Caterpillar® Product Information
Product Bulletin August 2006
Cat® 775F Cat 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.
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Table of Contents
Overview Overv iew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Marketing Strateg Marketing Strategyy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Cat ® C27 engine with ACERT™ Technology Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 MEUI Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Electronic Clutch Pressure Control (ECPC) System System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Operator Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Informatio Info rmation n Systems Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Brake System System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Body Systems Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Serviceability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Power Train – Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Power Train – Transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Structures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Engine – Power Train Train Integration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Brake System System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Operator’s Station. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Serviceabi Servi ceability lity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Information & Monitoring Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Truck Body Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Customer Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Safetyy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Safet Technical Te chnical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
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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.
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Cat 775F Off Highway Trucks
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Marketing Strategy
Cat ® C27 engine with ACERT™ Technology The 775F features the new Cat ® C27 engine with ACERT™ ACERT™ Technology, which will deliver 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™ monitori monitoring ng system offers extensive extensive machine functions functions and payload data. These trucks are also MineStar™ informati information on management system ready, ready, which links machine machiness in the field with business and operating systems.
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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 QuickEvac™ ™ system, standard standard on all F-Series trucks, reduces reduces engine oil service time by up to 50 percent.
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Power Train – Engine Power Train – Engine. The Cat ® C27 engine with ACERT ACERT ™ Techno echnology logy 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, one-piece, cast iron component component with a newly 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
Cat® C27 engine with ACERT™ Technology. With the C27 engine, Caterpillar Caterpillar optimizes optimizes engine performance while meeting U.S. EPA Tier 2 and European Union Stage II regulations in the 775F. ACERT™ ACER T™ Technology reduces emissions during the combustion process by using advanced technology in the air and fuel systems, in conjunction with integrated electronics. Caterpillar meets emission regulations at the combustion source, rather than recycling exhaust.
Engine Design. The Cat C27 engine uses ACERT Technology and iron-specific features to deliver strong performance and long-term durability.
Block. The C27 block features a new design that provid provides es higher structural structural strength through through increased iron compaction and thicker walls. This new design design supports the engine’s engine’s higher higher compression ratios and increases its power density relative to the 3412B.
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(one per head) are driven driven by gears on the flywheel flywheel end of the engine. Placing the cam gears at the flywheel end significantly reduces noise and vibration. Caterpillar has also added two pendulum absorbers, mounted at the front of the camshafts to further reduce noise and vibration. Together, these two features are contributing to the long life and durability of this engine.
Pistons, Connecting Rods, Cylinder Liners. Changes to the pistons, rods, and liners have been made to support the higher cylinder pressures and compress compression ion ratios associated with ACERT ACERT Technology echnology.. The C27 engine has a 137.2 mm (5.4 in) bore, 152.4 mm mm (6 in) stroke and and uses a single-piece steel piston mated to a more robust connecting rod to ensure long component life. The piston’ piston’ss steel skirt increases its durability. durability. The skirt also results in reduced reduced thermal expansion, expansion, allowing a tighter piston fit and reduced liner cavitations. The smaller overall piston surface area reduces friction and enhances fuel economy. Also, the tolerances between the pistons and the wet cylinder liners have been tightened to unprecedented levels.
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, non-waste gated with a with a full aluminum wheel. The C27 engine also includes a new turbine housing and an additional spacer bearing. The addition of a spacer bearing eliminates snap rings and therefore reduces complexity and improves shaft motion. These changes enable the C27 engine to deliver deliver longer life and lower lower maintenance costs, and contribute to better fuel eco economy nomy..
advanced engine management software to monitor, control and protect the engine using self-diagnosing electronic sensors. The computerized system senses operating conditions and power requirements and adjusts the engine for peak performance and the most efficient operation at all times.
EPA Compliant. The C27 engine is compliant with U.S. EPA Tier 2 and European Union Stage II emissions regulations in the 775F, reducing NOx 27.5 percent from 4.8 g/bhp-hr to 3.0 g/bhp-hr over the 3412E.
Advanced Diesel Engine Management A4 Engine Controller. The ADEM™ ADEM™ A4 electronic electronic control control module delivers optimum fuel performance. The engine management management system provides provides flexible fuel mapping, allowing the engine to respond quickly to varying application needs. It tracks engine and machine conditions while keeping the engine operating operating at peak efficiency efficiency..
Next Generation Modular Radiator (NGMR). Single-Piece Piston Design. New single-piece forged steel pistons with integrated forged steel skirt are more robust to withstand high engine heat and pressure, and enable enhanced combustion efficiency, improved fuel efficiency and lower emissions. Corrosion-resistant, stainless steel top ring reduces reduces ring, groove groove and liner wear for for greater reliability and longer life.
The new modular modular cooling system system with a single-pass single-pass flow core design uses brazed construction for stronger joints, better leak prevention and higher heat transfer. The simpler design of the single-pass system, which replaces the two-pass flow folded core system of the 775E, enables coolant to enter one end of the core and flow out the opposite end for more efficient ambient cooling capability and greater durability.
MEUI Fuel System. Fuel delivery, provided by the MEUI mechanically mechanically actuated actuated electronic unit injection system, involves a high degree of precision. Precisely shaping the combustion cycle lowers combustion combustion chamber temperatures, temperatures, generating fewer emissions and optimizing fuel combustion. The system senses operating conditions and regulates fuel delivery for optimum fuel efficiency, improved response times, lower emissions and less smoke.
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Fan (optional). The 775F includes a direct-drive fan, standard, or an optional on-demand fan with a Rockford clutch. clutch. The optional optional fan provides provides cooling airflow only when necessary resulting in a reduction in fuel consumption consumption,, over cooling and generated noise. Rockford’s unique variable speed technology enables the fan clutches to respond to changes in the engine cooling demands by varying the fan speed. This allows the fan to slow down or speed up as necessary necessary, utilizing less working working horsepower from the engine and lowering fuel consumption.
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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 converter adapter 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 drive power train and power shift transmission provides unmatched operating efficiency and control on steep grades, in poor underfoot conditions, and on haul roads with high rolling roll ing resi resistan stance. ce.
Transmission. Pairing the Caterpillar seven-speed planetary power shift transmission with the C27 diesel engine with ACERT ACERT Technology delivers constant power over a wide range of operating speeds.
• ECPC (Electronic Clutch Pressure Control) System. ECPC modulates clutch engagement individually, allowing for smoother speed and directional shifts. ECPC provides controls for both the torque converter lock-up clutch and the transmission clutches that are tailored to each particular upshift or downshift. This provides the operator a superior superior ride and reduced fatigue. fatigue.
• Transmission Chassis Control (TCC). TCC uses electronically transferred engine rpm data to execute shifts at preset points for optimum performance, performa nce, efficiency efficiency and clutch 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.
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Cat 775F Off Highway Trucks
August 2006
Power Train – Transmission
The new contamination control system was designed for ECPC systems. The design incorporates two, high capacity, 6-micron filters with sediment capacity increased by more than 35 percent (compared to the 20-micron filter on the 775E ICM system) and a Post Clutch Valve Main Relief (PCVMR) system. In the PCVMR system the main relief valve is located at the end of the ECPC valv valves’ es’ oil supply, reducing reducing debris build-up by supplying a constant oil flow past the ECPC valv valves. es. Another ECPC advantag advantagee is the incorporation of external pressure taps to improve maintenance. These pressure taps provide easy external access to pressure readings on the lube, main relief valve, and the seven transmission clutches. Without accessing the inside of the transmission, these pressure taps reduce the opportunity for contamination.
Final Drives. Cat final drives work as a system with the planetary power shift transmission to deliver maximum power to the ground. Built to withstand the forces of high torque and impact loads, double reduction final drives provide high torque multiplication to further reduce drive train trai n stre stress. ss.
• Steering System. Hydraulic steering control system is designed for exceptional smoothness and precise control. A separate circuit prevents cross contamination for long life.
• Battery Powered Supplemental Steering. A battery powered powered supplemental supplemental steering steering system uses pressure accumulators and allows up to three 90 degree turns turns in case of engine engine failure.
• Wheels and Rims. Cast rear wheels and Cat centercenter-mount mount rims are mounted mounted using studs and nuts to minimize maintenance and maximize durability.
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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 haulroad and loading impacts for longer frame life and a more comfortable ride.
• Cylinders. Four independent self-contained, oil pneumat pneumatic, ic, variable-rebound variable-rebound suspension 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 box-section design, incorporating two forgings and 19 castings in high-stress high-stress areas areas with deep penetrating and continuous wrap-around welds to resist damage damage from twisting twisting loads without without adding extra weight.
• Steel Structures. Mild steel used throughout the frame provides provides flexibility, flexibility, durability and resistance to impact loads, even in cold climates, and allows for easy field repairs.
• Castings. Castings have large radii with internal reinforcing ribs to dissipate stress in areas of high stress concentration. Castings move welds to lower stress areas for greater frame life.
– Front. Front cylinders with preset caster and camber are mounted to the frame and serve as steering kingpins for a tight turning radius with excellent maneuverability and low maintenance.
– Rear. Rear cylinders allow axle oscillation and absorb bending bending and twisting stresses stresses caused by uneven and rough haul roads rather than transmitting them to the frame.
Technology Enhanced. En hanced. Caterpillar structures are tested using System Structural Analysis (SSA) to dynamica dynamically lly simulate operations operations in field field environments and identify potential structural improvements in high stress areas. With analysis 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
Integral Four-Post ROPS Cab. Resiliently mounted to the main frame with all-new cab mounts that reduce vibration and sound, the integral ROPS is designed as an extension extension of the the truck frame. frame. The ROPS/FOPS structure provides “five-sided protection” for the operator. 10
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Machine (CMM) is used to inspect inspect truck frames frames for consistency in the manufacturing process. Easy rebuild ability is thereby achieved by ensuring the frames are within tolerance, removing the need to alter down-stream parts.
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 performanc e. Stored diagnostic data can be accessed via the Cat Electronic Technician Technician (Cat ET) service tool to improve troubleshooting troubleshooting and reduce downtime.
Controlled Throttle Shifting. Regulates engine rpm during shifting to reduce power train stress and clutch wear by controlling engine speed, torque converter lock-up, and transmission clutch engagement for smoother shifts and longer component life.
1 2 3 4
ET
Engine Control Module (ECM) Sensors Electronic Unit Injector (EUI) Automatic Retarder Control (ARC) (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
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7 2
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Directional Shift Management. Regulates engine
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speed during directional shifts to prevent damage caused by high-speed directional changes.
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Neutral Coast Inhibitor Inhibitor.. Prevents the transmission Cat Data Link. Electronically integrates machine computer systems to optimize overall power train performance, increase reliability and component life, and reduce operating costs. All control modules communicate via the Cat Data Link and work together together as an integrated integrated system system to maximize production efficiency and extend component life.
Transmission Chassis Control Con trol (TCC). TCC uses electronically transferred engine rpm data to execute shifts at preset points for optimum performance, efficiency and clutch life.
tool provides service technicians with easy access to stored diagnostic data through the Cat Data Link to simplify problem diagnosis and increase machine availability. Cat ET is beneficial because of how it displays the status of all engine parameters, including throttle position, timing and fuel flow. Critical data from the electronic engine and transmission controls, including transmission shifting, engine speed and fuel consumption, provides service technicians with enhanced diagnostic capability to reduce downtime and operating costs.
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Body-up Shift Limiter Limiter.. Prevents the transmission from shifting above a pre-programmed gear without the body being fully lowered. This function is programmable via Cat Electronic Technician (Cat ET) and Messenger or Advisor.
Body-up Reverse Neutralizer. Automatically shifts the transmission to neutral if the hoist lever is activated while the transmission is shifted in reverse.
Electronic Technician (Cat ET). Cat ET service
August 2006
from shifting to neutral at speeds above 6.5 km/h (4 mph), protecting the transmission from operating with insufficient lubrication.
Overspeed Protection. The transmission control electronically senses engine conditions and automatically up-shifts one gear to prevent overspeeding. If overspeeding occurs in the top gear, the lock-up clutch is disengaged, and the brakes are applied.
Programmable Top Gear. Transmission top gear maximum can be set using Cat Messenger, VIMS Advisor or the the Cat ET service tool tool to help the operator operator maintain speed speed limits.
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Engine – Power Train Integration
Anti-Hunt Function. This function minimizes
Reverse Shift Inhibitor Inhibitor.. Protects the engine from
shifting by not allowing the transmission to up or down shift immediately after a shift has occurred. This prevents gear hunting when operating near a shift point and minimizes transmission shifting for increased component life.
abrupt directional changes by slowing down the engine before shifting the transmission into reverse.
Cat Messenger. Critical data from the engine and
by keeping the transmission from downshifting until engine speed reaches the downshift point.
transmission, including transmission shifting, engine speed and fuel consumption, provides service technicians with enhanced diagnostic capability, through Cat Messenger, to reduce downtime and operating costs.
ECPC Control. Both the torque converter lock-up
Traction Control System (TCS) (optional).
clutch and the transmission clutches now have software-control for clutch fill and slip characteristics to provide superior smooth shifting.
TCS electroni electronically cally monitors monitors and controls rear wheel slippage for greater traction and enhanced 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, lower noise levels and potentially lengthen engine life. Economy Shift Mode is best used when a customer has extra truck capacity and wants to lower cost-per-ton. A customer who effectively uses Economy Shift Mode can reduce operating costs without sacrificing production.
The system reduces reduces parasitic losses losses in the power management system components. The system is operated by two new variable displacement piston pumps. These pumps primarily provide for the steering and are independent of the brake and hoist circuit.
Downshift Inhibitor Inhibitor.. Prevents engine overspeeding
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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 hydraul hydraulically ically controlled, controlled, reducing maintenance costs.
Integrated Braking System. The Cat oil-cooled braking system delivers reliable performance and control in the most extreme haul-road conditions. The integrated system combines the service, secondary, parking brake and retarding functions in the same system for optimum braking efficiency.
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The 775F brakes provide exceptional, fade-resistant braking and retarding for maximum performance and productivity in all haul-road conditions.
Extended Life Multiple Disc Brakes (optional). Extended life friction material has double the wear life of standard brakes and is twice as resistant to glazing for more consistent braking power with less noise.
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Brake System
Brake Design. Cat rear oil-cooled disc brakes are designed with large discs and plates for reliable, adjustment-free operation and performance. Rear brakes are completely completely enclosed enclosed and sealed to prev prevent ent contamination contamination and reduce maintenance. maintenance.
between the discs. This design absorbs the braking forces by shearing the oil molecules and carrying heat heat away to extend brake brake life.
Pistons. The Caterpillar two-piece piston design combines the service, secondary, parking brake and retarding functions in the same system. The primary piston piston hydraulically hydraulically actuates both service and retarding functions. The secondary piston is spring-applied and held in the disengaged position by hydraulic pressure. If hydraulic system pressure drops below a specified level, the spring-applied secondary piston automatically applies the brakes.
hydraulically released parking brake is applied to the rear wheels wheels for superior parking parking capability capability on all grades up to 15 percent. 2
1 2 3 4 5 6 7 8
Service Brake Sensor Service Sensor Engine Engin e Sensor Sensor AR C ARC Swit Switch ch Brak Br akes es Service Serv ice Brakes Brakes Axle Speed Speed Sensor Sensor T CS CS
500 0
10
20
30 40 50 Time (Seconds)
60
70
With Automatic Retarder Control (average speed, 1950 rpm) With Manual Retarder Control (average speed, 1730 rpm)
• Faster Speeds. ARC allows the operator to
Parking Brake. Oil-cooled, spring-applied,
ARC
2000 ) m p r (
d1500 e e p S e n1000 i g n E
Long Life. An oil film prevents direct contact
1
2500
TCS
maintain optimum engine speeds for up to 15 percent faster faster downhill downhill hauls and greater productivity.
• Superior Control. Automatic brake modulation offers a smoother ride and better control in slippery conditions, allowing the operator to concentrate on driving.
6 7 8
3 7 5
• Ease of Operation. ARC increases operating
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4
Automatic Retarder Control (ARC). Standard ARC electronically controls braking on grade to maintain engine at approximately 1,900 rpm (adjustable from 1,850-1,950 rpm in increments of 10). ARC is deactivated deactivated when the operator operator applies the brakes or throttle. throttle.
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ease, resulting in greater operator confidence with less fatig fatigue. ue.
• Engine Overspeed Protection. Automatically activates ARC when engine speed exceeds factory preset levels, regardless of operator inputs, to avoid potentially damaging engine overspeeds.
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Brake System
Traction Control System (TCS) (optional).
Compression Brake (optional). An all-new Cat
Electronically monitors and controls rear wheel slippage for greater traction and enhanced truck performance in poor underfoot conditions. If slippage exceeds exceeds a set limit, limit, the oil-cooled oil-cooled disc brakes engage engage to slow the spinning spinning wheel. Torque is then automatically automatically transferred to the wheel with better traction.
compression brake is available as an option on the 775F in addition addition to the standard standard Automatic Automatic Retarder Control (ARC). The Cat compression brake delays the release of pressure in the cylinders to brake the machine, and is integrated into the ARC braking system. It provides enginebraking torque by opening the exhaust valves during the compression stroke of the engine. A conv conventional entional master/slav master/slavee brake actuation system opens the cylinder’s exhaust valves to 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 components in retarding retarding applications. applications. This Caterpillar manufactured manufactured component component is built for long, carefree service. It requires no tune-ups, and no maintenance except periodic valve lash checks.
Differential Action. Normal differential action provides superior maneuvering and control in slippery conditions.
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Cat 775F Off Highway Trucks
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Operator’’s Station Operator Operator’s Station. The 775F features an all new operator station with enhanced visibility, increased operator space and ergonomically e rgonomically designed controls that set new industry standards for operator comfort. All controls and gauges are positioned for optimum efficiency and total machine con trol.
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 for easy operator operator control. 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 Ergonomic Layout. The 775F operator station is ergonomically designed for total machine control in a comfortable, productive and safe environment. All controls, levers, switches and gauges are positioned to maximize productivity and minimize operator fatigue.
New ISO Designed Cab Mounts. Integral, soundsuppressed cab is resiliently mounted to the frame to isolate the operator from sound and vibration for a quiet, secure and comfortable ride.
Viewing Area. Designed for excellent all-around visibility and clear sight lines to the haul road. The large viewing area, with 100 percent more glass, enables the operator to maneuver with confidence for greater productivity.
Air Suspension Seat w/Three-Point Operator Restraint. Ergonomically designed, fully adjustable air suspension seat with adjustable armrests providess optimal driving provide driving comfort. A wide, retractable 3-point seat/shoulder belt provides a secure, comfortab comfortable le restraint. restraint.
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left of the operator, which allows trainer to use same stairway sta irway.. When not in use, the fold-down trainer seat creates a working surface with cup holder. The seat also folds up, providing more room for the operator. Under seat storage is convenient for stowing a lunch box.
Operator Controls. Easy to reach turn signal, high beam, intermittent intermittent windshield windshield wiper and and windshield washer controls are located on the left side of the steering column, and are designed for optimum efficiency and comfort.
Heating/Air Conditioning. Electronically controlled, four-speed fan and 13 vents deliver temperaturecontrolled air circulation for a comfortable working environment in any climate. Electronic controls reduce maintenance. A 57% increase in heating capacity as well as a more robust air compressor offers a 25 percent increase in BTU’s, greater durability and longer life.
Cat 775F Off Highway Trucks
August 2006
Operator’’s Station Operator
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 conv conveniently eniently 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 Manag ement 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.
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Cat 775F Off Highway Trucks
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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 acc ess are designed to redu reduce ce downtim downtime. e.
Engine Prelube. Engine prelubrication provides engine oil pressure prior to engine cranking. This reduces engine engine dry and cold start wear, wear, and reduces engine component component wear. 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 Servicing Ease. Easy access to daily service points simplifies servicing and reduces time spent on regular maintenance procedures. Enhanced serviceability and extended 500-hour service intervals are designed to increase machine availability and productivity.
Maintenance Platform. Easy stairway access
change, reducing time required for air filter maintenance.
Sealed Electrical Connectors. Electrical connectors are sealed to lock out dust and moisture. Harnesses are braided for protection. Wires are color-coded for easy diagnosis and repair.
Spin-on Filters. Spin-on filters for fuel and oil
to engine, air filters, filters, steering steering hydraulic hydraulic tank and radi radiator ator..
systems reduce changing time and help ensure clean, tight seals.
Ground-Level Access. All maintenance points have convenient ground level or platform access. Common engine service points are grouped on the right side of the engine engine for quick access. access. Two fuel filters come standard standard with the machine and the primary fuel filter includes a water separator. These filters filters are easy to change change and are all spin-on/spin-off type.
On-Board Diagnostic Systems. Messenger continuously checks all critical machine functions and components, and helps locate faults quickly for faster repair. Electronic control system enables quick diagnosis of engine conditions and effective maintenance and repairs using the Electronic Technician (Cat ET) service tool.
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.
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Cat 775F Off Highway Trucks
August 2006
Serviceability
Lincoln’s Quick Lube Automatic Lubrication Lincoln’ (optional). This advanced lubrication system is available as a factory installed option on the 775F. This system provides optimal lubrication at preset intervals during machine operation significantly extends component life. Contaminants are purged from the open pins and bushings, and protective grease seals are maintained. As opposed to manual lubrication, this option reduces downtime, labor, and lubricant costs and improves machine resale value.
Clustered Grease Fittings (optional). Clustered grease fittings save time as all lubrication points are mounted in three main locations.
Oil Dipstick. New “rope-type” oil dipstick improves serviceability by allowing easy daily checks.
QuickEvac™ QuickEvac ™ System. Oil change labor time is reduced by as much as 50 percent with this standard on-board engine oil evacuation and pre-lube system. It speeds the process of evacuating the engine sump and allows for the purging of oil filters prior to removal, minimizing oil spills. QuickEvac system also enhances contamination control by ensuring complete filtration of new oil on engine refill.
Reduced Maintenance Costs/Higher Machine Availability. The C27 engine eng ine with ACER ACERT T Technology offers 500-hour service intervals under normal conditions. For the 775F, commonly used engine service points have been placed on the right side of the engine. Feedback from engine sensors provides data to the electronic controller. When engine data is out of spec, a warning is sent to the operator.
Next Generation Modular Radiator (NGMR). This cooling system’s system’s new 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.
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Cat 775F Off Highway Trucks
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Information & Monitoring Systems Information & Monitoring Systems. Standard on the 775F, 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. 3
2 1
7
8
9 11
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
10 6
5
• Standard LED lamps lamps replace replace incandesc incandescent ent lamps on the TPMS, extending lamp life by 25 tim times. es.
VIMS™ VIMS ™ Monitoring System (optional). Caterpillar
4
Instrument Cluster Cluster.. Critical operating information on the 775F is relayed via the Cat Data Link to five gauges, 18 LED indicator lights, and an LCD digital display display..
Cat Messenger Messeng er.. Standard on the 775F, Cat Messenger provides provides real-time real-time machine machine performance and operating data, and basic trip, maintenance, and diagnostic data using an LCD display display.. The viewable LCD screen screen area of the Messenger display is 22.5 mm 84.6 mm (0.89 in 3.33 in).
Truck Production Management Manag ement System (TPMS) (optional). TPMS provides valuable payload and cycle time data to improve productivity. • Uses strut strut pressure pressure sensors sensors and and on-board on-board microprocessor to determine payload weight. • Delivers Delivers consistent, consistent, accurate payloads and improves efficiency by minimizing overloading and underloading. • External lights signal signal loading loading tool operator operator when payload is reached.
• A second gear reweigh reweigh takes takes an additiona additionall measurement once the truck has reached second gear for improved accuracy.
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designed machine monitoring system provides more than 250 machine parameters, critical machine health and payload data in real-time to keep the 775F performing at top production levels. In addition to the usual Messenger monitoring system functionality, the system also monitors: • torque con converter verter screen switch, • torque con converter verter inlet filter filter,, • brak brakee oil temp temperat erature, ure, • fu fuel el le leve vel, l, • amb ambient ient air air tempera temperature ture,, • ‘R ‘R’’ term termina inal, l, • fron frontt aftercooler aftercooler tempera temperature ture,, • afte aftercoo rcooler ler coolant coolant level level,, • jack jacket-w et-water ater lev level, el, • high steeri steering ng pressure pressure switch switch,,
• On-board computer stores up to 2,400 cycles for analysis of payload payload weight, weight, cycle times, times, distances, and actual cycle dates and times.
20
• System System is accu accurate rate withi within n ± 5 percent percent under under normal loading conditions over a normal shift.
• stee steering ring oil oil tempera temperature ture,, • stee steering ring oil oil bypass bypass switch switch,, • pay payload load,, and and othe others. rs.
Cat 775F Off Highway Trucks
August 2006
Information & Monitoring Systems
Product Link (optional). Now available out of the factory, this system streamlines diagnostic efforts, downtime, and maintenance scheduling and costs by providing a two-way communication flow of vital machine data and location information between the dealer and the customer. Product Link provides updates on service meter hours, machine condition, machine location as well as integrated mapping/route planning.
MineStar™ Ready. MineStar information management system helps meet the challenges of the mining industry industry by linking linking the machines machines in the field with business business and operating operating systems to ensure peak performan performance ce of mining assets assets at the lowest possible cost. These products deliver customers everything from real-time machine health information to GPS-guided production aids. The 775F is equipped for quick and easy installation of MineStar information management system products. Specific Minestar information management system products include:
• MineStar Productio Production n – Monitors and reports reports mine production information in real time. Manages production and delay codes for accurate machine utilization tracking. • MineStar Fleet Command Commander er – Advan Advanced ced optimization algorithm increases truck/shovel fleet use. Maximizes shovel production and minimizes truck wait time, while simultaneously meeting mine production plan requirements for material blending. • MineStar Health – Monitors Monitors and communi communicates cates machine vital sign information in real time, enabling remote maintenance/service diagnostics and advanced prognostic analysis. Enhances the entire maintenance and repair process, allowing higher machine availabilities to be attained. • MineStar Business Enterprise – Provides Provides IT infrastructure platform for seamless integration of MineStar information management system with other mine planning and enterprise resource planning systems.
• MineStar Machine Trac Tracking king – Monitors 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 Material Tracking Tracking – Tracks 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.
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Cat 775F Off Highway Trucks
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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 d urability through rigorous 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 wear surfaces surfaces are equipped with 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
1) Dual Slope Body
2
2) Flat Floor Body
Body Design. With the introduction of the 775F, Body Selection. Selection of the right body system depends on material, haul road and loading conditions. The better the match of body to application, the greater the efficiency. Cat dealers can help select the right body system for sitespecific applications.
Body/Chassis Integration. Caterpillar truck body systems are designed and matched with the integrated chassis system for optimum structural reliability, durability and long life.
Electronic Hoist Control. Provides the operator with better control of the load when dumping, including over-center load control and modulated control throughout the operating range. The automatic body snubbing feature reduces impact on the frame, hoist cylinders and operator.
Fast Hoist Cycle Times. Two-stage hoist cylinders provide fast dump cycle times of 9.5 seconds for raise and 12.5 seconds for lower.
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Caterpillar offers five application-specific body systems. Dual slope and flat floor body offerings are available in three steel configurations and two rubber config configurations. urations. The new dual slope and flat floor body systems will continue to use fully fabricated, mild steel structures, offering a strong, yet weldable underbody structure. All interior, steel body surfaces that come in contact with material are fabricated from 400 BHN steel steel to provide superior superior wear characteristics and resistance to impact. Widee box-sect Wid box-section ion ribs provide excellent durability durability and impact support in the floor, front-wall, sidewall, and top rail areas. Full-length stringer rails enhance strength and rigidity throughout the body. Other new features that further enhance durability of the understructure include: • The body sidew sidewall all ties directly directly in with with the floor, floor, providing increased strength in the sidewalls. • Thickness Thickness of ribs ribs increased increased to 10 mm and the number of floor ribs have been increased from 7 to a total total of 9 ribs. ribs.
Cat 775F Off Highway Trucks
August 2006
Truck Body Systems
• Front wall wall body rest supports supports are integra integrated ted into the front wall structure for enhanced durability. • Front wall wall is 400 400 BHN and the thickness is increased from 10.2 mm 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
Target Payload Strategy. Your Caterpillar Dealer
optimum pass/match system, the 775F is best sized to match the 988H Wheel Loader, with 5 pass/mat pass/match, ch, the 990H Wheel Wheel Loader, Loader, with a 4 pass/mat pass/match, ch, and the 385C Hydraulic Excavator Excavator,, 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 Underloading increases increases costs due due to lost payloads, underutilizes equipment, and increases cost-per-ton. • Overloading Overloading causes causes excessive excessive wear on vehicle vehicle components, such as brakes, tires and drive train, reducing component life and increasing maintenance costs and repairs.
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Cat 775F Off Highway Trucks
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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 and built to provide provide maximum maximum productivity and operating economy throughout its working life. Cat dealers offer a wide range of service plans plans that will maximize maximize uptime and return on your investment, including: • Prev Preventiv entivee Maintenanc Maintenancee Programs Programs
Commitment Makes the Difference. Cat ® dealers offer a wide range of solutions, services and products that help you lower costs, enhance productivity and manage your operation more efficiently. Support goes far beyond parts and service. From the time you select a piece of Cat equipmen equipmentt until the day you rebuild, rebuild, trade trade or sell it, the support you get from your Cat dealer makes the difference that counts.
Dealer Capability. Cat dealers provide the level of support you need, on a global scale. Dealer expert technicians have the knowledge, experience, training and tooling necessary to handle your repair and maintenance needs, when and where you need them.
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• Diagnostic Diagnostic Programs, Programs, such such as Schedule Scheduled d Oil Sampling and Technical Analysis • Reb Rebuild uild and and Reman Reman Options Options • Cus Custome tomerr Support Support Agreeme Agreements nts
Application Awareness. Operating and maintenance costs are influenced by many application and site-specific factors, such as material density, loading position, payload, grades, speeds, haul road design and maintenance. To optimize total cost of owners ownership hip and productivity, productivity, your Cat dealer can provide you with a fundamental understanding of the effects application characteristics and operating techniques havee on main hav maintena tenance nce and operating operating costs. costs.
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 produ products. cts.
Technology Products. Prod ucts. Cat dealers offer a range of advanced technology products, such as VIMS™ monitoring monitorin g system and MineStar™ MineStar™ informa information tion 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 low er cost costs. s.
www.cat.com. For more complete information on Cat products, products, dealer services, services, and industry industry solutions, visit us on the web at www.cat.com.
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Cat 775F Off Highway Trucks
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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, Caterpillar, but an integral part of all machine and sys syste tems ms des desig igns ns..
High Intensity Discharge (HID) Lights (optional). Thirty-five Watt HID lights can replace the standard high beam 65 Watt Halogen lights. The powe powerful rful HID lights are almost almost two times brighter and 50 percent more efficient, improving night time visibility.
Brake Systems. Cat hydraulically controlled dry front and rear oil-cooled oil-cooled multiple multiple disc brakes provid providee exceptional, fade-resistant 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 to be proactive in developing machines that meet or exceed safety standards. Safety is an integral part of all machine and systems designs.
Integral ROPS Cab. Resiliently mounted to the frame to reduce vibration and sound, the integral ROPS structure, which provides “five-sided protection” for the operator, is designed as an extension of the truck frame.
Payload Guidelines. Safety is integral to maintaining the highest productivity in mining machine operation. The Caterpillar 10/10/20 Payload Guidelines ensures that steering and braking systems have sufficient capacity to perform.
camera system provides visibility to the rear of the machine through an LCD monitor in the cab. The monitor can be set to activate only when the truck is in reverse, and the display is equipped with a sensor to detect ambient light, which automatically brightens or dims the display.
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steering system is designed to deliver precise control under all loading and underfoot conditions. The steering hydraulic system is separate from the main hydraulic hydraulic system to prevent prevent crosscontamination and overheating.
Engine Shutoff Switch. A secondary engine shutoff switch is located at ground level.
Electrical System Disconnect. A battery disconnect switch, located directly above the front bumpe bumper, r, provides ground-level ground-level lockout lockout of the elec electric trical al syst system. em.
Ladder/Secondary Egress. A wide, stationary
WAVS Camera (optional). (optional). An optional rear vision
26
Steering System. A twin, double-acting cylinder
stairway allows easy access to and from the machine. The ladder on the left side of the machine permits secondary egress. A stairway lamp illuminates the cab access stairs and can be activated at ground level during entry and shut off with a switch in the cab.
Cat 775F Off Highway Trucks
August 2006
Safety
Standard Safety Features. • Slip resi resistan stantt surfac surfaces es • 75 mm (3 in) wide wide orange orange three-po three-point int operator oper ator rest restrain raintt • Heat Heated, ed, wide-a wide-angle ngle mirro mirrors rs • Body rais raised ed indi indicato catorr • Gu Guar ard d rai rails ls • Rev Reverse erse neutraliz neutralizer er when when dumping • Lo Low w interior interior sound sound lev level el • Service platform platform leve levell transmission, transmission, hoist hoist and steering disable switch • Service platform platform leve levell starter disable switch
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Technical Specifications Engine Engine Model Rated Engine Speed Gross Power – SAE J1995 Net Power – SAE J1349 Net Power – ISO 9249 Net Power – 80/1269/EEC Number of Cylinders Peak Torque Bore Stroke Displacement
Transmission Cat ® C27 ACERT™ 2,000 rpm 587 kW 787 hp 552 kW 740 hp 552 kW 740 hp 552 kW 740 hp 12 3501 N·m 2,582 lb ft 137 mm 5.4 in 152 mm 6 in 27 L 1,649 in3
• Power ratings ratings apply apply at 2,000 2,000 rpm when when tested under under the specified condition for the specified standard. • Ratings based based on SAE SAE J1995 J1995 standard standard air conditions conditions of of 25° C (77° F) and 100 kPa kPa (29.61 Hg) Hg) barometer. barometer. Power based on fuel having having API API gravity gravity of 35 at 16° C (60° F) and an LHV of 42 780 kJ/kg (18,390 BTU/lb) when when engine is used at 30° C (86° (86° F). • Compliant Compliant with U.S. Environm Environmental ental Protectio Protection n Agency Agency Tier 2 and European Union Stage II emissions standards.
1099 77 10 7700 kg
242, 24 2,00 0000 lb
31 633 kg 13 552 kg
69,738 lb 29,877 lb
• Chassis Chassis weight weight with 100% 100% fuel, hoist, hoist, body body mounting mounting group, rims and tires. • Body weight weight varies varies depending depending on how body body is equipped. equipped.
Operating Specifications Nominal Payload Class Body Capacity – SAE 2:1 Top Speed – Loaded
63.5 tonnes 42.5 m3 67.4 km/h
70 tons 55.6 yd3 41.9 mph
• Refer to the the Caterpillar Caterpillar 10/10/20 10/10/20 Payload Payload Guidelin Guidelines es for maximum gross machine weight limitations. • Cap Capaci acity ty with dual dual slope slope body body..
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10.8 km/h 15 km/h 20.3 km/h 27.3 km/h 37 km/h 49.9 km/h 67.5 km/h 14.2 km/h
6.7 mph 9.3 mph 12.6 mph 17 mph 23 mph 31 mph 41.9 mph 8.8 mph
• Maximu Maximum m travel speeds speeds with standard standard 24.00R35 24.00R35 (E4) (E4) tires.
Final Drives Differential Ratio Planetary Ratio Total Reduction Ratio
3.64:1 4.80:1 17.49:1
Brakes Brake Surface – Front Brake Surface – Rear Brake Standards
Weights – Approximate Tar arge gett Gr Gros osss Ma Mach chin ine e Operating Weight Chassis Weight Body Weight
Forward 1 Forward 2 Forward 3 Forward 4 Forward 5 Forward 6 Forward 7 Reverse
1395 cm2 216 in2 61 269 cm2 9,497 in2 ISO 3450: 1996
• Target Gross Gross Machine Machine Operating Operating Weight Weight is 109 770 kg (242,000 lb).
Body Hoists Pump Flow – High Idle Relief Valve Setting – Raise Relief Valve Setting – Lower Body Raise Time – High Idle Body Lower Time – Float Body Po Power Do Down – High Id Idle
560 L/min 148 gal/min 18 950 kPa 2,750 psi 3450 kPa 500 psi 9.5 Seconds 12.5 Seconds 12.5 Se Seconds
Capacity – Dual Slope – 100% fill factor Struck Heaped 2:1 (SAE)
Cat 775F Off Highway Trucks
33.1 m3 42.5 m3
43.3 yd3 55.6 yd3
August 2006
Technical Specifications Capacity – Flat Floor – 100% fill factor Struck Heaped 2:1 (SAE)
32 m3 41.9 m3
ROPS 41.8 yd3 54.8 yd3
ROPS/FOPS Standards • ROPS (Rollover (Rollover Protect Protective ive Structure) Structure) for for cab offered offered by Caterpillar meets ISO 3471:1994 ROPS criteria.
Weight Distributions – Approximate
• FOPS (Falling (Falling Objects Objects Protectiv Protective e Structure) Structure) meets meets ISO 3449 3449:1992 :1992 Level Level II FOPS criteria. criteria.
Front Axle – Empty Front Axle – Loaded Rear Axle – Empty Rear Axle – Loaded
Sound
49% 33% 51% 67%
Sound Standards
Suspension Effect Effe ctiv ive e Cy Cyli lind nder er St Stro roke ke – Fr Fron ontt Effective Cylinder Stroke – Rear Rear Axle Oscillation
235 mm 235 149 mm 8º
9.25 in 9.25 5.9 in
700 L 175 L 95 L 155 L 34 L 60 L 307 L
185 gal 46 gal 25 gal 41 gal 9 gal 16 gal 81 gal
53 L
14 gal
72 L
19 gal
133 L
35 gal
• The operator operator sound sound pressure pressure level level measured measured according according to ANSI/SAE J1166 MAY90 is 78 dB(A) for cab offered by Caterpillar, when properly installed, maintained and tested with doors and windows closed, engine speed at high idle, and fan at medium setting. • Hearing Hearing protection protection may be be needed needed when operating operating with with an open operator station station and cab (when not properly maintained or doors/windows open) for extended periods or in a noisy environme environment. nt.
Service Refill Capacities Fuel Tank Cooling System Crankcase Differentials and Final Drives Steering Tank Steering System (Includes Tank) Brake/Hoist System (Includes Tank) Torque Converter/ Transmission System Torque Converter/Transmission System (Includes Sump) Brake/Hoist Hydraulic System
Steering Steering Standards Steer Angle Turning Diameter – Front Turning Circle Clearance Diameter
SAE J1511 OCT90, ISO 5010: 1992 31º 23.5 m 77 ft 1 in 26.1 m 85 ft 8 in
• Target Gross Gross Machine Machine Operating Operating Weight Weight is 109 770 kg (242,000 lb).
Tires Standard Tire
24.00R35 (E4)
• Productive Productive capabiliti capabilities es of the 775F 775F truck are are such that, that, under certain job conditions, TKPH (TMPH) capabilities of standard or optional tires could be exceeded and, therefore, limit production. • Caterpillar Caterpillar recommen recommends ds the customer customer evaluate evaluate all all job conditions and consult the tire manufacturer for proper tire selection.
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Dimensions All dimensions are approximate. Shown with Dual Slope Body.
12
2 11
14
3
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
Heig igh ht 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
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
13 Centerline Front Tire Width
4
Overall Length
10 334 mm 33 ft 11 in
10 334 mm 33 ft 11 in
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
14 Engine Guard Clearance
6
Rear Axle to Trail
2833 mm
9 ft 3 in
2837 mm
9 ft 4 in
Canopy Width 15 Overall Ca
4955 mm mm
16 ftft 4 in
4986 mm
16 ftft 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 – E Em mpty 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
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
2729 mm
9 ft
2929 mm
9 ft 7 in
30 ft 5 in
20 Centerline Rear Dual Tire Width 21 Overall Tire Width
4411 mm
14 ft 6 in
4411 mm
14 ft 6 in
10 Inside Body Depth – Max
1978 mm
11 Overall Height – Body Raised
9261 mm
30
30 ft 5 in
9261 mm
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Cat 775F Off Highway Trucks
August 2006
Weight/Payload Calculation Calculation (Example)
Medium Impact Steel Body System (16 mm)
High Impact Steel Body System (20 mm)
Flat Floor Heavy Duty High Impact Steel Body System (25 mm)
109 769 (242,000)
109 769 (242,000)
109 769 (242,000)
109 769 (242,000)
109 769 (242,000)
Empty Chass Chassis is Weight* Weight* – k kgg (lb)
31 633 (69,738)
31 633 (69,738)
31 633 (69,738)
31 633 (69,738)
31 633 (69,738)
Body System Weight – k kgg (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 08 089 (99,403)
45 81 811 (100,995)
47 47 473 (104,659)
46 06 069 (101,564)
46 92 926 (103,453)
Target Gross Machine Weight*– k kgg (lb)
High Impact Rubber Body System (102 mm)
Heavy Duty High Impact Rubber Body System Rubber Liner
Attachments Fuel Tank Size – L (gal)
700
(185)
700
(185)
700
(1 8 5 )
700
(185)
700
(1 8 5 )
Fuel Tank – 90% fill – kg (lb)
531
(1,170)
531
(1,170)
531
(1,170)
531
(1,170)
531
(1,170)
Empty Operating Weight – k kgg (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)
Steel Liner (16 mm)
Steel Liner (20 mm)
Dual Slope Steel Liner (25 mm)
109 769 (242,000)
109 769 (242,000)
109 769 (242,000)
109 769 (242,000)
109 769 (242,000)
Empty Chass Chassis is Weight Weight – k kgg (lb)
31 633 (69,738)
31 633 (69,738)
31 633 (69,738)
31 633 (69,738)
31 633 (69,738)
Body System Weight – k kgg (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 18 185 (99,615)
45 80 808 (100,989)
47 62 620 (104,983)
45 96 960 (101,324)
46 82 821 (103,222)
Target Gross Machine Weight* – k kgg (lb)
Rubber Liner (102 mm)
Heavy-Duty Rubber Liner
Attachments Fuel Tank Size – L (gal)
700
(185)
700
(185)
700
(1 8 5 )
700
(185)
700
(1 8 5 )
Fuel Tank – 90% fill – kg (lb)
531
(1,170)
531
(1,170)
531
(1,170)
531
(1,170)
531
(1,170)
Empty Operating Weight** – k kgg (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 the Caterpillar Caterpillar 10/10/2 10/10/20 0 overload overload policy. policy. ** Includes weight of all attachments. attachments.
August 2006
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Cat 775F Off Highway Trucks
31
Retarding Performance To determine retarding performance: Add lengths of all downhill segments and, using this total, refer to proper retarding chart. Read from gross weight down to the percent effective grade. Effective grade equals actual % grade minus 1% for each 10 kg/t (20 lb/ton) of rolling resistance. From this weight-effective grade point, read horizontally to the curve with the highest obtainable gear, then down to maximum descent speed brakes can properly handle without exceeding
cooling capacity. The following charts are based on these conditions: 32° 32° C (90° (90° F) ambient temperature, at sea level, with 24.00 R35 tires. NOTE: Select the proper gear to maintain engine rpm at the highest possible level, without overspeeding the engine. If cooling oil overheats, reduce ground speed to allow transmission to shift to the next lower speed range.
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 0
25
50
15
75
100
30
125
45
15 0
60
175
200
75
225
90
250
105 30%
E
lb x 1000 120 kg x 1000
25%
L 20%
1st Gear 15% 2nd Gear
3rd Gear
10%
4th Gear 5th Gear 5%
6th Gear
) e c n a t s i s e e d R a r g n G i l e l v o i t R c s e f f u n E i M e d a r G (
7th Gear
0 0
10 5
20 10
30 15
20
40 25
50 30
60 35
70 40
80 km/h 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
Gross Weight
E – Typical Field Empty Weight L – Target Gross Machine Operating Weight 109 770 kg (242,000 lb)
0 0
25
50
15
75 100 125 150 175 200 225 250 30
45
60
75
90
105
30%
E
120 kg x 1000
) e c n a t s i s e e d R a r g n G i l l e v o i t R c s e f f u n i E M e d a r G (
25%
L
20%
1st Gear 2nd Gear 3rd Gear 4th Gear
15%
5th Gear
10%
6th Gear 7th Gear 5%
0 0
10 5
20 10
30 15
40
20
25
50 30
60 35
70 40
lb x 1000
80
45
km/h
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 Weight 109 770 kg (242,000 lb)
Gross Weight 0 0
25
50
15
75 100 125 150 175 200 225 250 30
45
60
75
90
105
120 kg x 1000
) e c n a t s i s e e d R a r g n G i l l e v o i t R c s e f f u n i E M e d a r G (
30% 25%
E
L
20%
1st Gear 2nd Gear
15%
3rd Gear 4th Gear 5th Gear
10%
6th Gear 7th Gear 5%
0 0
10 5
20 10
30 15
20
40 25
50 30
60 35
70 40
45
lb x 1000
80
km/h
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
Gross Weight
E – Typical Field Empty Weight L – Target Gross Machine Operating Weight 109 770 kg (242,000 lb)
0
25
50
0
15
75 100 125 150 175 200 225 250 30
45
60
75
90
105
30%
120 kg x 1000
) e c n a t s i s e e d R a r g n G i l l e v o i t R c s e f f u n i E M e d a r G (
25%
E
L 20%
1st Gear 2nd Gear 15%
3rd Gear 4th Gear
10%
5th Gear 6th Gear
7th Gear 5%
0 0
10 5
20 10
30 15
40
20
25
50 30
60 35
70 40
lb x 1000
80
45
km/h
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 Weight 109 770 kg (242,000 lb)
Gross Weight 0 0
25
50
15
75 100 125 150 175 200 225 250 30
45
60
75
90
105
120 kg x 1000
30% 25%
E
L 20%
1st Gear 2nd Gear
15%
3rd Gear 4th Gear 10%
5th Gear
6th Gear 7th Gear 5%
0 0
10 5
20 10
30 15
20
40 25
50 30
60 35
70 40
45
lb x 1000
80
) e c n a t s i s e e d R a r g n G i l l e v o i t R c s e f f u n i E M e d a r G ( km/h
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 weight down to the percent of total resistance. Total resistance equals actual percent 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, then down to maximum speed. Usable rimpull will depend upon traction available and weight on drive wheels.
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
lb x 1000 110
100 90 80
kg x 1000 50
0
50
100
15
30
45
150 60
200 75
90
105
E
40 30 20
lb x 1000
120 kg x 1000
L
45 40 1st Gear 35
70
l l 60 u p m50 i R
250
30
30%
25
25%
20
20%
1st Gear
15%
2nd Gear
15
3rd Gear 10
10
5
0
0
10%
4th Gear 5th Gear
0 0
5% 7th Gear
6th Gear
Torque Converter Drive Direct Drive
) e g n c i l n l o a t R s i s s u e l R p l e a t d o a r T G (
5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 km/h 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 Air conditioning Ashtray and cigarette lighter Coat hook Cup holders (4) Diagnostic connection port, 24V Entertainment Radio Ready 5 amp converter Speakers Antenna Wiring harness Gauges/indicators: Air cleaner service indicator Brake oil temperature gauge Coolant temperature gauge Engine overspeed indicator Fuel level Hour meter Speedometer/odometer Tachometer Transmission Transmis sion gear indicator Heater/defroster,, (11 070 kCal/43,930 BTU) Heater/defroster Hoist lever Horn Light, dome/courtesy Load counter, automatic Messenger display unit Mirrors, heated (left/right) Power port, 24V and 12V (2) ROPS cab, insulated/sound suppressed Seat, Caterpillar Comfort Full air suspension Retractable, 3-point seat belt with shoulder harness Seat, training with lap belt Steering wheel, padded, tilt and telescopic Storage compartment Sun visor, tinted glass Throttle lock Windshield Windshiel d wiper (intermittent (intermittent)) and washer
36
TEJB9246
POWER TRAIN Cat ® C27 Engine with ACERT™ ACERT™ Technology 12– 12 –cylinder diesel Air-to-Air Aftercooler (ATAAC) Air cleaner with precleaner (2) Automatic cold mode idle control Electric priming pump Ether starting aid Exhaust, body heat Fuel filter/water separator QuickEvac™ QuickEvac ™ System with engine prelube Turbocharger (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 inhibitor Controlled throttle shifting Directional shift management Downshift inhibitor Neutral start switch Neutral coast inhibitor Reverse shift inhibitor Reverse neutralizer during dumping Programmable top gear selection ANTIFREEZE Extended Life Coolant to –35 35°° C (– (–30 30°° F) ELECTRICAL Alarm, backup Alternator,, 50-amp Alternator Auxiliary jump start receptacle Batteries, maintenance-free, maintenance-free, 12V (4), 190 amp-hour Electrical system, 25-amp, 24V to 12V convert converter er 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™ MineStar ™ Ready Product Link Ready (Level 1)
Cat 775F Off Highway Trucks
August 2006
Standard Equipment Standard equipment may vary. Consult your Caterpillar dealer for details.
GUARDS Engine crankcase Driveline Fan and Air Conditioning
OTHER STANDARD EQUIPMENT Body mounting group Body safety pin (secures body in up position) Body down indicator CD-ROM parts book Center mounted rims Direct drive fan Fuel tank, 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
SUSPENSION SYSTEM Suspension, rear (European Union compliant)
Optional Equipment Optional equipment may vary. Consult your Caterpillar dealer for details.
Optional Body Systems: Body Liner, Dual Slope/Flat Floor, Steel, 16 mm, 20 mm or 25 mm Body Liner, Dual Slope/Flat Floor, Rubber, High Impact or Heavy Duty Cat Compression Brake Lincoln Quick Lube Automatic Lubrication System Clustered Grease Fittings Electric cold weather starter Engine Coolant Heater Extended Life Disc Brakes Fast Fuel, Non-pressurizing Fuel Heater HID Lights Hoist Control
August 2006
TEJB9246
Muffler Exhaust Body Product Link (Level 3) Rockford Fan Spare Rim, 17 in Traction Control System (TCS) Truck Production Management System (TPMS) VIMS™ VIMS ™ Monitoring System Work Area Vision System (WAVS) Rear Vision Camera Wheel Chocks Wiggins High Speed Oil Change Wiggins Service Center
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 t he full understanding that these are subject to change without notice. Any reproduction of this r elease 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 CAT, and may not be used without permission.
TEJB9246 August 2006 www.cat.com © 2006 Caterpillar All Rights Reserved Printed in the U.S.A.
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