haul roads rather thantransmitting them to the frame.

Technology Enhanced. Caterpillar structures aretested using System Structural Analysis (SSA)to dynamically simulate operations in fieldenvironments and identify potential structuralimprovements in high stress areas. With analysisof machine structures and variables, such as haulroad and payload, structural improvements weremade to the frame to accommodate the new cab,platform, engine and radiator.

Quality Control. A Coordinate MeasuringMachine (CMM) is used to inspect truck framesfor consistency in the manufacturing process.Easy rebuild ability is thereby achieved byensuring the frames are within tolerance,removing the need to alter down-stream parts.

Structures. The 775F features a mild-steel, box-section type frame, proven on the 775E to deliverdurability and long life with low operating costs. Castings and forgings are strategically placed inhigh-stress areas to evenly distribute stresses and provide long fatigue life.


Engine – Power Train Integration

Cat Data Link. Electronically integrates machinecomputer systems to optimize overall power trainperformance, increase reliability and componentlife, and reduce operating costs. All controlmodules communicate via the Cat Data Linkand work together as an integrated system tomaximize production efficiency and extendcomponent life.

Transmission Chassis Control (TCC). TCC useselectronically transferred engine rpm data toexecute shifts at preset points for optimumperformance, efficiency and clutch life.

Electronic Technician (Cat ET). Cat ET servicetool provides service technicians with easy accessto stored diagnostic data through the Cat DataLink to simplify problem diagnosis and increasemachine availability. Cat ET is beneficial becauseof how it displays the status of all engine parameters,including throttle position, timing and fuel flow.Critical data from the electronic engine andtransmission controls, including transmissionshifting, engine speed and fuel consumption,provides service technicians with enhanceddiagnostic capability to reduce downtime andoperating costs.

Controlled Throttle Shifting. Regulates engine rpmduring shifting to reduce power train stress andclutch wear by controlling engine speed, torqueconverter lock-up, and transmission clutchengagement for smoother shifts and longercomponent life.

Directional Shift Management. Regulates enginespeed during directional shifts to prevent damagecaused by high-speed directional changes.

Neutral Coast Inhibitor. Prevents the transmissionfrom shifting to neutral at speeds above 6.5 km/h(4 mph), protecting the transmission from operatingwith insufficient lubrication.

Body-up Shift Limiter. Prevents the transmissionfrom shifting above a pre-programmed gearwithout the body being fully lowered. This functionis programmable via Cat Electronic Technician(Cat ET) and Messenger or Advisor.

Body-up Reverse Neutralizer. Automatically shiftsthe transmission to neutral if the hoist lever isactivated while the transmission is shifted in reverse.

Overspeed Protection. The transmission controlelectronically senses engine conditions andautomatically up-shifts one gear to preventoverspeeding. If overspeeding occurs in the topgear, the lock-up clutch is disengaged, and thebrakes are applied.

Programmable Top Gear. Transmission top gearmaximum can be set using Cat Messenger,VIMS Advisor or the Cat ET service tool tohelp the operator maintain speed limits.

ET

8

7

6

5

9

4

2

1

3

1 Engine Control Module (ECM) 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

10

Engine – Power Train Integration. The Cat Data Link electronically combines engine, transmission,brake and operational information to optimize overall truck performance. Stored diagnostic data canbe accessed via the Cat Electronic Technician (Cat ET) service tool to improve troubleshooting andreduce downtime.


Engine – Power Train Integration

Anti-Hunt Function. This function minimizesshifting by not allowing the transmission to up ordown shift immediately after a shift has occurred.This prevents gear hunting when operating near ashift point and minimizes transmission shifting forincreased component life.

Downshift Inhibitor. Prevents engine overspeedingby keeping the transmission from downshiftinguntil engine speed reaches the downshift point.

ECPC Control. Both the torque converter lock-upclutch and the transmission clutches now havesoftware-control for clutch fill and slipcharacteristics to provide superior smooth shifting.

Economy Shift Mode. Engine speed in third gearand above is reduced to improve fuel consumption,lower noise levels and potentially lengthen enginelife. Economy Shift Mode is best used when acustomer has extra truck capacity and wants tolower cost-per-ton. A customer who effectivelyuses Economy Shift Mode can reduce operatingcosts without sacrificing production.

Reverse Shift Inhibitor. Protects the engine fromabrupt directional changes by slowing down theengine before shifting the transmission into reverse.

Cat Messenger. Critical data from the engine andtransmission, including transmission shifting,engine speed and fuel consumption, providesservice technicians with enhanced diagnosticcapability, through Cat Messenger, to reducedowntime and operating costs.

Traction Control System (TCS) (optional).TCS electronically monitors and controls rearwheel slippage for greater traction and enhancedtruck performance in poor underfoot conditions.

Hydraulic Power Management System.The system reduces parasitic losses in the powermanagement system components. The system isoperated by two new variable displacement pistonpumps. These pumps primarily provide for thesteering and are independent of the brake andhoist circuit.


Brake System

Integrated Braking System. The Cat oil-cooledbraking system delivers reliable performance andcontrol in the most extreme haul-road conditions.The integrated system combines the service,secondary, parking brake and retarding functionsin the same system for optimum braking efficiency.

Oil-Cooled Multiple Disc Brakes. Cat dry frontand rear oil-cooled, multiple disc brakes arenow hydraulically controlled, reducingmaintenance costs.

The 775F brakes provide exceptional, fade-resistantbraking and retarding for maximum performanceand productivity in all haul-road conditions.

Extended Life Multiple Disc Brakes (optional).Extended life friction material has double thewear life of standard brakes and is twice asresistant to glazing for more consistent brakingpower with less noise.

Brake System. The front dry disc and rear oil-cooled, multiple disc brakes are now hydraulicallycontrolled, reducing maintenance costs and improving operator control and modulation. They provideexceptional, fade-resistant braking and retarding for maximum performance and productivity in allhaul-road conditions.


Brake System

Brake Design. Cat rear oil-cooled disc brakes aredesigned with large discs and plates for reliable,adjustment-free operation and performance.Rear brakes are completely enclosed and sealedto prevent contamination and reduce maintenance.

Long Life. An oil film prevents direct contactbetween the discs. This design absorbs thebraking forces by shearing the oil moleculesand carrying heat away to extend brake life.

Pistons. The Caterpillar two-piece piston designcombines the service, secondary, parking brakeand retarding functions in the same system.The primary piston hydraulically actuates bothservice and retarding functions. The secondarypiston is spring-applied and held in the disengagedposition by hydraulic pressure. If hydraulic systempressure drops below a specified level, thespring-applied secondary piston automaticallyapplies the brakes.

Parking Brake. Oil-cooled, spring-applied,hydraulically released parking brake is appliedto the rear wheels for superior parking capabilityon all grades up to 15 percent.

Automatic Retarder Control (ARC). Standard ARCelectronically controls braking on grade to maintainengine at approximately 1,900 rpm (adjustablefrom 1,850-1,950 rpm in increments of 10).ARC is deactivated when the operator appliesthe brakes or throttle.

• Faster Speeds. ARC allows the operator tomaintain optimum engine speeds for up to15 percent faster downhill hauls and greaterproductivity.

• Superior Control. Automatic brake modulationoffers a smoother ride and better control inslippery conditions, allowing the operator toconcentrate on driving.

• Ease of Operation. ARC increases operatingease, resulting in greater operator confidencewith less fatigue.

• Engine Overspeed Protection. Automaticallyactivates ARC when engine speed exceeds factorypreset levels, regardless of operator inputs, toavoid potentially damaging engine overspeeds.

10Time (Seconds)

20 30 40 50 60

With Automatic Retarder Control(average speed, 1950 rpm)

With Manual Retarder Control(average speed, 1730 rpm)

Engi

ne S

peed

(rpm

)700

2500

1500

1000

500

2000

1 2

4

3

5

8

6

6

7

7

TCSARC 1 Service Brake Sensor2 Engine Sensor3 ARC4 ARC Switch5 Brakes6 Service Brakes7 Axle Speed Sensor8 TCS


Brake System

Traction Control System (TCS) (optional).Electronically monitors and controls rear wheelslippage for greater traction and enhanced truckperformance in poor underfoot conditions.If slippage exceeds a set limit, the oil-cooleddisc brakes engage to slow the spinning wheel.Torque is then automatically transferred to thewheel with better traction.

Differential Action. Normal differential actionprovides superior maneuvering and control inslippery conditions.

Compression Brake (optional). An all-new Catcompression brake is available as an option onthe 775F in addition to the standard AutomaticRetarder Control (ARC). The Cat compressionbrake delays the release of pressure in thecylinders to brake the machine, and is integratedinto the ARC braking system. It provides engine-braking torque by opening the exhaust valvesduring the compression stroke of the engine.A conventional master/slave brake actuationsystem opens the cylinder’s exhaust valves torelease compressed air. By working in combinationwith ARC, the system provides up to 35 percenthigher downhill travel speed that reduces wearon brake components in retarding applications.This Caterpillar manufactured component is built forlong, carefree service. It requires no tune-ups, andno maintenance except periodic valve lash checks.


Operator’s Station

Ergonomic Layout. The 775F operator station isergonomically designed for total machine controlin a comfortable, productive and safe environment.All controls, levers, switches and gauges arepositioned to maximize productivity and minimizeoperator fatigue.

New ISO Designed Cab Mounts. Integral, sound-suppressed cab is resiliently mounted to the frameto isolate the operator from sound and vibrationfor a quiet, secure and comfortable ride.

Viewing Area. Designed for excellent all-aroundvisibility and clear sight lines to the haul road.The large viewing area, with 100 percent moreglass, enables the operator to maneuver withconfidence for greater productivity.

Air Suspension Seat w/Three-Point OperatorRestraint. Ergonomically designed, fully adjustableair suspension seat with adjustable armrestsprovides optimal driving comfort. A wide,retractable 3-point seat/shoulder belt providesa secure, comfortable restraint.

Hoist Lever. Four-position, low effort electronichoist control system is positioned next to the gearselector in the right-hand console.

Secondary Brake Pedal. Conveniently locatedon the floor for easy operator control.

Steering Column. Comfortable steering wheelwith tilt and telescoping function provides acomfortable driving position for all operators.

Transmission Console. Ergonomic gear shift leverwith backlit gear indicators provides easy operation.The parking brake function is integrated into thegear selector.

Trainer Seat. The trainer seat is relocated to theleft of the operator, which allows trainer to usesame stairway.

When not in use, the fold-down trainer seatcreates a working surface with cup holder. Theseat also folds up, providing more room for theoperator. Under seat storage is convenient forstowing a lunch box.

Operator Controls. Easy to reach turn signal,high beam, intermittent windshield wiper andwindshield washer controls are located on the leftside of the steering column, and are designed foroptimum efficiency and comfort.

Heating/Air Conditioning. Electronically controlled,four-speed fan and 13 vents deliver temperature-controlled air circulation for a comfortable workingenvironment in any climate. Electronic controlsreduce maintenance. A 57% increase in heatingcapacity as well as a more robust air compressoroffers a 25 percent increase in BTU’s, greaterdurability and longer life.

Operator’s Station. The 775F features an all new operator station with enhanced visibility, increasedoperator space and ergonomically designed controls that set new industry standards for operatorcomfort. All controls and gauges are positioned for optimum efficiency and total machine control.


Operator’s Station

Radio Ready. Cab is prewired with powerconverter, speakers, wiring harness, antenna andnecessities for add-on communication systems.

Multiple Power Ports. Power ports are convenientlylocated in three locations in the cab: one in theright-hand console, two behind the trainer seat,and one in the dash.

Truck Production Management System (TPMS)(optional). TPMS provides valuable payload andcycle time data, which is viewed through Messengeror VIMS Advisor to improve productivity.

Now the system provides 2,400 cycles, as opposedto the previous 1,400 cycles, and takes a secondpayload measurement when the truck reachessecond gear for increased accuracy.

Standard LED lamps replace incandescent lampson the TPMS, extending lamp life by 25 times.


Serviceability

Servicing Ease. Easy access to daily servicepoints simplifies servicing and reduces time spenton regular maintenance procedures. Enhancedserviceability and extended 500-hour serviceintervals are designed to increase machineavailability and productivity.

Maintenance Platform. Easy stairway accessto engine, air filters, steering hydraulic tankand radiator.

Ground-Level Access. All maintenance pointshave convenient ground level or platform access.Common engine service points are grouped onthe right side of the engine for quick access.Two fuel filters come standard with the machineand the primary fuel filter includes a water separator.These filters are easy to change and are allspin-on/spin-off type.

Engine oil check and fill are accessed via theservice platform. The newly designed engine oildipstick is “rope-type” style, making daily checkseasier for the operator.

Engine Prelube. Engine prelubrication providesengine oil pressure prior to engine cranking.This reduces engine dry and cold start wear,and reduces engine component wear. This systemautomatically fills engine oil filters and galleries,and ensures components are lubed prior to startingthe engine.

Scheduled Oil Sampling. S•O•SSM sampling valvesspeed sampling and analysis reliability.

Pressure Test Points. Disconnect valves areconveniently located throughout the hydraulicsystems for easy pressure testing. New ECPCtransmission provides multiple pressure tapsoutside the transmission.

Air Filters. Radial seal air filters are easy tochange, reducing time required for air filtermaintenance.

Sealed Electrical Connectors. Electrical connectorsare sealed to lock out dust and moisture. Harnessesare braided for protection. Wires are color-codedfor easy diagnosis and repair.

Spin-on Filters. Spin-on filters for fuel and oilsystems reduce changing time and help ensureclean, tight seals.

On-Board Diagnostic Systems. Messengercontinuously checks all critical machine functionsand components, and helps locate faults quicklyfor faster repair. Electronic control system enablesquick diagnosis of engine conditions and effectivemaintenance and repairs using the ElectronicTechnician (Cat ET) service tool.

Serviceability. The 775F offers 500-hour engine service intervals – 250 hours more than the 775E.Simplified service and maintenance features combined with improved service access are designedto reduce downtime.


Serviceability

Lincoln’s Quick Lube Automatic Lubrication(optional). This advanced lubrication system isavailable as a factory installed option on the 775F.This system provides optimal lubrication at presetintervals during machine operation significantlyextends component life. Contaminants are purgedfrom the open pins and bushings, and protectivegrease seals are maintained. As opposed tomanual lubrication, this option reduces downtime,labor, and lubricant costs and improves machineresale value.

Clustered Grease Fittings (optional). Clusteredgrease fittings save time as all lubrication pointsare mounted in three main locations.

Oil Dipstick. New “rope-type” oil dipstick improvesserviceability by allowing easy daily checks.

Next Generation Modular Radiator (NGMR).This cooling system’s new modular designpermits removal of a single core without removingthe entire radiator, reducing downtime and repaircosts. The less complex design offers improvedreliability and higher efficiency over the two-passflow core. NGMR also offers wider fin spacingfor greater resistance to plugging and moreconvenient cleaning.

QuickEvac™ System. Oil change labor time isreduced by as much as 50 percent with this standardon-board engine oil evacuation and pre-lube system.It speeds the process of evacuating the engine sumpand allows for the purging of oil filters prior toremoval, minimizing oil spills. QuickEvac systemalso enhances contamination control by ensuringcomplete filtration of new oil on engine refill.

Reduced Maintenance Costs/Higher MachineAvailability. The C27 engine with ACERTTechnology offers 500-hour service intervalsunder normal conditions. For the 775F, commonlyused engine service points have been placed onthe right side of the engine. Feedback from enginesensors provides data to the electronic controller.When engine data is out of spec, a warning is sentto the operator.


Information & Monitoring Systems

Instrument Cluster. Critical operating informationon the 775F is relayed via the Cat Data Link tofive gauges, 18 LED indicator lights, and anLCD digital display.

Cat Messenger. Standard on the 775F,Cat Messenger provides real-time machineperformance and operating data, and basic trip,maintenance, and diagnostic data using anLCD display. The viewable LCD screen area ofthe Messenger display is 22.5 mm � 84.6 mm(0.89 in � 3.33 in).

Truck Production Management System (TPMS)(optional). TPMS provides valuable payload andcycle time data to improve productivity.

• Uses strut pressure sensors and on-boardmicroprocessor to determine payload weight.

• Delivers consistent, accurate payloads andimproves efficiency by minimizing overloadingand underloading.

• External lights signal loading tool operatorwhen payload is reached.

• On-board computer stores up to 2,400 cyclesfor analysis of payload weight, cycle times,distances, and actual cycle dates and times.

• A second gear reweigh takes an additionalmeasurement once the truck has reached secondgear for improved accuracy.

• System is accurate within ± 5 percent undernormal loading conditions over a normal shift.

• Standard LED lamps replace incandescentlamps on the TPMS, extending lamp life by25 times.

VIMS™ Monitoring System (optional). Caterpillardesigned machine monitoring system providesmore than 250 machine parameters, criticalmachine health and payload data in real-time tokeep the 775F performing at top production levels.In addition to the usual Messenger monitoringsystem functionality, the system also monitors:

• torque converter screen switch,

• torque converter inlet filter,

• brake oil temperature,

• fuel level,

• ambient air temperature,

• ‘R’ terminal,

• front aftercooler temperature,

• aftercooler coolant level,

• jacket-water level,

• high steering pressure switch,

• steering oil temperature,

• steering oil bypass switch,

• payload, and others.

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1 Gauge Cluster 2 Advisor Display 3 Action Alarm 4 ADEM A4 Engine Control Module 5 CAT Data Link 6 Payload Lamps 7 Data Port (VIMS-PC) 8 Diagnostic Connector (ET) 9 Automatic Retarder Control (ARC) and Traction Control System (TCS) 10 Transmission/Chassis Control (TCC) Module 11 Telemetry Port

Information & Monitoring Systems. Standard on the 775F, the Cat Messenger system provides real-timeengine performance and operating data. The 775F also offers the optional VIMS Advisor monitoringsystem, providing data for more than 250 machine functions.


Information & Monitoring Systems

Product Link (optional). Now available out of thefactory, this system streamlines diagnostic efforts,downtime, and maintenance scheduling and costsby providing a two-way communication flow ofvital machine data and location information betweenthe dealer and the customer. Product Link providesupdates on service meter hours, machine condition,machine location as well as integratedmapping/route planning.

MineStar™ Ready. MineStar informationmanagement system helps meet the challengesof the mining industry by linking the machinesin the field with business and operating systemsto ensure peak performance of mining assets atthe lowest possible cost. These products delivercustomers everything from real-time machinehealth information to GPS-guided productionaids. The 775F is equipped for quick and easyinstallation of MineStar information managementsystem products.

Specific Minestar information managementsystem products include:

• MineStar Machine Tracking – Monitorsmachine locations and fleet movement via GPS,alerting controllers to delays against expectedarrival times. Provides position analysis ofmachine operational and health events.

• MineStar Material Tracking – Tracks andmanages material types and grades, improvingoverall ore recovery by ensuring material ismoved to correct destinations. Includes materialstockpile tracking. Allows for real-time gradedetermination at the excavation face.

• MineStar Production – Monitors and reportsmine production information in real time.Manages production and delay codes foraccurate machine utilization tracking.

• MineStar Fleet Commander – Advancedoptimization algorithm increases truck/shovelfleet use. Maximizes shovel production andminimizes truck wait time, while simultaneouslymeeting mine production plan requirements formaterial blending.

• MineStar Health – Monitors and communicatesmachine vital sign information in real time,enabling remote maintenance/service diagnosticsand advanced prognostic analysis. Enhances theentire maintenance and repair process, allowinghigher machine availabilities to be attained.

• MineStar Business Enterprise – Provides ITinfrastructure platform for seamless integrationof MineStar information management systemwith other mine planning and enterpriseresource planning systems.


Truck Body Systems

Body Selection. Selection of the right body systemdepends on material, haul road and loadingconditions. The better the match of body toapplication, the greater the efficiency. Cat dealerscan help select the right body system for site-specific applications.

Body/Chassis Integration. Caterpillar truck bodysystems are designed and matched with theintegrated chassis system for optimum structuralreliability, durability and long life.

Electronic Hoist Control. Provides the operator withbetter control of the load when dumping, includingover-center load control and modulated controlthroughout the operating range. The automaticbody snubbing feature reduces impact on theframe, hoist cylinders and operator.

Fast Hoist Cycle Times. Two-stage hoist cylindersprovide fast dump cycle times of 9.5 seconds forraise and 12.5 seconds for lower.

Body Liners. Two liner materials, steel and rubber,are available to help extend body system life.All steel liner wear surfaces are equipped with400 BHN steel to handle tough impact loads whileresisting abrasion. Optional rubber liners deliverlong life in high-wear and high-impact areas aswell as increases operator comfort during loading.

1) Dual Slope Body 2) Flat Floor Body

Body Design. With the introduction of the 775F,Caterpillar offers five application-specific bodysystems. Dual slope and flat floor body offeringsare available in three steel configurations andtwo rubber configurations.

The new dual slope and flat floor body systemswill continue to use fully fabricated, mild steelstructures, offering a strong, yet weldable underbodystructure. All interior, steel body surfaces thatcome in contact with material are fabricatedfrom 400 BHN steel to provide superior wearcharacteristics and resistance to impact.Wide box-section ribs provide excellent durabilityand impact support in the floor, front-wall,sidewall, and top rail areas. Full-length stringerrails enhance strength and rigidity throughout thebody. Other new features that further enhancedurability of the understructure include:

• The body sidewall ties directly in with the floor,providing increased strength in the sidewalls.

• Thickness of ribs increased to 10 mm and thenumber of floor ribs have been increased from7 to a total of 9 ribs.

21

Truck Body Systems. The 775F offers five different body system selections to accommodate almost anytype of application. These systems are designed to maximize strength and durability through rigoroustesting in harsh environments to ensure the lowest cost per ton.


Truck Body Systems

• Front wall body rest supports are integrated intothe front wall structure for enhanced durability.

• Front wall is 400 BHN and the thickness isincreased from 10.2 mm (0.4 in) to 16.0 mm(0.63 in), eliminating the need for additionalliners for impact resistance in most applications.

Target Payload Strategy. Your Caterpillar Dealercan help you manage to target payload to maximizeequipment use, ensure safe operation, increaseproductivity and lower cost-per-ton.

• Underloading increases costs due to lostpayloads, underutilizes equipment, andincreases cost-per-ton.

• Overloading causes excessive wear on vehiclecomponents, such as brakes, tires and drivetrain, reducing component life and increasingmaintenance costs and repairs.

Matched Systems. Designed to work as anoptimum pass/match system, the 775F is bestsized to match the 988H Wheel Loader, with5 pass/match, the 990H Wheel Loader, with a4 pass/match, and the 385C Hydraulic Excavator,with a 7 pass/match.


Customer Support

Commitment Makes the Difference. Cat® dealersoffer a wide range of solutions, services andproducts that help you lower costs, enhanceproductivity and manage your operation moreefficiently. Support goes far beyond parts andservice. From the time you select a piece ofCat equipment until the day you rebuild, trade orsell it, the support you get from your Cat dealermakes the difference that counts.

Dealer Capability. Cat dealers provide the level ofsupport you need, on a global scale. Dealer experttechnicians have the knowledge, experience,training and tooling necessary to handle yourrepair and maintenance needs, when and whereyou need them.

Product Support. Cat dealers believe superiorproducts deserve superior support. When Catproducts reach the field, they are supported by aworldwide network of parts distribution facilities,dealer service centers, and technical trainingfacilities to keep your equipment up and running.Cat customers rely on prompt, dependable partsavailability and expertise through our globaldealer network, ready to meet your needs 24/7.

Service Support. Every piece of Cat equipmentis designed and built to provide maximumproductivity and operating economy throughoutits working life. Cat dealers offer a wide rangeof service plans that will maximize uptime andreturn on your investment, including:

• Preventive Maintenance Programs

• Diagnostic Programs, such as Scheduled OilSampling and Technical Analysis

• Rebuild and Reman Options

• Customer Support Agreements

Application Awareness. Operating andmaintenance costs are influenced by manyapplication and site-specific factors, such asmaterial density, loading position, payload, grades,speeds, haul road design and maintenance.To optimize total cost of ownership and productivity,your Cat dealer can provide you with a fundamentalunderstanding of the effects applicationcharacteristics and operating techniqueshave on maintenance and operating costs.

Customer Support. Caterpillar® dealers provide unmatched product support, anywhere in the world.With industry-best parts availability and a wide range of maintenance and service options, Cat dealershave what it takes to keep your hauling machines productive.


Customer Support

Operation. With today’s complex products,equipment operators must have a thoroughunderstanding of machine systems and operatingtechniques to maximize efficiency and profitability.Your Cat dealer can arrange training programs tohelp operator’s improve productivity, decreasedowntime, reduce operating costs, enhance safety,and improve return on the investment you makein Cat products.

Technology Products. Cat dealers offer a range ofadvanced technology products, such as VIMS™monitoring system and MineStar™ informationmanagement system. These products include radiodata communications, machine monitoring anddiagnostics, fleet management, and haul roadmaintenance software – all designed to improvefleet efficiency, increase productivity, andlower costs.

www.cat.com. For more complete informationon Cat products, dealer services, and industrysolutions, visit us on the web at www.cat.com.


Safety

Product Safety. Caterpillar has been and continuesto be proactive in developing machines that meetor exceed safety standards. Safety is an integralpart of all machine and systems designs.

Integral ROPS Cab. Resiliently mounted to theframe to reduce vibration and sound, the integralROPS structure, which provides “five-sidedprotection” for the operator, is designed as anextension of the truck frame.

Payload Guidelines. Safety is integral to maintainingthe highest productivity in mining machineoperation. The Caterpillar 10/10/20 PayloadGuidelines ensures that steering and brakingsystems have sufficient capacity to perform.

WAVS Camera (optional). An optional rear visioncamera system provides visibility to the rear ofthe machine through an LCD monitor in the cab.The monitor can be set to activate only when thetruck is in reverse, and the display is equippedwith a sensor to detect ambient light, whichautomatically brightens or dims the display.

High Intensity Discharge (HID) Lights (optional).Thirty-five Watt HID lights can replace thestandard high beam 65 Watt Halogen lights.The powerful HID lights are almost two timesbrighter and 50 percent more efficient, improvingnight time visibility.

Brake Systems. Cat hydraulically controlleddry front and rear oil-cooled multiple discbrakes provide exceptional, fade-resistant brakingand retarding for maximum performance andproductivity in all haul-road conditions. The servicebrakes and retarding system are actuated bymodulated hydraulic pressure, while secondaryand parking brake functions are spring appliedand hydraulic released. This reliable and durablesystem ensures braking in the event of completehydraulic failure.

Steering System. A twin, double-acting cylindersteering system is designed to deliver precisecontrol under all loading and underfoot conditions.The steering hydraulic system is separate fromthe main hydraulic system to prevent cross-contamination and overheating.

Engine Shutoff Switch. A secondary engineshutoff switch is located at ground level.

Electrical System Disconnect. A batterydisconnect switch, located directly above thefront bumper, provides ground-level lockoutof the electrical system.

Ladder/Secondary Egress. A wide, stationarystairway allows easy access to and from themachine. The ladder on the left side of themachine permits secondary egress.

A stairway lamp illuminates the cab access stairsand can be activated at ground level during entryand shut off with a switch in the cab.

Safety. Caterpillar sets the standard when it comes to safety in the design and manufacturing ofheavy equipment. Safety is not an afterthought at Caterpillar, but an integral part of all machineand systems designs.


Safety

Standard Safety Features.

• Slip resistant surfaces

• 75 mm (3 in) wide orange three-pointoperator restraint

• Heated, wide-angle mirrors

• Body raised indicator

• Guard rails

• Reverse neutralizer when dumping

• Low interior sound level

• Service platform level transmission, hoist andsteering disable switch

• Service platform level starter disable switch

Technical Specifications

28 TEJB9246 Cat 775F Off Highway Trucks August 2006

Transmission

Forward 1 10.8 km/h 6.7 mphForward 2 15 km/h 9.3 mphForward 3 20.3 km/h 12.6 mphForward 4 27.3 km/h 17 mphForward 5 37 km/h 23 mphForward 6 49.9 km/h 31 mphForward 7 67.5 km/h 41.9 mphReverse 14.2 km/h 8.8 mph

• Maximum travel speeds with standard 24.00R35 (E4) tires.

Final Drives

Differential Ratio 3.64:1Planetary Ratio 4.80:1Total Reduction Ratio 17.49:1

Brakes

Brake Surface – Front 1395 cm2 216 in2

Brake Surface – Rear 61 269 cm2 9,497 in2

Brake Standards ISO 3450: 1996

• Target Gross Machine Operating Weight is 109 770 kg(242,000 lb).

Body Hoists

Pump Flow – High Idle 560 L/min 148 gal/minRelief Valve Setting – Raise 18 950 kPa 2,750 psiRelief Valve Setting – Lower 3450 kPa 500 psiBody Raise Time – High Idle 9.5 SecondsBody Lower Time – Float 12.5 SecondsBody Power Down – High Idle 12.5 Seconds

Capacity – Dual Slope – 100% fill factor

Struck 33.1 m3 43.3 yd3

Heaped 2:1 (SAE) 42.5 m3 55.6 yd3

Engine

Engine Model Cat® C27 ACERT™Rated Engine Speed 2,000 rpmGross Power – SAE J1995 587 kW 787 hpNet Power – SAE J1349 552 kW 740 hpNet Power – ISO 9249 552 kW 740 hpNet Power – 80/1269/EEC 552 kW 740 hpNumber of Cylinders 12Peak Torque 3501 N·m 2,582 lb ftBore 137 mm 5.4 inStroke 152 mm 6 inDisplacement 27 L 1,649 in3

• Power ratings apply at 2,000 rpm when tested under thespecified condition for the specified standard.

• Ratings based on SAE J1995 standard air conditions of25° C (77° F) and 100 kPa (29.61 Hg) barometer. Powerbased on fuel having API gravity of 35 at 16° C (60° F) andan LHV of 42 780 kJ/kg (18,390 BTU/lb) when engine is usedat 30° C (86° F).

• Compliant with U.S. Environmental Protection AgencyTier 2 and European Union Stage II emissions standards.

Weights – Approximate

Target Gross Machine 109 770 kg 242,000 lbOperating WeightChassis Weight 31 633 kg 69,738 lbBody Weight 13 552 kg 29,877 lb

• Chassis weight with 100% fuel, hoist, body mountinggroup, rims and tires.

• Body weight varies depending on how body is equipped.

Operating Specifications

Nominal Payload Class 63.5 tonnes 70 tonsBody Capacity – SAE 2:1 42.5 m3 55.6 yd3

Top Speed – Loaded 67.4 km/h 41.9 mph

• Refer to the Caterpillar 10/10/20 Payload Guidelinesfor maximum gross machine weight limitations.

• Capacity with dual slope body.

Technical Specifications

29August 2006 TEJB9246 Cat 775F Off Highway Trucks

ROPS

ROPS/FOPS Standards

• ROPS (Rollover Protective Structure) for cab offeredby Caterpillar meets ISO 3471:1994 ROPS criteria.

• FOPS (Falling Objects Protective Structure) meetsISO 3449:1992 Level II FOPS criteria.

Sound

Sound Standards

• The operator sound pressure level measured accordingto ANSI/SAE J1166 MAY90 is 78 dB(A) for cab offered byCaterpillar, when properly installed, maintained and testedwith doors and windows closed, engine speed at high idle,and fan at medium setting.

• Hearing protection may be needed when operating withan open operator station and cab (when not properlymaintained or doors/windows open) for extended periodsor in a noisy environment.

Steering

Steering Standards SAE J1511 OCT90, ISO 5010: 1992

Steer Angle 31ºTurning Diameter – Front 23.5 m 77 ft 1 inTurning Circle Clearance 26.1 m 85 ft 8 inDiameter

• Target Gross Machine Operating Weight is 109 770 kg(242,000 lb).

Capacity – Flat Floor – 100% fill factor

Struck 32 m3 41.8 yd3

Heaped 2:1 (SAE) 41.9 m3 54.8 yd3

Weight Distributions – Approximate

Front Axle – Empty 49%Front Axle – Loaded 33%Rear Axle – Empty 51%Rear Axle – Loaded 67%

Suspension

Effective Cylinder Stroke – Front 235 mm 9.25 inEffective Cylinder Stroke – Rear 149 mm 5.9 inRear Axle Oscillation 8º

Service Refill Capacities

Fuel Tank 700 L 185 galCooling System 175 L 46 galCrankcase 95 L 25 galDifferentials and Final Drives 155 L 41 galSteering Tank 34 L 9 galSteering System (Includes Tank) 60 L 16 galBrake/Hoist System 307 L 81 gal(Includes Tank)Torque Converter/ 53 L 14 galTransmission SystemTorque Converter/Transmission 72 L 19 galSystem (Includes Sump)Brake/Hoist Hydraulic System 133 L 35 gal

Tires

Standard Tire 24.00R35 (E4)

• Productive capabilities of the 775F truck are such that,under certain job conditions, TKPH (TMPH) capabilitiesof standard or optional tires could be exceeded and,therefore, limit production.

• Caterpillar recommends the customer evaluate all jobconditions and consult the tire manufacturer for propertire selection.


DimensionsAll dimensions are approximate. Shown with Dual Slope Body.

Dual Slope Flat Floor1 Height to Top of ROPS 4108 mm 13 ft 6 in 4105 mm 13 ft 6 in2 Overall Body Length 9216 mm 30 ft 3 in 9294 mm 30 ft 6 in3 Inside Body Length 6119 mm 20 ft 1 in 6198 mm 20 ft 4 in4 Overall Length 10 334 mm 33 ft 11 in 10 334 mm 33 ft 11 in5 Wheelbase 4206 mm 13 ft 9 in 4215 mm 13 ft 10 in6 Rear Axle to Trail 2833 mm 9 ft 3 in 2837 mm 9 ft 4 in7 Ground Clearance 777 mm 2 ft 6 in 791 mm 2 ft 7 in8 Dump Clearance 613 mm 2 ft 625 mm 2 ft 1 in9 Loading Height – Empty 3946 mm 12 ft 11 in 3972 mm 13 ft10 Inside Body Depth – 1978 mm 6 ft 6 in 1978 mm 6 ft 6 in

Max11 Overall Height – 9261 mm 30 ft 5 in 9261 mm 30 ft 5 in

Body Raised

Dual Slope Flat Floor12 Operating Width 5255 mm 17 ft 2 in 5392 mm 17 ft 8 in13 Centerline Front 3205 mm 10 ft 6 in 3205 mm 10 ft 6 in

Tire Width14 Engine Guard 698 mm 2 ft 4 in 698 mm 2 ft 4 in

Clearance15 Overall Canopy Width 4955 mm 16 ft 4 in 4986 mm 16 ft 5 in16 Outside Body Width 4257 mm 14 ft 4223 mm 13 ft 11 in17 Inside Body Width 3990 mm 13 ft 1 in 3989 mm 13 ft 1 in18 Front Canopy Height 4428 mm 14 ft 6 in 4430 mm 14 ft 6 in19 Rear Axle Clearance 675 mm 2 ft 2 in 675 mm 2 ft 2 in20 Centerline Rear Dual 2729 mm 9 ft 2929 mm 9 ft 7 in

Tire Width21 Overall Tire Width 4411 mm 14 ft 6 in 4411 mm 14 ft 6 in

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Flat FloorHeavy Duty Heavy Duty

Medium Impact High Impact High Impact High Impact High ImpactSteel Body Steel Body Steel Body Rubber Body Rubber Body

System System System System System(16 mm) (20 mm) (25 mm) (102 mm) Rubber Liner

Target Gross Machine Weight*– kg (lb) 109 769 (242,000) 109 769 (242,000) 109 769 (242,000) 109 769 (242,000) 109 769 (242,000)

Empty Chassis Weight* – kg (lb) 31 633 (69,738) 31 633 (69,738) 31 633 (69,738) 31 633 (69,738) 31 633 (69,738)

Body System Weight – kg (lb) 13 456 (29,665) 14 178 (31,257) 15 840 (34,921) 14 436 (31,826) 15 293 (33,715)

Empty Machine Weight – kg (lb) 45 089 (99,403) 45 811 (100,995) 47 473 (104,659) 46 069 (101,564) 46 926 (103,453)

AttachmentsFuel Tank Size – L (gal) 700 (185) 700 (185) 700 (185) 700 (185) 700 (185)

Fuel Tank – 90% fill – kg (lb) 531 (1,170) 531 (1,170) 531 (1,170) 531 (1,170) 531 (1,170)

Empty Operating Weight – kg (lb) 45 620 (100,573) 46 342 (102,165) 48 004 (105,829) 46 600 (102,734) 47 457 (104,623)

Target Payload* – kg (lb) 64 149 (141,427) 63 427 (139,835) 61 765 (136,171) 63 169 (139,266) 62 312 (137,377)Target Payload* – tonnes (tons) 64.15 (70.71) 63.43 (69.92) 61.77 (68.09) 63.17 (69.63) 62.31 (68.69)

Dual SlopeSteel Liner Steel Liner Steel Liner Rubber Liner Heavy-Duty

(16 mm) (20 mm) (25 mm) (102 mm) Rubber LinerTarget Gross Machine Weight* – kg (lb) 109 769 (242,000) 109 769 (242,000) 109 769 (242,000) 109 769 (242,000) 109 769 (242,000)

Empty Chassis Weight – kg (lb) 31 633 (69,738) 31 633 (69,738) 31 633 (69,738) 31 633 (69,738) 31 633 (69,738)

Body System Weight – kg (lb) 13 552 (29,877) 14 175 (31,251) 15 987 (35,245) 14 327 (31,586) 15 188 (33,484)

Empty Machine Weight – kg (lb) 45 185 (99,615) 45 808 (100,989) 47 620 (104,983) 45 960 (101,324) 46 821 (103,222)

AttachmentsFuel Tank Size – L (gal) 700 (185) 700 (185) 700 (185) 700 (185) 700 (185)

Fuel Tank – 90% fill – kg (lb) 531 (1,170) 531 (1,170) 531 (1,170) 531 (1,170) 531 (1,170)

Empty Operating Weight** – kg (lb) 45 716 (100,785) 46 339 (102,159) 48 151 (106,153) 46 491 (102,494) 47 352 (104,392)

Target Payload* – kg (lb) 64 053 (141,215) 63 430 (139,841) 61 618 (135,847) 63 278 (139,506) 62 417 (137,608)Target Payload* – tonnes (tons) 64.05 (70.61) 63.43 (69.92) 61.62 (67.92) 63.28 (69.75) 62.42 (68.80)

* Refer to the Caterpillar 10/10/20 overload policy.** Includes weight of all attachments.

Weight/Payload Calculation(Example)


0 10 20 30 40 50 60 70 80

0 5 10 15 20 25 30 35 40 45 50

0 25 lb x 1000

mph

km/h

15%

SpeedContinuous Grade Length

Effe

ctiv

e G

rade

(Gra

de M

inus

Rol

ling

Resi

stan

ce)

0 15 30 45 60 75 90 105 120 kg x 1000

Gross Weight

1st Gear

5%

10%

50 75 100 125 150 175 200 225 250

4th Gear

5th Gear

6th Gear7th Gear

30%

2nd Gear

3rd Gear

25%

20%

E L

To determine retarding performance: Add lengths of alldownhill segments and, using this total, refer to properretarding chart. Read from gross weight down to the percenteffective grade. Effective grade equals actual % grade minus1% for each 10 kg/t (20 lb/ton) of rolling resistance. From thisweight-effective grade point, read horizontally to the curvewith the highest obtainable gear, then down to maximumdescent speed brakes can properly handle without exceeding

cooling capacity. The following charts are based on theseconditions: 32° C (90° F) ambient temperature, at sea level,with 24.00 R35 tires.

NOTE: Select the proper gear to maintain engine rpm at the highestpossible level, without overspeeding the engine. If cooling oiloverheats, reduce ground speed to allow transmission to shift tothe next lower speed range.

Retarding Performance

With ARC Only

ARC and Engine Brake

E – Typical Field Empty Weight

L – Target Gross Machine Operating Weight 109 770 kg (242,000 lb)



0 10 20 30 40 50 60 70 80

0 5 10 15 20 25 30 35 40 45 50

0 25 50 75 100 125 150 175 200 225 250 lb x 1000

mph

km/h

SpeedGrade Distance — 450 m (1,500 ft.)

Effe

ctiv

e G

rade

(Gra

de M

inus

Rol

ling

Resi

stan

ce)

0 15 30 45 60 75 90 105 120 kg x 1000

Gross Weight

1st Gear

2nd Gear

3rd Gear

4th Gear

5th Gear

6th Gear7th Gear

30%

5%

10%

15%

25%

20%E L

0 10 20 30 40 50 60 70 80

0 5 10 15 20 25 30 35 40 45 50

0 25 50 75 100 125 150 175 200 225 250 lb x 1000

mph

km/h


Effe

ctiv

e G

rade

(Gra

de M

inus

Rol

ling

Resi

stan

ce)

0 15 30 45 60 75 90 105 120 kg x 1000

Gross Weight

1st Gear

2nd Gear

3rd Gear 4th Gear

5th Gear

6th Gear

30%

5%

10%

15%

25%

20%E L

7th Gear

With ARC Only



L – Target Gross Machine Operating

Weight 109 770 kg (242,000 lb)

With ARC Only




Weight 109 770 kg (242,000 lb)



0 10 20 30 40 50 60 70 80

0 5 10 15 20 25 30 35 40 45 50

0 25 50 75 100 125 150 175 200 225 250 lb x 1000

mph

km/h


Effe

ctiv

e G

rade

(Gra

de M

inus

Rol

ling

Resi

stan

ce)

0 15 30 45 60 75 90 105 120 kg x 1000

Gross Weight

1st Gear

2nd Gear

3rd Gear 4th Gear

5th Gear

6th Gear

30%

5%

10%

15%

25%

20%

E L

7th Gear

0 10 20 30 40 50 60 70 80

0 5 10 15 20 25 30 35 40 45 50

0 25 50 75 100 125 150 175 200 225 250 lb x 1000

mph

km/h


Effe

ctiv

e G

rade

(Gra

de M

inus

Rol

ling

Resi

stan

ce)

0 15 30 45 60 75 90 105 120 kg x 1000

Gross Weight

1st Gear

2nd Gear

3rd Gear 4th Gear

5th Gear

6th Gear

30%

5%

10%

15%

25%

20%

7th Gear

E L

With ARC Only




Weight 109 770 kg (242,000 lb)

With ARC Only




Weight 109 770 kg (242,000 lb)


Gross Weight

5%

10%

15%

20%

25%

30%

100

110

90

80

70

60

50

40

30

20

10

0

50

45

40

35

30

25

20

15

10

5

0

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

0 5 10 15 20 25 30 35 40 45

Speed

Rim

pull

Tota

l Res

ista

nce

(Gra

de p

lus

Rolli

ng)

500 100 150 200 250

1st Gear

1st Gear

Torque Converter Drive

Direct Drive

2nd Gear

3rd Gear

LE

150 30 45 60 75 90 105 120

4th Gear

5th Gear6th Gear

km/h

mph

kg x 1000

lb x 1000

lb x1000

kg x1000

7th Gear

To determine gradeability performance: Read from grossweight down to the percent of total resistance. Total resistanceequals actual percent grade plus 1% for each 10 kg/t (20 lb/ton)of rolling resistance. From this weight-resistance point, read

horizontally to the curve with the highest obtainable gear, thendown to maximum speed. Usable rimpull will depend upontraction available and weight on drive wheels.

Gradeability/Speed/Rimpull

With ARC Only



L – Target Gross Machine Operating Weight 109 770 kg (242,000 lb)

Standard EquipmentStandard equipment may vary. Consult your Caterpillar dealer for details.


POWER TRAINCat® C27 Engine with ACERT™ Technology

12–cylinder dieselAir-to-Air Aftercooler (ATAAC)Air cleaner with precleaner (2)Automatic cold mode idle controlElectric priming pumpEther starting aidExhaust, body heatFuel filter/water separatorQuickEvac™ System with engine prelubeTurbocharger (2)

Braking system:Automatic Retarder Control (ARC) (utilizes rear

oil-cooled brakes)Brake release motor (towing)Manual retarder (utilizes rear oil-cooled brakes)Oil-cooled, multiple disc (rear)Front dry disc brakes

Transmission:7–speed automatic powershift w/Electronic

Clutch Pressure Control (ECPC)Body up shift inhibitorControlled throttle shiftingDirectional shift managementDownshift inhibitorNeutral start switchNeutral coast inhibitorReverse shift inhibitorReverse neutralizer during dumpingProgrammable top gear selection

ANTIFREEZEExtended Life Coolant to –35° C (–30° F)

ELECTRICALAlarm, backupAlternator, 50-ampAuxiliary jump start receptacleBatteries, maintenance-free, 12V (4), 190 amp-hourElectrical system, 25-amp, 24V to 12V converterLighting system:

Backup light (halogen)Directional signals/hazard warning, (front/rear LED)Headlights, halogen with dimmerOperator access courtesy lightsSide profile lightsStop/tail lights LED

MineStar™ ReadyProduct Link Ready (Level 1)

OPERATOR ENVIRONMENTAir conditioningAshtray and cigarette lighterCoat hookCup holders (4)Diagnostic connection port, 24VEntertainment Radio Ready

5 amp converterSpeakersAntennaWiring harness

Gauges/indicators:Air cleaner service indicatorBrake oil temperature gaugeCoolant temperature gaugeEngine overspeed indicatorFuel levelHour meterSpeedometer/odometerTachometerTransmission gear indicator

Heater/defroster, (11 070 kCal/43,930 BTU)Hoist leverHornLight, dome/courtesyLoad counter, automaticMessenger display unitMirrors, heated (left/right)Power port, 24V and 12V (2)ROPS cab, insulated/sound suppressedSeat, Caterpillar Comfort

Full air suspensionRetractable, 3-point seat belt with shoulder harness

Seat, training with lap beltSteering wheel, padded, tilt and telescopicStorage compartmentSun visor, tinted glassThrottle lockWindshield wiper (intermittent) and washer

Standard EquipmentStandard equipment may vary. Consult your Caterpillar dealer for details.


OTHER STANDARD EQUIPMENTBody mounting groupBody safety pin (secures body in up position)Body down indicatorCD-ROM parts bookCenter mounted rimsDirect drive fanFuel tank, 700 L (185 gal)Ground level battery disconnectGround level engine shutdownGround level grease fittingsRimsRock ejectorsService platform level start/disable switchService platform level transmission, hoist and

steering disable switchSupplemental steering (automatic)Tow hooks, frontTow pin, rearVandalism protection locks

GUARDSEngine crankcaseDrivelineFan and Air Conditioning

SUSPENSION SYSTEMSuspension, rear (European Union compliant)

Optional EquipmentOptional equipment may vary. Consult your Caterpillar dealer for details.

Muffler Exhaust BodyProduct Link (Level 3)Rockford FanSpare Rim, 17 inTraction Control System (TCS)Truck Production Management System (TPMS)VIMS™ Monitoring SystemWork Area Vision System (WAVS) Rear Vision CameraWheel ChocksWiggins High Speed Oil Change Wiggins Service Center

Optional Body Systems:Body Liner, Dual Slope/Flat Floor, Steel, 16 mm, 20 mm

or 25 mmBody Liner, Dual Slope/Flat Floor, Rubber, High Impact

or Heavy DutyCat Compression BrakeLincoln Quick Lube Automatic Lubrication SystemClustered Grease FittingsElectric cold weather starterEngine Coolant HeaterExtended Life Disc BrakesFast Fuel, Non-pressurizingFuel HeaterHID LightsHoist Control

Notes


TEJB9246August 2006www.cat.com

© 2006 CaterpillarAll Rights ReservedPrinted in the U.S.A.

The information contained herein is intended for circulation only to Caterpillar and dealer employees whose duties require knowledge of such reports andis intended exclusively for their information and training. It may contain unverified analysis and facts observed by various Caterpillar or dealer employees.However, effort has been made to provide reliable results regarding any information comparing Caterpillar built and competitive machines. Effort has beenmade to use the latest available spec sheet and other material in the full understanding that these are subject to change without notice. Any reproductionof this release without the foregoing explanation is prohibited.

CAT, CATERPILLAR, their respective logos and “Caterpillar Yellow,” as well as corporate and product identity used herein, are trademarks of Caterpillarand may not be used without permission.

®

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