Caterpillar® Product Information

Product Bulletin
August 2006

Cat® 775F
Off Highway Trucks

For Dealer Sales Personnel ®

This document supplements information in the Specalog. Marketing

content will be available only on secured dealer extranets and by
accessing the PDF in the Electronic Sales Library.
Table of Contents

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

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

2 TEJB9246 Cat 775F Off Highway Trucks August 2006

 Overview

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

August 2006 TEJB9246 Cat 775F Off Highway Trucks 3

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 meets
U.S. EPA Tier 2 and European Union Stage II regulations. Through the added efficiencies of the ACERT
Technology, the C27 engine’s service intervals have increased from 250 hours to 500 hours. A newly
designed 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 of
electronic control with the simplicity of direct mechanically controlled fuel injection. The system senses
operating 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 shifts
through the use of the Electronic Clutch Pressure Control (ECPC) system. This proven transmission is
built 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 increased
width than the 775E. A new ergonomic design and layout of controls provides increased productivity
and reduced operator fatigue. This truck features the Caterpillar Comfort Seat, delivering improved
comfort, support and durability to the operator. A lighted stairway access system allows the operator to
easily and safely enter and exit the truck. An optional HID lighting package provides superior nighttime
visibility. Also available is an optional camera system, which provides visibility to the rear of the truck
through 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 comes
standard with Cat Messenger, providing real-time machine performance and diagnostic data. An optional
VIMS™ monitoring system offers extensive machine functions and payload data. These trucks are also
MineStar™ information management system ready, which links machines in the field with business and
operating systems.

4 TEJB9246 Cat 775F Off Highway Trucks August 2006

 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 selector
for easy operation.

Body Systems

The new 775F offers a variety of application-specific body systems to provide versatility as well as the
strength, capacity and durability of its predecessor. Caterpillar will now offer dual slope and flat floor
body 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 operating
costs and reduces downtime. Newly configured electrical access allows for up to 50 percent faster
servicing. A new machine lockout switch allows maintenance and trouble-shooting while the engine is
running. QuickEvac™ system, standard on all F-Series trucks, reduces engine oil service time by up to
50 percent.

August 2006 TEJB9246 Cat 775F Off Highway Trucks 5

Power Train – Engine

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

Cylinder Head. A reengineered cylinder head

delivers dramatically improved airflow with a
unique cross-flow design and new intake manifolds.
The new cross flow air design routes air straight
across the head removing bends and turns that
create resistance to flow. By removing the
resistance to flow, parasitic loads are reduced as
pumping needs are lessened. The cylinder head
is a one-piece, cast iron component with a newly
designed graphite and steel composite head gasket
that seals the combustion chamber with better
rigidity and wear capability.

Overhead Cam. Two, single overhead cams

(one per head) are driven by gears on the flywheel
end of the engine. Placing the cam gears at the
flywheel end significantly reduces noise and
Cat® C27 engine with ACERT™ Technology.
vibration. Caterpillar has also added two pendulum
With the C27 engine, Caterpillar optimizes engine
absorbers, mounted at the front of the camshafts
performance while meeting U.S. EPA Tier 2 and
to further reduce noise and vibration. Together,
European Union Stage II regulations in the 775F.
these two features are contributing to the long life
ACERT™ Technology reduces emissions during
and durability of this engine.
the combustion process by using advanced
technology in the air and fuel systems, in
Pistons, Connecting Rods, Cylinder Liners.
conjunction with integrated electronics. Caterpillar
Changes to the pistons, rods, and liners have been
meets emission regulations at the combustion
made to support the higher cylinder pressures
source, rather than recycling exhaust.
and compression ratios associated with ACERT
Technology. The C27 engine has a 137.2 mm
Engine Design. The Cat C27 engine uses ACERT
(5.4 in) bore, 152.4 mm (6 in) stroke and uses a
Technology and iron-specific features to deliver
single-piece steel piston mated to a more robust
strong performance and long-term durability.
connecting rod to ensure long component life.
The piston’s steel skirt increases its durability.
Block. The C27 block features a new design
The skirt also results in reduced thermal expansion,
that provides higher structural strength through
allowing a tighter piston fit and reduced liner
increased iron compaction and thicker walls.
cavitations. The smaller overall piston surface
This new design supports the engine’s higher
area reduces friction and enhances fuel economy.
compression ratios and increases its power density
Also, the tolerances between the pistons and the
relative to the 3412B.
wet cylinder liners have been tightened to
unprecedented levels.

6 TEJB9246 Cat 775F Off Highway Trucks August 2006

 Power Train – Engine

Turbochargers. The two side-mounted Electronic Control Module (ECM). ECM uses
turbochargers on the C27 engine are air-cooled, advanced engine management software to monitor,
non-waste gated with a with a full aluminum control and protect the engine using self-diagnosing
wheel. The C27 engine also includes a new electronic sensors. The computerized system
turbine housing and an additional spacer bearing. senses operating conditions and power requirements
The addition of a spacer bearing eliminates snap and adjusts the engine for peak performance and
rings and therefore reduces complexity and the most efficient operation at all times.
improves shaft motion. These changes enable
the C27 engine to deliver longer life and lower Advanced Diesel Engine Management A4 Engine
maintenance costs, and contribute to better Controller. The ADEM™ A4 electronic control
fuel economy. module delivers optimum fuel performance.
The engine management system provides flexible
EPA Compliant. The C27 engine is compliant with fuel mapping, allowing the engine to respond
U.S. EPA Tier 2 and European Union Stage II quickly to varying application needs. It tracks
emissions regulations in the 775F, reducing NOx engine and machine conditions while keeping
27.5 percent from 4.8 g/bhp-hr to 3.0 g/bhp-hr the engine operating at peak efficiency.
over the 3412E.
Next Generation Modular Radiator (NGMR).
Single-Piece Piston Design. New single-piece The new modular cooling system with a single-pass
forged steel pistons with integrated forged steel flow core design uses brazed construction for
skirt are more robust to withstand high engine stronger joints, better leak prevention and higher
heat and pressure, and enable enhanced combustion heat transfer. The simpler design of the single-pass
efficiency, improved fuel efficiency and lower system, which replaces the two-pass flow folded
emissions. Corrosion-resistant, stainless steel core system of the 775E, enables coolant to enter
top ring reduces ring, groove and liner wear for one end of the core and flow out the opposite end
greater reliability and longer life. for more efficient ambient cooling capability and
greater durability.
MEUI Fuel System. Fuel delivery, provided by
the MEUI mechanically actuated electronic unit Fan (optional). The 775F includes a direct-drive
injection system, involves a high degree of fan, standard, or an optional on-demand fan with
precision. Precisely shaping the combustion a Rockford clutch. The optional fan provides
cycle lowers combustion chamber temperatures, cooling airflow only when necessary resulting in
generating fewer emissions and optimizing fuel a reduction in fuel consumption, over cooling and
combustion. The system senses operating conditions generated noise. Rockford’s unique variable speed
and regulates fuel delivery for optimum fuel technology enables the fan clutches to respond to
efficiency, improved response times, lower changes in the engine cooling demands by varying
emissions and less smoke. the fan speed. This allows the fan to slow down
or speed up as necessary, utilizing less working
horsepower from the engine and lowering fuel
consumption.

August 2006 TEJB9246 Cat 775F Off Highway Trucks 7

Power Train – Transmission

Power Train – Transmission. The Cat seven-speed power shift transmission matched with the Cat C27
engine with ACERT Technology provides constant power and efficiency over a wide operating speed
range for optimal power train performance.

Lock-Up Torque Converter. Combines maximum

rimpull and cushioned shifting of torque converter
drive with the efficiency and performance of
direct drive. The torque converter includes: an
additional clutch plate to maintain power train
capability for higher horsepower and top speed,
a new torque converter adapter that provides extra
length to house the additional clutch plate and
enables the converter components to be changed
without having to change the housing, and a new
sump oil level switch that serves as an emergency
warning if oil is lost. The lock-up torque converter
engages at approximately 8 km/h (5 mph),
delivering more power to the wheels.

• Lock-Up Clutch. Quickly releases and re-engages

to reduce power train torque loads for smoother
shifting, long life and a more comfortable ride.
Mechanical Power Train. The Cat mechanical
• ECPC (Electronic Clutch Pressure Control)
drive power train and power shift transmission
System. ECPC modulates clutch engagement
provides unmatched operating efficiency and
individually, allowing for smoother speed and
control on steep grades, in poor underfoot
directional shifts. ECPC provides controls for
conditions, and on haul roads with high
both the torque converter lock-up clutch and the
rolling resistance.
transmission clutches that are tailored to each
particular upshift or downshift. This provides
Transmission. Pairing the Caterpillar seven-speed
the operator a superior ride and reduced fatigue.
planetary power shift transmission with the
C27 diesel engine with ACERT Technology
delivers constant power over a wide range of
operating speeds.

• Transmission Chassis Control (TCC). TCC uses

electronically transferred engine rpm data to
execute shifts at preset points for optimum
performance, efficiency and clutch life. The TCC
provides integrated functionality to controlled
throttle shifting, directional shift management,
neutral coast inhibitor, body-up shift limiter and
body-up reverse neutralizer.

8 TEJB9246 Cat 775F Off Highway Trucks August 2006

 Power Train – Transmission

The new contamination control system was designed Final Drives. Cat final drives work as a system
for ECPC systems. The design incorporates two, with the planetary power shift transmission to
high capacity, 6-micron filters with sediment deliver maximum power to the ground. Built to
capacity increased by more than 35 percent withstand the forces of high torque and impact
(compared to the 20-micron filter on the 775E loads, double reduction final drives provide high
ICM system) and a Post Clutch Valve Main Relief torque multiplication to further reduce drive
(PCVMR) system. In the PCVMR system the train stress.
main relief valve is located at the end of the
ECPC valves’ oil supply, reducing debris build-up • Steering System. Hydraulic steering control
by supplying a constant oil flow past the system is designed for exceptional smoothness
ECPC valves. Another ECPC advantage is the and precise control. A separate circuit prevents
incorporation of external pressure taps to improve cross contamination for long life.
maintenance. These pressure taps provide easy
external access to pressure readings on the lube, • Battery Powered Supplemental Steering.
main relief valve, and the seven transmission A battery powered supplemental steering system
clutches. Without accessing the inside of the uses pressure accumulators and allows up to
transmission, these pressure taps reduce the three 90 degree turns in case of engine failure.
opportunity for contamination.
• Wheels and Rims. Cast rear wheels and
Cat center-mount rims are mounted using studs
and nuts to minimize maintenance and maximize
durability.

August 2006 TEJB9246 Cat 775F Off Highway Trucks 9

Structures

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

Suspension System. Designed to dissipate haul-

road and loading impacts for longer frame life and
a more comfortable ride.

• Cylinders. Four independent self-contained,

oil pneumatic, variable-rebound suspension
cylinders are designed to absorb shocks in the
most severe applications.

• Durable Design. Rugged cylinders use a large

diameter bore and low pressure nitrogen/oil
design for long life with minimal maintenance.
Box-Section Design. The 775F frame uses a
– Front. Front cylinders with preset caster and
box-section design, incorporating two forgings
camber are mounted to the frame and serve as
and 19 castings in high-stress areas with deep
steering kingpins for a tight turning radius with
penetrating and continuous wrap-around welds
excellent maneuverability and low maintenance.
to resist damage from twisting loads without
adding extra weight.
– Rear. Rear cylinders allow axle oscillation
and absorb bending and twisting stresses caused
• Steel Structures. Mild steel used throughout
by uneven and rough haul roads rather than
the frame provides flexibility, durability and
transmitting them to the frame.
resistance to impact loads, even in cold climates,
and allows for easy field repairs.
Technology Enhanced. Caterpillar structures are
tested using System Structural Analysis (SSA)
• Castings. Castings have large radii with internal
to dynamically simulate operations in field
reinforcing ribs to dissipate stress in areas of high
environments and identify potential structural
stress concentration. Castings move welds to
improvements in high stress areas. With analysis
lower stress areas for greater frame life.
of machine structures and variables, such as haul
road and payload, structural improvements were
made to the frame to accommodate the new cab,
platform, engine and radiator.

Quality Control. A Coordinate Measuring

Machine (CMM) is used to inspect truck frames
for consistency in the manufacturing process.
Easy rebuild ability is thereby achieved by
ensuring the frames are within tolerance,
Integral Four-Post ROPS Cab. Resiliently mounted
removing the need to alter down-stream parts.
to the main frame with all-new cab mounts that
reduce vibration and sound, the integral ROPS
is designed as an extension of the truck frame.
The ROPS/FOPS structure provides “five-sided
protection” for the operator.

10 TEJB9246 Cat 775F Off Highway Trucks August 2006

 Engine – Power Train Integration

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

Controlled Throttle Shifting. Regulates engine rpm

during shifting to reduce power train stress and
1 Engine Control Module (ECM) clutch wear by controlling engine speed, torque
2 Sensors

ET
10
3
4
Electronic Unit Injector (EUI)
Automatic Retarder Control (ARC)
converter lock-up, and transmission clutch
and Traction Control System (TCS)
5
6
Transmission/Chassis Control (TCC)
Transmission
engagement for smoother shifts and longer
7 Wheel Sensor

3
4 8
9
Brakes
CAT Data Link
component life.
10 Cat Messenger
5
7

2 9 6 8 Directional Shift Management. Regulates engine

1
speed during directional shifts to prevent damage
caused by high-speed directional changes.

Neutral Coast Inhibitor. Prevents the transmission

from shifting to neutral at speeds above 6.5 km/h
Cat Data Link. Electronically integrates machine
(4 mph), protecting the transmission from operating
computer systems to optimize overall power train
with insufficient lubrication.
performance, increase reliability and component
life, and reduce operating costs. All control
Body-up Shift Limiter. Prevents the transmission
modules communicate via the Cat Data Link
from shifting above a pre-programmed gear
and work together as an integrated system to
without the body being fully lowered. This function
maximize production efficiency and extend
is programmable via Cat Electronic Technician
component life.
(Cat ET) and Messenger or Advisor.
Transmission Chassis Control (TCC). TCC uses
Body-up Reverse Neutralizer. Automatically shifts
electronically transferred engine rpm data to
the transmission to neutral if the hoist lever is
execute shifts at preset points for optimum
activated while the transmission is shifted in reverse.
performance, efficiency and clutch life.
Overspeed Protection. The transmission control
Electronic Technician (Cat ET). Cat ET service
electronically senses engine conditions and
tool provides service technicians with easy access
automatically up-shifts one gear to prevent
to stored diagnostic data through the Cat Data
overspeeding. If overspeeding occurs in the top
Link to simplify problem diagnosis and increase
gear, the lock-up clutch is disengaged, and the
machine availability. Cat ET is beneficial because
brakes are applied.
of how it displays the status of all engine parameters,
including throttle position, timing and fuel flow.
Programmable Top Gear. Transmission top gear
Critical data from the electronic engine and
maximum can be set using Cat Messenger,
transmission controls, including transmission
VIMS Advisor or the Cat ET service tool to
shifting, engine speed and fuel consumption,
help the operator maintain speed limits.
provides service technicians with enhanced
diagnostic capability to reduce downtime and
operating costs.

August 2006 TEJB9246 Cat 775F Off Highway Trucks 11

Engine – Power Train Integration

Anti-Hunt Function. This function minimizes Reverse Shift Inhibitor. Protects the engine from
shifting by not allowing the transmission to up or abrupt directional changes by slowing down the
down shift immediately after a shift has occurred. engine before shifting the transmission into reverse.
This prevents gear hunting when operating near a
shift point and minimizes transmission shifting for Cat Messenger. Critical data from the engine and
increased component life. transmission, including transmission shifting,
engine speed and fuel consumption, provides
Downshift Inhibitor. Prevents engine overspeeding service technicians with enhanced diagnostic
by keeping the transmission from downshifting capability, through Cat Messenger, to reduce
until engine speed reaches the downshift point. downtime and operating costs.

ECPC Control. Both the torque converter lock-up Traction Control System (TCS) (optional).
clutch and the transmission clutches now have TCS electronically monitors and controls rear
software-control for clutch fill and slip wheel slippage for greater traction and enhanced
characteristics to provide superior smooth shifting. truck performance in poor underfoot conditions.

Economy Shift Mode. Engine speed in third gear Hydraulic Power Management System.
and above is reduced to improve fuel consumption, The system reduces parasitic losses in the power
lower noise levels and potentially lengthen engine management system components. The system is
life. Economy Shift Mode is best used when a operated by two new variable displacement piston
customer has extra truck capacity and wants to pumps. These pumps primarily provide for the
lower cost-per-ton. A customer who effectively steering and are independent of the brake and
uses Economy Shift Mode can reduce operating hoist circuit.
costs without sacrificing production.

12 TEJB9246 Cat 775F Off Highway Trucks August 2006

 Brake System

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

Oil-Cooled Multiple Disc Brakes. Cat dry front

and rear oil-cooled, multiple disc brakes are
now hydraulically controlled, reducing
maintenance costs.

The 775F brakes provide exceptional, fade-resistant

Integrated Braking System. The Cat oil-cooled braking and retarding for maximum performance
braking system delivers reliable performance and and productivity in all haul-road conditions.
control in the most extreme haul-road conditions.
The integrated system combines the service, Extended Life Multiple Disc Brakes (optional).
secondary, parking brake and retarding functions Extended life friction material has double the
in the same system for optimum braking efficiency. wear life of standard brakes and is twice as
resistant to glazing for more consistent braking
power with less noise.

August 2006 TEJB9246 Cat 775F Off Highway Trucks 13

Brake System

Brake Design. Cat rear oil-cooled disc brakes are 2500

designed with large discs and plates for reliable,
adjustment-free operation and performance. 2000
Rear brakes are completely enclosed and sealed

Engine Speed (rpm)

to prevent contamination and reduce maintenance.
1500
Long Life. An oil film prevents direct contact
between the discs. This design absorbs the
braking forces by shearing the oil molecules 1000
and carrying heat away to extend brake life.

Pistons. The Caterpillar two-piece piston design 500

combines the service, secondary, parking brake
and retarding functions in the same system. 0 10 20 30 40 50 60 70
The primary piston hydraulically actuates both Time (Seconds)
service and retarding functions. The secondary
piston is spring-applied and held in the disengaged With Automatic Retarder Control
position by hydraulic pressure. If hydraulic system (average speed, 1950 rpm)
pressure drops below a specified level, the
With Manual Retarder Control
spring-applied secondary piston automatically (average speed, 1730 rpm)
applies the brakes.
• Faster Speeds. ARC allows the operator to
Parking Brake. Oil-cooled, spring-applied,
maintain optimum engine speeds for up to
hydraulically released parking brake is applied
15 percent faster downhill hauls and greater
to the rear wheels for superior parking capability
productivity.
on all grades up to 15 percent.
ARC TCS
1 2
1
2
Service Brake Sensor
Engine Sensor • Superior Control. Automatic brake modulation
3 ARC
4
5
ARC Switch
Brakes
offers a smoother ride and better control in
6 Service Brakes
7 Axle Speed Sensor
6
slippery conditions, allowing the operator to
8 TCS 7

8
concentrate on driving.
3
7

5 6

4
• Ease of Operation. ARC increases operating
ease, resulting in greater operator confidence
Automatic Retarder Control (ARC). Standard ARC with less fatigue.
electronically controls braking on grade to maintain
engine at approximately 1,900 rpm (adjustable • Engine Overspeed Protection. Automatically
from 1,850-1,950 rpm in increments of 10). activates ARC when engine speed exceeds factory
ARC is deactivated when the operator applies preset levels, regardless of operator inputs, to
the brakes or throttle. avoid potentially damaging engine overspeeds.

14 TEJB9246 Cat 775F Off Highway Trucks August 2006

 Brake System

Traction Control System (TCS) (optional). Compression Brake (optional). An all-new Cat
Electronically monitors and controls rear wheel compression brake is available as an option on
slippage for greater traction and enhanced truck the 775F in addition to the standard Automatic
performance in poor underfoot conditions. Retarder Control (ARC). The Cat compression
If slippage exceeds a set limit, the oil-cooled brake delays the release of pressure in the
disc brakes engage to slow the spinning wheel. cylinders to brake the machine, and is integrated
Torque is then automatically transferred to the into the ARC braking system. It provides engine-
wheel with better traction. braking torque by opening the exhaust valves
during the compression stroke of the engine.
Differential Action. Normal differential action A conventional master/slave brake actuation
provides superior maneuvering and control in system opens the cylinder’s exhaust valves to
slippery conditions. release compressed air. By working in combination
with ARC, the system provides up to 35 percent
higher downhill travel speed that reduces wear
on brake components in retarding applications.
This Caterpillar manufactured component is built for
long, carefree service. It requires no tune-ups, and
no maintenance except periodic valve lash checks.

August 2006 TEJB9246 Cat 775F Off Highway Trucks 15

Operator’s Station

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

Hoist Lever. Four-position, low effort electronic

hoist control system is positioned next to the gear
selector in the right-hand console.

Secondary Brake Pedal. Conveniently located

on the floor for easy operator control.

Steering Column. Comfortable steering wheel

with tilt and telescoping function provides a
comfortable driving position for all operators.

Transmission Console. Ergonomic gear shift lever

with backlit gear indicators provides easy operation.
The parking brake function is integrated into the
gear selector.

Trainer Seat. The trainer seat is relocated to the

left of the operator, which allows trainer to use
same stairway.
Ergonomic Layout. The 775F operator station is
ergonomically designed for total machine control
When not in use, the fold-down trainer seat
in a comfortable, productive and safe environment.
creates a working surface with cup holder. The
All controls, levers, switches and gauges are
seat also folds up, providing more room for the
positioned to maximize productivity and minimize
operator. Under seat storage is convenient for
operator fatigue.
stowing a lunch box.
New ISO Designed Cab Mounts. Integral, sound-
Operator Controls. Easy to reach turn signal,
suppressed cab is resiliently mounted to the frame
high beam, intermittent windshield wiper and
to isolate the operator from sound and vibration
windshield washer controls are located on the left
for a quiet, secure and comfortable ride.
side of the steering column, and are designed for
optimum efficiency and comfort.
Viewing Area. Designed for excellent all-around
visibility and clear sight lines to the haul road.
Heating/Air Conditioning. Electronically controlled,
The large viewing area, with 100 percent more
four-speed fan and 13 vents deliver temperature-
glass, enables the operator to maneuver with
controlled air circulation for a comfortable working
confidence for greater productivity.
environment in any climate. Electronic controls
reduce maintenance. A 57% increase in heating
Air Suspension Seat w/Three-Point Operator
capacity as well as a more robust air compressor
Restraint. Ergonomically designed, fully adjustable
offers a 25 percent increase in BTU’s, greater
air suspension seat with adjustable armrests
durability and longer life.
provides optimal driving comfort. A wide,
retractable 3-point seat/shoulder belt provides
a secure, comfortable restraint.

16 TEJB9246 Cat 775F Off Highway Trucks August 2006

 Operator’s Station

Radio Ready. Cab is prewired with power

converter, speakers, wiring harness, antenna and
necessities for add-on communication systems.

Multiple Power Ports. Power ports are conveniently

located in three locations in the cab: one in the
right-hand console, two behind the trainer seat,
and one in the dash.

Truck Production Management System (TPMS)

(optional). TPMS provides valuable payload and
cycle time data, which is viewed through Messenger
or VIMS Advisor to improve productivity.

Now the system provides 2,400 cycles, as opposed

to the previous 1,400 cycles, and takes a second
payload measurement when the truck reaches
second gear for increased accuracy.

Standard LED lamps replace incandescent lamps

on the TPMS, extending lamp life by 25 times.

August 2006 TEJB9246 Cat 775F Off Highway Trucks 17

Serviceability

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 designed
to reduce downtime.

Engine Prelube. Engine prelubrication provides

engine oil pressure prior to engine cranking.
This reduces engine dry and cold start wear,
and reduces engine component wear. This system
automatically fills engine oil filters and galleries,
and ensures components are lubed prior to starting
the engine.

Scheduled Oil Sampling. S•O•SSM sampling valves

speed sampling and analysis reliability.

Pressure Test Points. Disconnect valves are

conveniently located throughout the hydraulic
systems for easy pressure testing. New ECPC
transmission provides multiple pressure taps
outside the transmission.

Air Filters. Radial seal air filters are easy to

change, reducing time required for air filter
Servicing Ease. Easy access to daily service
maintenance.
points simplifies servicing and reduces time spent
on regular maintenance procedures. Enhanced
Sealed Electrical Connectors. Electrical connectors
serviceability and extended 500-hour service
are sealed to lock out dust and moisture. Harnesses
intervals are designed to increase machine
are braided for protection. Wires are color-coded
availability and productivity.
for easy diagnosis and repair.
Maintenance Platform. Easy stairway access
Spin-on Filters. Spin-on filters for fuel and oil
to engine, air filters, steering hydraulic tank
systems reduce changing time and help ensure
and radiator.
clean, tight seals.
Ground-Level Access. All maintenance points
On-Board Diagnostic Systems. Messenger
have convenient ground level or platform access.
continuously checks all critical machine functions
Common engine service points are grouped on
and components, and helps locate faults quickly
the right side of the engine for quick access.
for faster repair. Electronic control system enables
Two fuel filters come standard with the machine
quick diagnosis of engine conditions and effective
and the primary fuel filter includes a water separator.
maintenance and repairs using the Electronic
These filters are easy to change and are all
Technician (Cat ET) service tool.
spin-on/spin-off type.

Engine oil check and fill are accessed via the

service platform. The newly designed engine oil
dipstick is “rope-type” style, making daily checks
easier for the operator.

18 TEJB9246 Cat 775F Off Highway Trucks August 2006

 Serviceability

Lincoln’s Quick Lube Automatic Lubrication QuickEvac™ System. Oil change labor time is
(optional). This advanced lubrication system is reduced by as much as 50 percent with this standard
available as a factory installed option on the 775F. on-board engine oil evacuation and pre-lube system.
This system provides optimal lubrication at preset It speeds the process of evacuating the engine sump
intervals during machine operation significantly and allows for the purging of oil filters prior to
extends component life. Contaminants are purged removal, minimizing oil spills. QuickEvac system
from the open pins and bushings, and protective also enhances contamination control by ensuring
grease seals are maintained. As opposed to complete filtration of new oil on engine refill.
manual lubrication, this option reduces downtime,
labor, and lubricant costs and improves machine Reduced Maintenance Costs/Higher Machine
resale value. Availability. The C27 engine with ACERT
Technology offers 500-hour service intervals
Clustered Grease Fittings (optional). Clustered under normal conditions. For the 775F, commonly
grease fittings save time as all lubrication points used engine service points have been placed on
are mounted in three main locations. the right side of the engine. Feedback from engine
sensors provides data to the electronic controller.
Oil Dipstick. New “rope-type” oil dipstick improves When engine data is out of spec, a warning is sent
serviceability by allowing easy daily checks. to the operator.

Next Generation Modular Radiator (NGMR).

This cooling system’s new modular design
permits removal of a single core without removing
the entire radiator, reducing downtime and repair
costs. The less complex design offers improved
reliability and higher efficiency over the two-pass
flow core. NGMR also offers wider fin spacing
for greater resistance to plugging and more
convenient cleaning.

August 2006 TEJB9246 Cat 775F Off Highway Trucks 19

Information & Monitoring Systems

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

1 Gauge Cluster
• System is accurate within ± 5 percent under
2 Advisor Display

1
2
3
4
5
Action Alarm
ADEM A4 Engine Control Module
CAT Data Link
normal loading conditions over a normal shift.
6 Payload Lamps
7 Data Port (VIMS-PC)
8 Diagnostic Connector (ET)
7 8 9 Automatic Retarder Control (ARC) and

9
Traction Control System (TCS)
10 Transmission/Chassis Control (TCC) Module
11 Telemetry Port
• Standard LED lamps replace incandescent
11

10
lamps on the TPMS, extending lamp life by
6

5
25 times.

4
VIMS™ Monitoring System (optional). Caterpillar
designed machine monitoring system provides
Instrument Cluster. Critical operating information more than 250 machine parameters, critical
on the 775F is relayed via the Cat Data Link to machine health and payload data in real-time to
five gauges, 18 LED indicator lights, and an keep the 775F performing at top production levels.
LCD digital display. In addition to the usual Messenger monitoring
system functionality, the system also monitors:
Cat Messenger. Standard on the 775F,
Cat Messenger provides real-time machine • torque converter screen switch,
performance and operating data, and basic trip,
maintenance, and diagnostic data using an • torque converter inlet filter,
LCD display. The viewable LCD screen area of
the Messenger display is 22.5 mm  84.6 mm • brake oil temperature,
(0.89 in  3.33 in).
• fuel level,
Truck Production Management System (TPMS)
(optional). TPMS provides valuable payload and • ambient air temperature,
cycle time data to improve productivity.
• ‘R’ terminal,
• Uses strut pressure sensors and on-board
microprocessor to determine payload weight. • front aftercooler temperature,
• Delivers consistent, accurate payloads and • aftercooler coolant level,
improves efficiency by minimizing overloading
and underloading. • jacket-water level,
• External lights signal loading tool operator • high steering pressure switch,
when payload is reached.
• steering oil temperature,
• On-board computer stores up to 2,400 cycles
for analysis of payload weight, cycle times, • steering oil bypass switch,
distances, and actual cycle dates and times.
• payload, and others.
• A second gear reweigh takes an additional
measurement once the truck has reached second
gear for improved accuracy.

20 TEJB9246 Cat 775F Off Highway Trucks August 2006

 Information & Monitoring Systems

Product Link (optional). Now available out of the • MineStar Production – Monitors and reports
factory, this system streamlines diagnostic efforts, mine production information in real time.
downtime, and maintenance scheduling and costs Manages production and delay codes for
by providing a two-way communication flow of accurate machine utilization tracking.
vital machine data and location information between
the dealer and the customer. Product Link provides • MineStar Fleet Commander – Advanced
updates on service meter hours, machine condition, optimization algorithm increases truck/shovel
machine location as well as integrated fleet use. Maximizes shovel production and
mapping/route planning. minimizes truck wait time, while simultaneously
meeting mine production plan requirements for
MineStar™ Ready. MineStar information material blending.
management system helps meet the challenges
of the mining industry by linking the machines • MineStar Health – Monitors and communicates
in the field with business and operating systems machine vital sign information in real time,
to ensure peak performance of mining assets at enabling remote maintenance/service diagnostics
the lowest possible cost. These products deliver and advanced prognostic analysis. Enhances the
customers everything from real-time machine entire maintenance and repair process, allowing
health information to GPS-guided production higher machine availabilities to be attained.
aids. The 775F is equipped for quick and easy
installation of MineStar information management • MineStar Business Enterprise – Provides IT
system products. infrastructure platform for seamless integration
of MineStar information management system
Specific Minestar information management with other mine planning and enterprise
system products include: resource planning systems.

• MineStar Machine Tracking – Monitors

machine locations and fleet movement via GPS,
alerting controllers to delays against expected
arrival times. Provides position analysis of
machine operational and health events.

• MineStar Material Tracking – Tracks and

manages material types and grades, improving
overall ore recovery by ensuring material is
moved to correct destinations. Includes material
stockpile tracking. Allows for real-time grade
determination at the excavation face.

August 2006 TEJB9246 Cat 775F Off Highway Trucks 21

Truck Body Systems

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

Body Liners. Two liner materials, steel and rubber,

are available to help extend body system life.
All steel liner wear surfaces are equipped with
400 BHN steel to handle tough impact loads while
resisting abrasion. Optional rubber liners deliver
long life in high-wear and high-impact areas as
well as increases operator comfort during loading.
1 2

1) Dual Slope Body 2) Flat Floor Body

Body Design. With the introduction of the 775F,

Caterpillar offers five application-specific body
Body Selection. Selection of the right body system systems. Dual slope and flat floor body offerings
depends on material, haul road and loading are available in three steel configurations and
conditions. The better the match of body to two rubber configurations.
application, the greater the efficiency. Cat dealers
can help select the right body system for site- The new dual slope and flat floor body systems
specific applications. will continue to use fully fabricated, mild steel
structures, offering a strong, yet weldable underbody
Body/Chassis Integration. Caterpillar truck body structure. All interior, steel body surfaces that
systems are designed and matched with the come in contact with material are fabricated
integrated chassis system for optimum structural from 400 BHN steel to provide superior wear
reliability, durability and long life. characteristics and resistance to impact.
Wide box-section ribs provide excellent durability
Electronic Hoist Control. Provides the operator with and impact support in the floor, front-wall,
better control of the load when dumping, including sidewall, and top rail areas. Full-length stringer
over-center load control and modulated control rails enhance strength and rigidity throughout the
throughout the operating range. The automatic body. Other new features that further enhance
body snubbing feature reduces impact on the durability of the understructure include:
frame, hoist cylinders and operator.
• The body sidewall ties directly in with the floor,
Fast Hoist Cycle Times. Two-stage hoist cylinders providing increased strength in the sidewalls.
provide fast dump cycle times of 9.5 seconds for
raise and 12.5 seconds for lower. • Thickness of ribs increased to 10 mm and the
number of floor ribs have been increased from
7 to a total of 9 ribs.

22 TEJB9246 Cat 775F Off Highway Trucks August 2006

 Truck Body Systems

• Front wall body rest supports are integrated into

the front wall structure for enhanced durability.

• Front wall is 400 BHN and the thickness is

increased from 10.2 mm (0.4 in) to 16.0 mm
(0.63 in), eliminating the need for additional
liners for impact resistance in most applications.

Matched Systems. Designed to work as an

optimum pass/match system, the 775F is best
sized to match the 988H Wheel Loader, with
5 pass/match, the 990H Wheel Loader, with a
4 pass/match, and the 385C Hydraulic Excavator,
Target Payload Strategy. Your Caterpillar Dealer with a 7 pass/match.
can help you manage to target payload to maximize
equipment use, ensure safe operation, increase
productivity and lower cost-per-ton.

• Underloading increases costs due to lost

payloads, underutilizes equipment, and
increases cost-per-ton.

• Overloading causes excessive wear on vehicle

components, such as brakes, tires and drive
train, reducing component life and increasing
maintenance costs and repairs.

August 2006 TEJB9246 Cat 775F Off Highway Trucks 23

Customer Support

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 dealers
have what it takes to keep your hauling machines productive.

Product Support. Cat dealers believe superior

products deserve superior support. When Cat
products reach the field, they are supported by a
worldwide network of parts distribution facilities,
dealer service centers, and technical training
facilities to keep your equipment up and running.
Cat customers rely on prompt, dependable parts
availability and expertise through our global
dealer network, ready to meet your needs 24/7.

Service Support. Every piece of Cat equipment

is designed and built to provide maximum
productivity and operating economy throughout
its working life. Cat dealers offer a wide range
of service plans that will maximize uptime and
return on your investment, including:

• Preventive Maintenance Programs

Commitment Makes the Difference. Cat ® dealers
• Diagnostic Programs, such as Scheduled Oil
offer a wide range of solutions, services and
Sampling and Technical Analysis
products that help you lower costs, enhance
productivity and manage your operation more
• Rebuild and Reman Options
efficiently. Support goes far beyond parts and
service. From the time you select a piece of
• Customer Support Agreements
Cat equipment until the day you rebuild, trade or
sell it, the support you get from your Cat dealer
Application Awareness. Operating and
makes the difference that counts.
maintenance costs are influenced by many
application and site-specific factors, such as
Dealer Capability. Cat dealers provide the level of
material density, loading position, payload, grades,
support you need, on a global scale. Dealer expert
speeds, haul road design and maintenance.
technicians have the knowledge, experience,
To optimize total cost of ownership and productivity,
training and tooling necessary to handle your
your Cat dealer can provide you with a fundamental
repair and maintenance needs, when and where
understanding of the effects application
you need them.
characteristics and operating techniques
have on maintenance and operating costs.

24 TEJB9246 Cat 775F Off Highway Trucks August 2006

 Customer Support

Operation. With today’s complex products,

equipment operators must have a thorough
understanding of machine systems and operating
techniques to maximize efficiency and profitability.
Your Cat dealer can arrange training programs to
help operator’s improve productivity, decrease
downtime, reduce operating costs, enhance safety,
and improve return on the investment you make
in Cat products.

Technology Products. Cat dealers offer a range of

advanced technology products, such as VIMS™
monitoring system and MineStar™ information
management system. These products include radio
data communications, machine monitoring and
diagnostics, fleet management, and haul road
maintenance software – all designed to improve
fleet efficiency, increase productivity, and
lower costs.

www.cat.com. For more complete information

on Cat products, dealer services, and industry
solutions, visit us on the web at www.cat.com.

August 2006 TEJB9246 Cat 775F Off Highway Trucks 25

Safety

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

High Intensity Discharge (HID) Lights (optional).

Thirty-five Watt HID lights can replace the
standard high beam 65 Watt Halogen lights.
The powerful HID lights are almost two times
brighter and 50 percent more efficient, improving
night time visibility.

Brake Systems. Cat hydraulically controlled

dry front and rear oil-cooled multiple disc
brakes provide exceptional, fade-resistant braking
and retarding for maximum performance and
productivity in all haul-road conditions. The service
brakes and retarding system are actuated by
modulated hydraulic pressure, while secondary
and parking brake functions are spring applied
and hydraulic released. This reliable and durable
system ensures braking in the event of complete
hydraulic failure.
Product Safety. Caterpillar has been and continues
Steering System. A twin, double-acting cylinder
to be proactive in developing machines that meet
steering system is designed to deliver precise
or exceed safety standards. Safety is an integral
control under all loading and underfoot conditions.
part of all machine and systems designs.
The steering hydraulic system is separate from
the main hydraulic system to prevent cross-
Integral ROPS Cab. Resiliently mounted to the
contamination and overheating.
frame to reduce vibration and sound, the integral
ROPS structure, which provides “five-sided
Engine Shutoff Switch. A secondary engine
protection” for the operator, is designed as an
shutoff switch is located at ground level.
extension of the truck frame.
Electrical System Disconnect. A battery
Payload Guidelines. Safety is integral to maintaining
disconnect switch, located directly above the
the highest productivity in mining machine
front bumper, provides ground-level lockout
operation. The Caterpillar 10/10/20 Payload
of the electrical system.
Guidelines ensures that steering and braking
systems have sufficient capacity to perform.
Ladder/Secondary Egress. A wide, stationary
stairway allows easy access to and from the
WAVS Camera (optional). An optional rear vision
machine. The ladder on the left side of the
camera system provides visibility to the rear of
machine permits secondary egress.
the machine through an LCD monitor in the cab.
The monitor can be set to activate only when the
A stairway lamp illuminates the cab access stairs
truck is in reverse, and the display is equipped
and can be activated at ground level during entry
with a sensor to detect ambient light, which
and shut off with a switch in the cab.
automatically brightens or dims the display.

26 TEJB9246 Cat 775F Off Highway Trucks August 2006

 Safety

Standard Safety Features.

• Slip resistant surfaces

• 75 mm (3 in) wide orange three-point

operator restraint

• Heated, wide-angle mirrors

• Body raised indicator

• Guard rails

• Reverse neutralizer when dumping

• Low interior sound level

• Service platform level transmission, hoist and

steering disable switch

• Service platform level starter disable switch

August 2006 TEJB9246 Cat 775F Off Highway Trucks 27

Technical Specifications

Engine Transmission

Engine Model Cat ® C27 ACERT™ Forward 1 10.8 km/h 6.7 mph
Rated Engine Speed 2,000 rpm Forward 2 15 km/h 9.3 mph
Gross Power – SAE J1995 587 kW 787 hp Forward 3 20.3 km/h 12.6 mph
Net Power – SAE J1349 552 kW 740 hp Forward 4 27.3 km/h 17 mph
Net Power – ISO 9249 552 kW 740 hp Forward 5 37 km/h 23 mph
Net Power – 80/1269/EEC 552 kW 740 hp Forward 6 49.9 km/h 31 mph
Number of Cylinders 12 Forward 7 67.5 km/h 41.9 mph
Peak Torque 3501 N·m 2,582 lb ft Reverse 14.2 km/h 8.8 mph
Bore 137 mm 5.4 in • Maximum travel speeds with standard 24.00R35 (E4) tires.
Stroke 152 mm 6 in
Displacement 27 L 1,649 in3
• Power ratings apply at 2,000 rpm when tested under the Final Drives
specified condition for the specified standard.
Differential Ratio 3.64:1
• Ratings based on SAE J1995 standard air conditions of
25° C (77° F) and 100 kPa (29.61 Hg) barometer. Power Planetary Ratio 4.80:1
based on fuel having API gravity of 35 at 16° C (60° F) and Total Reduction Ratio 17.49:1
an LHV of 42 780 kJ/kg (18,390 BTU/lb) when engine is used
at 30° C (86° F).
• Compliant with U.S. Environmental Protection Agency Brakes
Tier 2 and European Union Stage II emissions standards.
Brake Surface – Front 1395 cm2 216 in2
Brake Surface – Rear 61 269 cm2 9,497 in2
Weights – Approximate Brake Standards ISO 3450: 1996
• Target Gross Machine Operating Weight is 109 770 kg
Target Gross Machine 109 770 kg 242,000 lb
(242,000 lb).
Operating Weight
Chassis Weight 31 633 kg 69,738 lb
Body Weight 13 552 kg 29,877 lb Body Hoists
• Chassis weight with 100% fuel, hoist, body mounting
group, rims and tires. Pump Flow – High Idle 560 L/min 148 gal/min
• Body weight varies depending on how body is equipped. Relief Valve Setting – Raise 18 950 kPa 2,750 psi
Relief Valve Setting – Lower 3450 kPa 500 psi
Body Raise Time – High Idle 9.5 Seconds
Operating Specifications Body Lower Time – Float 12.5 Seconds
Body Power Down – High Idle 12.5 Seconds
Nominal Payload Class 63.5 tonnes 70 tons
Body Capacity – SAE 2:1 42.5 m3 55.6 yd3
Top Speed – Loaded 67.4 km/h 41.9 mph Capacity – Dual Slope – 100% fill factor
• Refer to the Caterpillar 10/10/20 Payload Guidelines
for maximum gross machine weight limitations. Struck 33.1 m3 43.3 yd3
• Capacity with dual slope body. Heaped 2:1 (SAE) 42.5 m3 55.6 yd3

28 TEJB9246 Cat 775F Off Highway Trucks August 2006

 Technical Specifications

Capacity – Flat Floor – 100% fill factor ROPS

Struck 32 m3 41.8 yd3 ROPS/FOPS Standards

Heaped 2:1 (SAE) 41.9 m3 54.8 yd3 • ROPS (Rollover Protective Structure) for cab offered
by Caterpillar meets ISO 3471:1994 ROPS criteria.
• FOPS (Falling Objects Protective Structure) meets
Weight Distributions – Approximate ISO 3449:1992 Level II FOPS criteria.

Front Axle – Empty 49%

Front Axle – Loaded 33% Sound
Rear Axle – Empty 51%
Rear Axle – Loaded 67% Sound Standards
• The operator sound pressure level measured according
to ANSI/SAE J1166 MAY90 is 78 dB(A) for cab offered by
Suspension Caterpillar, when properly installed, maintained and tested
with doors and windows closed, engine speed at high idle,
Effective Cylinder Stroke – Front 235 mm 9.25 in and fan at medium setting.
Effective Cylinder Stroke – Rear 149 mm 5.9 in • Hearing protection may be needed when operating with
Rear Axle Oscillation 8º an open operator station and cab (when not properly
maintained or doors/windows open) for extended periods
or in a noisy environment.
Service Refill Capacities

Fuel Tank 700 L 185 gal Steering

Cooling System 175 L 46 gal
Steering Standards SAE J1511 OCT90,
Crankcase 95 L 25 gal
ISO 5010: 1992
Differentials and Final Drives 155 L 41 gal
Steer Angle 31º
Steering Tank 34 L 9 gal
Turning Diameter – Front 23.5 m 77 ft 1 in
Steering System (Includes Tank) 60 L 16 gal
Turning Circle Clearance 26.1 m 85 ft 8 in
Brake/Hoist System 307 L 81 gal Diameter
(Includes Tank)
• Target Gross Machine Operating Weight is 109 770 kg
Torque Converter/ 53 L 14 gal
(242,000 lb).
Transmission System
Torque Converter/Transmission 72 L 19 gal
System (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) capabilities
of standard or optional tires could be exceeded and,
therefore, limit production.
• Caterpillar recommends the customer evaluate all job
conditions and consult the tire manufacturer for proper
tire selection.

August 2006 TEJB9246 Cat 775F Off Highway Trucks 29

Dimensions
All dimensions are approximate. Shown with Dual Slope Body.

12

2
11
3 14

13

10
15

1 9 16

17

7 8

5 6

4
18

19

20

21

Dual Slope Flat Floor Dual Slope Flat Floor

1 Height to Top of ROPS 4108 mm 13 ft 6 in 4105 mm 13 ft 6 in 12 Operating Width 5255 mm 17 ft 2 in 5392 mm 17 ft 8 in
2 Overall Body Length 9216 mm 30 ft 3 in 9294 mm 30 ft 6 in 13 Centerline Front 3205 mm 10 ft 6 in 3205 mm 10 ft 6 in
3 Inside Body Length 6119 mm 20 ft 1 in 6198 mm 20 ft 4 in Tire Width
4 Overall Length 10 334 mm 33 ft 11 in 10 334 mm 33 ft 11 in 14 Engine Guard 698 mm 2 ft 4 in 698 mm 2 ft 4 in
5 Wheelbase 4206 mm 13 ft 9 in 4215 mm 13 ft 10 in Clearance
6 Rear Axle to Trail 2833 mm 9 ft 3 in 2837 mm 9 ft 4 in 15 Overall Canopy Width 4955 mm 16 ft 4 in 4986 mm 16 ft 5 in
7 Ground Clearance 777 mm 2 ft 6 in 791 mm 2 ft 7 in 16 Outside Body Width 4257 mm 14 ft 4223 mm 13 ft 11 in
8 Dump Clearance 613 mm 2 ft 625 mm 2 ft 1 in 17 Inside Body Width 3990 mm 13 ft 1 in 3989 mm 13 ft 1 in
9 Loading Height – Empty 3946 mm 12 ft 11 in 3972 mm 13 ft 18 Front Canopy Height 4428 mm 14 ft 6 in 4430 mm 14 ft 6 in
10 Inside Body Depth – 1978 mm 6 ft 6 in 1978 mm 6 ft 6 in 19 Rear Axle Clearance 675 mm 2 ft 2 in 675 mm 2 ft 2 in
Max 20 Centerline Rear Dual 2729 mm 9 ft 2929 mm 9 ft 7 in
11 Overall Height – 9261 mm 30 ft 5 in 9261 mm 30 ft 5 in Tire Width
Body Raised 21 Overall Tire Width 4411 mm 14 ft 6 in 4411 mm 14 ft 6 in

30 TEJB9246 Cat 775F Off Highway Trucks August 2006

Weight/Payload Calculation
(Example)

Flat Floor
Heavy Duty Heavy Duty
Medium Impact High Impact High Impact High Impact High Impact
Steel 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)

Attachments
Fuel 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 Slope
Steel Liner Steel Liner Steel Liner Rubber Liner Heavy-Duty
(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) 13 552 (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)

Attachments
Fuel 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.

August 2006 TEJB9246 Cat 775F Off Highway Trucks 31

Retarding Performance

To determine retarding performance: Add lengths of all cooling capacity. The following charts are based on these
downhill segments and, using this total, refer to proper conditions: 32° C (90° F) ambient temperature, at sea level,
retarding chart. Read from gross weight down to the percent with 24.00 R35 tires.
effective grade. Effective grade equals actual % grade minus NOTE: Select the proper gear to maintain engine rpm at the highest
1% for each 10 kg/t (20 lb/ton) of rolling resistance. From this possible level, without overspeeding the engine. If cooling oil
weight-effective grade point, read horizontally to the curve overheats, reduce ground speed to allow transmission to shift to
with the highest obtainable gear, then down to maximum the next lower speed range.
descent speed brakes can properly handle without exceeding

With ARC Only

ARC and Engine Brake
E – Typical Field Empty Weight
L – Target Gross Machine Operating Weight 109 770 kg (242,000 lb)

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

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

30%
25%

E L

(Grade Minus Rolling Resistance)

20%

Effective Grade
1st Gear
15%

2nd Gear

3rd Gear 10%

4th Gear

5th Gear
6th Gear 5%
7th Gear

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

0 5 10 15 20 25 30 35 40 45 50 mph
Speed
Continuous Grade Length

32 TEJB9246 Cat 775F Off Highway Trucks August 2006

Retarding Performance

With ARC Only

ARC and Engine Brake
E – Typical Field Empty Weight Gross Weight
L – Target Gross Machine Operating 0 25 50 75 100 125 150 175 200 225 250 lb x 1000
Weight 109 770 kg (242,000 lb)
0 15 30 45 60 75 90 105 120 kg x 1000
30%

(Grade Minus Rolling Resistance)

25%

E L
20%
1st Gear

Effective Grade
2nd Gear
3rd 15%
Gear
4th Gear
5th Gear
10%
6th Gear
7th Gear
5%

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

0 5 10 15 20 25 30 35 40 45 50 mph
Speed
Grade Distance — 450 m (1,500 ft.)

With ARC Only

ARC and Engine Brake
E – Typical Field Empty Weight
L – Target Gross Machine Operating Gross Weight
Weight 109 770 kg (242,000 lb) 0 25 50 75 100 125 150 175 200 225 250 lb x 1000

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

30%
(Grade Minus Rolling Resistance)

25%
E L
20%
1st Gear
Effective Grade

2nd Gear
3rd 15%
Gear 4th Gear

5th Gear 10%

6th Gear
7th Gear
5%

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

0 5 10 15 20 25 30 35 40 45 50 mph
Speed
Grade Distance — 600 m (2,000 ft.)

August 2006 TEJB9246 Cat 775F Off Highway Trucks 33

Retarding Performance

With ARC Only

ARC and Engine Brake
E – Typical Field Empty Weight Gross Weight
L – Target Gross Machine Operating 0 25 50 75 100 125 150 175 200 225 250 lb x 1000
Weight 109 770 kg (242,000 lb)
0 15 30 45 60 75 90 105 120 kg x 1000
30%

(Grade Minus Rolling Resistance)

25%

E L
20%

Effective Grade
1st Gear
2nd Gear
15%
3rd
Gear 4th Gear

5th Gear 10%

6th Gear
7th Gear
5%

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

0 5 10 15 20 25 30 35 40 45 50 mph
Speed
Grade Distance — 900 m (3,000 ft.)

With ARC Only

ARC and Engine Brake
E – Typical Field Empty Weight
L – Target Gross Machine Operating Gross Weight
Weight 109 770 kg (242,000 lb) 0 25 50 75 100 125 150 175 200 225 250 lb x 1000

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

30%
(Grade Minus Rolling Resistance)

25%
E L
20%
Effective Grade

1st Gear
2nd Gear
15%
3rd
Gear 4th Gear

5th Gear 10%

6th Gear
7th Gear 5%

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

0 5 10 15 20 25 30 35 40 45 50 mph
Speed
Grade Distance — 1500 m (5,000 ft.)

34 TEJB9246 Cat 775F Off Highway Trucks August 2006

Gradeability/Speed/Rimpull

To determine gradeability performance: Read from gross horizontally to the curve with the highest obtainable gear, then
weight down to the percent of total resistance. Total resistance down to maximum speed. Usable rimpull will depend upon
equals actual percent grade plus 1% for each 10 kg/t (20 lb/ton) traction available and weight on drive wheels.
of rolling resistance. From this weight-resistance point, read

With ARC Only

ARC and Engine Brake
E – Typical Field Empty Weight
L – Target Gross Machine Operating Weight 109 770 kg (242,000 lb)

Gross Weight
0 50 100 150 200 250 lb x 1000

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

lb x kg x
1000 1000
110 50
E L
100 45

90
40
80 1st Gear
35

(Grade plus Rolling)

Total Resistance
70
30 30%
Rimpull

60
25 25%
50
20 1st Gear 20%
40
15 2nd Gear 15%
30
3rd Gear
10 10%
20 4th Gear
5th Gear
5 6th Gear 5%
10 Torque Converter Drive 7th Gear
Direct Drive
0 0
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 km/h

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

August 2006 TEJB9246 Cat 775F Off Highway Trucks 35

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

OPERATOR ENVIRONMENT POWER TRAIN

Air conditioning Cat ® C27 Engine with ACERT™ Technology
Ashtray and cigarette lighter 12–cylinder diesel
Coat hook Air-to-Air Aftercooler (ATAAC)
Cup holders (4) Air cleaner with precleaner (2)
Diagnostic connection port, 24V Automatic cold mode idle control
Entertainment Radio Ready Electric priming pump
5 amp converter Ether starting aid
Speakers Exhaust, body heat
Antenna Fuel filter/water separator
Wiring harness QuickEvac™ System with engine prelube
Gauges/indicators: Turbocharger (2)
Air cleaner service indicator Braking system:
Brake oil temperature gauge Automatic Retarder Control (ARC) (utilizes rear
Coolant temperature gauge oil-cooled brakes)
Engine overspeed indicator Brake release motor (towing)
Fuel level Manual retarder (utilizes rear oil-cooled brakes)
Hour meter Oil-cooled, multiple disc (rear)
Speedometer/odometer Front dry disc brakes
Tachometer Transmission:
Transmission gear indicator 7–speed automatic powershift w/Electronic
Heater/defroster, (11 070 kCal/43,930 BTU) Clutch Pressure Control (ECPC)
Hoist lever Body up shift inhibitor
Horn Controlled throttle shifting
Light, dome/courtesy Directional shift management
Load counter, automatic Downshift inhibitor
Messenger display unit Neutral start switch
Mirrors, heated (left/right) Neutral coast inhibitor
Power port, 24V and 12V (2) Reverse shift inhibitor
ROPS cab, insulated/sound suppressed Reverse neutralizer during dumping
Seat, Caterpillar Comfort Programmable top gear selection
Full air suspension
Retractable, 3-point seat belt with shoulder harness ANTIFREEZE
Seat, training with lap belt Extended Life Coolant to –35° C (–30° F)
Steering wheel, padded, tilt and telescopic
Storage compartment ELECTRICAL
Sun visor, tinted glass Alarm, backup
Throttle lock Alternator, 50-amp
Windshield wiper (intermittent) and washer 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 Ready (Level 1)

36 TEJB9246 Cat 775F Off Highway Trucks August 2006

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

GUARDS OTHER STANDARD EQUIPMENT

Engine crankcase Body mounting group
Driveline Body safety pin (secures body in up position)
Fan and Air Conditioning Body down indicator
CD-ROM parts book
SUSPENSION SYSTEM Center mounted rims
Suspension, rear (European Union compliant) Direct drive fan
Fuel tank, 700 L (185 gal)
Ground level battery disconnect
Ground level engine shutdown
Ground level grease fittings
Rims
Rock ejectors
Service platform level start/disable switch
Service platform level transmission, hoist and
steering disable switch
Supplemental steering (automatic)
Tow hooks, front
Tow pin, rear
Vandalism protection locks

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

Optional Body Systems: Muffler Exhaust Body

Body Liner, Dual Slope/Flat Floor, Steel, 16 mm, 20 mm Product Link (Level 3)
or 25 mm Rockford Fan
Body Liner, Dual Slope/Flat Floor, Rubber, High Impact Spare Rim, 17 in
or Heavy Duty Traction Control System (TCS)
Cat Compression Brake Truck Production Management System (TPMS)
Lincoln Quick Lube Automatic Lubrication System VIMS™ Monitoring System
Clustered Grease Fittings Work Area Vision System (WAVS) Rear Vision Camera
Electric cold weather starter Wheel Chocks
Engine Coolant Heater Wiggins High Speed Oil Change
Extended Life Disc Brakes Wiggins Service Center
Fast Fuel, Non-pressurizing
Fuel Heater
HID Lights
Hoist Control

August 2006 TEJB9246 Cat 775F Off Highway Trucks 37

Notes

38 TEJB9246 Cat 775F Off Highway Trucks August 2006

 Notes

August 2006 TEJB9246 Cat 775F Off Highway Trucks 39

The information contained herein is intended for circulation only to Caterpillar and dealer employees whose duties require knowledge of such reports and
is 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 been
made to use the latest available spec sheet and other material in the full understanding that these are subject to change without notice. Any reproduction
of 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 Caterpillar
and may not be used without permission.

TEJB9246
August 2006 ®
www.cat.com

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All Rights Reserved
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