775F

Off-Highway Truck

Cat® Engine C27 with ACERT™ Technology

Gross Power (SAE J1995) 587 kW/798 hp
Net Power (ISO 9249) at 2000 rpm 552 kW/751 hp
Target Gross Machine Operating Weight 109 770 kg
Nominal Payload Class 63.5 tonnes
Body Capacity – SAE 2:1
(with dual slope body) 42.5 m3
 775F Off-Highway Truck
Engineered for performance, designed for comfort, built to last.

Power Train – Engine Power Train – Transmission Structures

✔ The Cat® C27 engine with ACERT™ ✔ The Cat® seven-speed power shift ✔ The 775F features a mild-steel, box-
Technology uses advanced engine transmission matched with the Cat C27 section type frame, proven on the 775E
technology to reduce emissions without engine with ACERT Technology to deliver durability and long life with
after-treatment. The turbocharged, provides constant power and efficiency low operating costs. Castings and
aftercooled 12-cylinder engine has over a wide operating speed range for forgings are strategically placed in high-
higher horsepower and faster response optimal power train performance. pg. 5 stress areas to evenly distribute stresses
for superior performance in demanding and provide long fatigue life. pg. 6
applications. pg. 4

Serviceability Information & Monitoring Systems

✔ The 775F offers 500-hour engine ✔ Standard on the 775F, the Cat Messenger
service intervals – 250 hours more system provides real-time engine
than the 775E. Simplified service and performance and operating data.
maintenance features combined with The 775F also offers the optional
improved service access are designed VIMS Advisor monitoring system,
to reduce downtime. pg. 12 providing data for more than
250 machine functions. pg. 13

Top Performance.
Developed specifically for mining,
quarry and construction applications,
the 775F keeps material moving at
high volume to lower cost-per ton.
Reliable, Durable, Dependable.
Rugged construction and easy
maintenance procedures ensure
long life with low operating costs.

✔ New Feature

2
 Operator’s Station Engine – Power Train Integration Brake System
✔ The 775F features an all new operator ✔ The Cat Data Link electronically ✔ Front dry disc and rear oil-cooled,
station with enhanced visibility, increased combines engine, transmission, brake multiple disc brakes are now hydraulically
operator space and ergonomically and operational information to optimize controlled, reducing maintenance costs
designed controls that set new industry overall truck performance. Stored and improving operator control and
standards for operator comfort. diagnostic data can be accessed via the modulation. They provide exceptional,
All controls and gauges are positioned Cat Electronic Technician (Cat ET) fade-resistant braking and retarding for
for optimum efficiency and total service tool to improve troubleshooting maximum performance and productivity
machine control. pg. 7 and reduce downtime. pg. 8 in all haul-road conditions. pg. 10

Truck Body Systems Customer Support

✔ The 775F offers five different body ✔ Caterpillar® dealers provide unmatched
system selections to accommodate almost product support, anywhere in the world.
any type of application. These systems With industry-best parts availability
are designed to maximize strength and and a wide range of maintenance and
durability through rigorous testing in service options, Cat dealers have what
harsh environments to ensure the lowest it takes to keep your hauling machines
cost per ton. pg. 14 productive. pg. 16

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. pg. 17

3
Power Train – Engine
The Cat® C27 engine with ACERT™ Technology is built for power, reliability and efficiency
for superior performance in the toughest applications.

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 ring, groove and liner wear
for greater reliability and longer life.
MEUI Fuel System. Fuel delivery,
provided by the MEUI mechanically
actuated electronic unit injection system,
involves a high degree of precision.
Precisely shaping the combustion cycle
lowers combustion chamber 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.
Electronic Control Module (ECM).
ECM uses advanced engine management
software to monitor, control and protect
the engine using self-diagnosing
Cat C27 Engine with ACERT™ Engine Design. The Cat C27 engine uses electronic sensors. The computerized
Technology. With the C27 engine, ACERT Technology and iron-specific system senses operating conditions and
Caterpillar optimizes engine features to deliver strong performance power requirements and adjusts the
performance while meeting European and long-term durability. engine for peak performance and the
Union Stage II regulations. ACERT most efficient operation at all times.
EPA Compliant. The C27 engine is
Technology reduces emissions during
compliant with European Union Advanced Diesel Engine Management
the combustion process by using
Stage II emissions regulations, reducing A4 Engine Controller. The ADEM™ A4
advanced technology in the air and fuel
NOx 27.5 percent over the 3412E. electronic control module delivers
systems, in conjunction with integrated
electronics. Caterpillar meets emission Altitude Compensation. Electronic engine optimum fuel performance. The engine
regulations at the combustion source, control automatically compensates for management system provides flexible
rather than recycling exhaust. load demand, high-altitude conditions fuel mapping, allowing the engine to
and cold starting. respond quickly to varying application
needs. It tracks engine and machine
conditions while keeping the engine
operating at peak efficiency.

4
Power Train – Transmission
Cat power train delivers more power to the ground for greater productivity and lower
operating costs.

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 resistance.
Transmission. Pairing the Caterpillar
seven-speed 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 per-
formance, efficiency and clutch life.
Lock-Up Torque Converter. Combines
maximum rimpull and cushioned shifting
of torque converter drive with the
efficiency and performance of direct
drive. The lock-up torque converter
engages at approximately 8 km/h,
delivering more power to the wheels.
• Lock-Up Clutch. Quickly releases
and re-engages to reduce power train Final Drives. Cat final drives work as a • Battery Powered Supplemental
torque loads for smoother shifting, system with the planetary power shift Steering. A battery powered
long life and a more comfortable ride. transmission to deliver maximum power supplemental steering system uses
• ECPC (Electronic Clutch Pressure to the ground. Built to withstand the pressure accumulators and allows up
Control) System. ECPC modulates forces of high torque and impact loads, to three 90 degree turns in case of
clutch engagement individually, double reduction final drives provide engine failure.
allowing for smoother speed and high torque multiplication to further • Wheels and Rims. Cast rear wheels
directional shifts. ECPC provides reduce drive train stress. and Cat center-mount rims are
controls for both the torque converter • Steering System. Hydraulic steering mounted using studs and nuts to
lock-up clutch and the transmission control system is designed for minimize maintenance and maximize
clutches that are tailored to each exceptional smoothness and precise durability.
particular upshift or downshift. control. A separate circuit prevents
This provides the operator a superior cross contamination for long life.
ride and reduced fatigue.

5
Structures
Rugged Cat structures are the backbone of the 775F off-highway truck’s durability.

Box-Section Design. The 775F Integral Four-Post ROPS Cab. Resiliently Technology Enhanced. Caterpillar
frame uses a box-section design, mounted to the main frame with all-new cab structures are tested using System
incorporating two forgings and mounts that reduce vibration and sound, Structural Analysis (SSA) to
19 castings in high-stress areas with the integral ROPS is designed as an extension dynamically simulate operations
deep penetrating and continuous of the truck frame. The ROPS/FOPS structure in field environments and identify
wrap-around welds to resist damage provides “five-sided protection” for the operator. potential structural improvements in
from twisting loads without adding high stress areas. With analysis of
Suspension System. Designed to dissipate
extra weight. machine structures and variables,
haul-road and loading impacts for longer
• Steel Structures. Mild steel used such as haul road and payload,
frame life and a more comfortable ride.
throughout the frame provides structural improvements were made
• Cylinders. Four independent self-contained,
flexibility, durability and resistance to the frame to accommodate the new
oil pneumatic, variable-rebound suspension
to impact loads, even in cold cab, platform, engine and radiator.
cylinders are designed to absorb shocks in
climates, and allows for easy
the most severe applications. Quality Control. A Coordinate
field repairs.
• Durable Design. Rugged cylinders use Measuring Machine (CMM) is used
• Castings. Castings have large radii
a large diameter bore and low pressure to inspect truck frames for consistency
with internal reinforcing ribs to
nitrogen/oil design for long life with in the manufacturing process.
dissipate stress in areas of high
minimal maintenance. Easy rebuild ability is thereby achieved
stress concentration. Castings
– Front. Front cylinders with preset caster by ensuring the frames are within
move welds to lower stress areas
and camber are mounted to the frame tolerance, removing the need to alter
for greater frame life.
and serve as steering kingpins for down-stream parts.
a tight turning radius with excellent
maneuverability and low maintenance.
– Rear. Rear cylinders allow axle
oscillation and absorb bending and
twisting stresses caused by uneven
and rough haul roads rather than
transmitting them to the frame.

6
Operator’s Station
Ergonomically designed for operator comfort, superior control and high productivity.

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,
sound-suppressed 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 with Three-Point Operator
Restraint. Ergonomically designed, fully
adjustable air suspension seat with adjustable
armrests provides optimal driving comfort.
A wide, retractable 3-point seat/shoulder belt
provides a secure, comfortable restraint.
Hoist Lever. Four-position, low effort electronic
hoist control system is positioned next to the
gear selector in the right-hand console. Operator Controls. Easy to reach turn Radio Ready. Cab is prewired with
signal, high beam, intermittent power converter, speakers, wiring
Secondary Brake Pedal. Conveniently located
windshield wiper and windshield harness, antenna and necessities for
on the floor for easy operator control.
washer controls are located on the left add-on communication systems.
Steering Column. Comfortable steering wheel side of the steering column, and are
Multiple Power Ports. Power ports
with tilt and telescoping function provides designed for optimum efficiency and
are conveniently located in three
a comfortable driving position for all operators. comfort.
locations in the cab: one in the right-
Transmission Console. Ergonomic gear shift Heating/Air Conditioning. hand console, two behind the trainer
lever with backlit gear indicators provides Electronically controlled, four-speed seat, and one in the dash.
easy operation. The parking brake function fan and 13 vents deliver temperature-
Truck Production Management
is integrated into the gear selector. controlled air circulation for a
System (TPMS) (optional). TPMS
comfortable working environment
Trainer Seat. The trainer seat is relocated to provides valuable payload and cycle
in any climate. Electronic controls
the left of the operator, which allows trainer time data, which is viewed through
reduce maintenance. More robust air
to use same stairway. Messenger or VIMS Advisor to
compressor offers a 25 percent
When not in use, the fold-down trainer seat improve productivity.
increase in BTU’s, greater durability
creates a working surface with cup holder. The
and longer life.
seat also folds up, providing more room for the
operator. Under seat storage is convenient for
stowing a lunch box.

7
Engine – Power Train Integration
This system electronically combines critical power train components to work together more
intelligently to optimize overall truck performance.

ET
10

4
3

5
7

2 9 6 8

1 Engine Control Module (ECM) Cat Data Link. Electronically integrates Transmission Chassis Control (TCC).
2 Sensors machine computer systems to optimize TCC uses electronically transferred
3 Electronic Unit Injector (EUI) overall power train performance, engine rpm data to execute shifts at
4 Automatic Retarder Control (ARC) increase reliability and component life, preset points for optimum performance,
and Traction Control System (TCS) and reduce operating costs. All control efficiency and clutch life.
5 Transmission Chassis Control (TCC) modules communicate via the Cat Data
Electronic Technician (Cat ET). Cat ET
6 Transmission Link and work together as an integrated
service tool provides service technicians
7 Wheel Sensor system to maximize production
with easy access to stored diagnostic data
8 Brakes efficiency and extend component life.
through the Cat Data Link to simplify
9 Cat Data Link
problem diagnosis and increase machine
10 Cat Messenger
availability.

8
Controlled Throttle Shifting. Regulates Overspeed Protection. The transmission Economy Shift Mode. Modifies engine
engine rpm during shifting to reduce control electronically senses engine maps for greater fuel economy.
power train stress and clutch wear conditions and automatically up-shifts one
Reverse Shift Inhibitor. Protects the
by controlling engine speed, torque gear to prevent overspeeding.
engine from abrupt directional changes by
converter lock-up, and transmission If overspeeding occurs in the top gear, the
slowing down the engine before shifting
clutch engagement for smoother shifts lock-up clutch is disengaged, and the
the transmission into reverse.
and longer component life. brakes are applied.
Cat Messenger. Critical data from the
Directional Shift Management. Regulates Programmable Top Gear. Transmission
engine and transmission, including
engine speed during directional shifts to top gear maximum can be set using
transmission shifting, engine speed
prevent damage caused by high-speed Cat Messenger, VIMS Advisor or the
and fuel consumption, provides service
directional changes. Cat ET service tool to help the operator
technicians with enhanced diagnostic
maintain speed limits.
Neutral Coast Inhibitor. Prevents the capability, through Cat Messenger, to
transmission from shifting to neutral Anti-Hunt Function. This function reduce downtime and operating costs.
at speeds above 6.5 km/h, protecting the minimizes shifting by not allowing
Traction Control System (TCS) (optional).
transmission from operating with the transmission to up or down shift
TCS electronically monitors and controls
insufficient lubrication. immediately after a shift has occurred.
rear wheel slippage for greater traction
This prevents gear hunting when
Body-up Shift Limiter. Prevents the and enhanced truck performance in poor
operating near a shift point and minimizes
transmission from shifting above a underfoot conditions.
transmission shifting for increased
pre-programmed gear without the body
component life.
being fully lowered. This function is
programmable via Cat Electronic Downshift Inhibitor. Prevents engine
Technician (Cat ET) and Messenger overspeeding by keeping the transmission
or Advisor. from downshifting until engine speed
reaches the downshift point.
Body-up Reverse Neutralizer.
Automatically shifts the transmission ECPC Control. Both the torque converter
to neutral if the hoist lever is activated lock-up clutch and the transmission
while the transmission is shifted clutches now have software-control for
in reverse. clutch fill and slip characteristics to
provide superior smooth shifting.

9
Brake System
Reliable braking with superior control gives the operator the confidence to focus
on productivity.

Long Life. An oil film prevents direct

contact between the discs. This design
absorbs the braking forces by shearing
the oil molecules and carrying heat
away to extend 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
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.
Integrated Braking System. The Cat Extended Life Multiple Disc Brakes Parking Brake. Oil-cooled, spring-
oil-cooled braking system delivers (optional). Extended life friction applied, hydraulically released parking
reliable performance and control in material has double the wear life of brake is applied to the rear wheels for
the most extreme haul-road conditions. standard brakes and is twice as resistant superior parking capability on all grades
The integrated system combines the to glazing for more consistent braking up to 15 percent.
service, secondary, parking brake and power with less noise.
retarding functions in the same system
Brake Design. Cat rear oil-cooled disc
for optimum braking efficiency.
brakes are designed with large discs
Oil-Cooled Multiple Disc Brakes. and plates for reliable, adjustment-free
Cat dry front and rear oil-cooled, operation and performance. Rear brakes
multiple disc brakes are now are completely enclosed and sealed to
hydraulically controlled, reducing prevent contamination and reduce
maintenance costs. maintenance.
The 775F brakes provide exceptional,
fade-resistant braking and retarding for
maximum performance and productivity
in all haul-road conditions.

10
 1 ARC 2 1 Service Brake Sensor TCS
2 Engine Sensor
3 ARC
4 ARC Switch 6
5 Brakes
6 Service Brakes 7
7 Axle Speed Sensor
8
8 TCS
3
7

5 6

Automatic Retarder Control (ARC). • Faster Speeds. ARC allows the Traction Control System (TCS)
Standard ARC electronically controls operator to maintain optimum engine (optional). Electronically monitors
braking on grade to maintain engine at speeds for up to 15 percent faster and controls rear wheel slippage for
approximately 1900 rpm (adjustable downhill hauls and greater greater traction and enhanced truck
from 1850-1950 rpm in increments productivity. performance in poor underfoot
of 10). ARC is deactivated when the • Superior Control. Automatic brake conditions. If slippage exceeds a set
operator applies the brakes or throttle. modulation offers a smoother ride and limit, the oil-cooled disc brakes engage
better control in slippery conditions, to slow the spinning wheel. Torque is
allowing the operator to concentrate then automatically transferred to the
on driving. wheel with better traction.
ARC Operating Efficiency Advantages • Ease of Operation. ARC increases
Differential Action. Normal differential
operating ease, resulting in greater
action provides superior maneuvering
2500 operator confidence with less fatigue.
and control in slippery conditions.
• Engine Overspeed Protection.
2000
Automatically activates ARC when Compression Brake (optional). Optional
engine speed exceeds factory preset Compression Brake is integrated with
Engine Speed (rpm)

1500 levels, regardless of operator inputs, Automatic Retarder Control (ARC) to

to avoid potentially damaging engine provide up to 35 percent higher downhill
1000
overspeeds. travel speed and reduce wear on brake
components.

500

0 10 20 30 40 50 60 70
Time (Seconds)

With Automatic Retarder Control

(average speed, 1950 rpm)

With Manual Retarder Control

(average speed, 1730 rpm)

11
Serviceability
Less time spent on maintenance means more time on the haul roads.

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.
Lincoln’s Quick Lube Automatic Lubrication
(optional). This advanced lubrication system
is available as a factory installed option on the
775F.
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.
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
Servicing Ease. Easy access to daily Scheduled Oil Sampling. S•O•SSM improved reliability and higher efficiency over
service points simplifies servicing sampling valves speed sampling and the two-pass flow core. NGMR also offers wider
and reduces time spent on regular analysis reliability. fin spacing for greater resistance to plugging and
maintenance procedures. Enhanced more convenient cleaning.
Pressure Test Points. Disconnect
serviceability and extended 500-hour
valves are conveniently located QuickEvac™ System. Oil change labor time is
service intervals are designed to
throughout the hydraulic systems for reduced by as much as 50 percent with this
increase machine availability and
easy pressure testing. New ECPC standard on-board engine oil evacuation and pre-
productivity.
transmission provides multiple lube system. It speeds the process of evacuating
Maintenance Platform. Easy pressure taps outside the transmission. the engine sump and allows for the purging of
stairway access to engine, air filters, oil filters prior to removal, minimizing oil spills.
Air Filters. Radial seal air filters are
steering hydraulic tank and radiator. QuickEvac system also enhances contamination
easy to change, reducing time required
control by ensuring complete filtration of new
Ground-Level Access. Allows for air filter maintenance.
oil on engine refill.
convenient servicing to tanks, filters,
Sealed Electrical Connectors.
drains, battery disconnect and engine Reduced Maintenance Costs/Higher Machine
Electrical connectors are sealed to
shutdown. Availability. The C27 engine with ACERT
lock out dust and moisture. Harnesses
Technology offers 500-hour service intervals
Engine Prelube. Engine prelubri- are braided for protection. Wires are
under normal conditions. For the 775F,
cation provides engine oil pressure color-coded for easy diagnosis and
commonly used engine service points have been
prior to engine cranking. This repair.
placed on the right side of the engine. Feedback
reduces engine dry and cold start
Spin-on Filters. Spin-on filters for fuel from engine sensors provides data to the
wear, and reduces engine component
and oil systems reduce changing time electronic controller. When engine data is out
wear. This system automatically fills
and help ensure clean, tight seals. of spec, a warning is sent to the operator.
engine oil filters and galleries, and
ensures components are lubed prior
to starting the engine.

12
Information & Monitoring Systems
Vital machine health and payload data keeps the 775F performing at peak production levels.

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

Instrument Cluster. Critical operating • External lights signal loading tool Product Link (optional). Now available
information on the 775F is relayed operator when payload is reached. out of the factory, this system
via the Cat Data Link to five gauges, • On-board computer stores up to streamlines diagnostic efforts,
18 LED indicator lights, and an LCD 2400 cycles for analysis of payload downtime, and maintenance scheduling
digital display. weight, cycle times, distances, and and costs by providing a two-way
actual cycle dates and times. communication flow of vital machine
Cat Messenger. Standard on the 775F,
• A second gear reweigh takes an data and location information between
Cat Messenger provides real-time
additional measurement once the the dealer and the customer. Product
machine performance and operating
truck has reached second gear for Link provides updates on service meter
data, and basic trip, maintenance, and
improved accuracy. hours, machine condition, machine
diagnostic data using an LCD display.
• System is accurate within ± 5 percent location as well as integrated
The viewable LCD screen area
under normal loading conditions over mapping/route planning.
of the Messenger display
a normal shift.
is 22.5 mm x 84.6 mm. MineStar™ Ready. MineStar
• Standard LED lamps replace
information management system helps
Truck Production Management System incandescent lamps on the TPMS,
meet the challenges of the mining
(TPMS) (optional). TPMS provides extending lamp life by 25 times.
industry by linking the machines in the
valuable payload and cycle time data
VIMS™ Monitoring System (optional). field with business and operating
to improve productivity.
Caterpillar designed machine systems to ensure peak performance of
• Uses strut pressure sensors and on-
monitoring system provides more than mining assets at the lowest possible
board microprocessor to determine
250 machine parameters, critical cost. These products deliver customers
payload weight.
machine health and payload data in everything from real-time machine
• Delivers consistent, accurate
real-time to keep the 775F performing health information to GPS-guided
payloads and improves efficiency
at top production levels. production aids. The 775F is equipped
by minimizing overloading and
for quick and easy installation of
underloading.
MineStar information management
system products.

13
Truck Body Systems
Cat designed and built for rugged performance and reliability in the toughest
hauling applications.

Dual Slope Body

Flat Floor Body

Body Selection. Selection of the Electronic Hoist Control. Provides the Body Design. With the introduction of the
right body system depends on operator with better control of the 775F, Caterpillar offers five application-
material, haul road and loading load when dumping, including over- specific body systems. Dual slope and flat
conditions. The better the match of center load control and modulated floor body offerings are available in three
body to application, the greater the control throughout the operating steel configurations and two rubber
efficiency. Cat dealers can help range. The automatic body snubbing configurations.
select the right body system for site- feature reduces impact on the
The new dual slope and flat floor body
specific applications. frame, hoist cylinders and operator.
systems will continue to use fully fabricated,
Body/Chassis Integration. Caterpillar Fast Hoist Cycle Times. Two-stage mild steel structures, offering a strong, yet
truck body systems are designed and hoist cylinders provide fast dump weldable underbody structure. All interior,
matched with the integrated chassis cycle times of 9.5 seconds for raise steel body surfaces that come in contact with
system for optimum structural and 12.5 seconds for lower. material are fabricated from 400 BHN steel
reliability, durability and long life. to provide superior wear characteristics and
Body Liners. Two liner materials,
resistance to impact. Wide box-section ribs
steel and rubber, are available to help
provide excellent durability and impact
extend body system life. All steel
support in the floor, front-wall, sidewall,
liner wear surfaces are equipped
and top rail areas. Full-length stringer rails
with 400 BHN steel to handle tough
enhance strength and rigidity throughout the
impact loads while resisting abrasion.
body.
Optional rubber liners deliver long
life in high-wear and high-impact
areas as well as increases operator
comfort during loading.

14
Other new features that further enhance Target Payload Strategy
durability of the understructure include:
• The body sidewall ties directly in
with the floor, providing increased

Number of Loads
strength in the sidewalls.

Productivity

Durability
• Thickness of ribs increased to 10 mm

Safety
and the number of floor ribs have
been increased from 7 to a total
of 9 ribs.
• 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
to 16.0 mm, eliminating the need for % of Target Payload
additional liners for impact resistance
in most applications. 90 percent of loads should fall into this range

Target Payload Strategy. Your No more than 10 percent of loads should exceed target payload by 10 percent
Caterpillar Dealer can help you manage
to target payload to maximize equipment No loads should exceed the target payload by 20 percent
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.
Matched Systems. Designed to work as
an optimum pass/match system, the
775F is best sized to match the 988H
Wheel Loader, with a 5 pass/match, the
990H Wheel Loader, with 4 pass/match,
and the 385C Hydraulic Excavator with
a 7 pass match.

15
Customer Support
Caterpillar dealers have what it takes to keep trucks productive.

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 ownership and productivity, your
Cat dealer can provide you with a
fundamental understanding of the
effects application characteristics and
operating techniques have on
maintenance and operating costs.
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
Commitment Makes the Difference. Product Support. Cat dealers believe
return on the investment you make in
Cat dealers offer a wide range of superior products deserve superior
Cat products.
solutions, services and products that support. When Cat products reach the
help you lower costs, enhance producti- field, they are supported by a worldwide Technology Products. Cat dealers offer
vity and manage your operation more network of parts distribution facilities, a range of advanced technology
efficiently. Support goes far beyond dealer service centers, and technical products, such as VIMS™ monitoring
parts and service. From the time you training facilities to keep your system and MineStar™ information
select a piece of Cat equipment until the equipment up and running. Cat management system. These products
day you rebuild, trade or sell it, the customers rely on prompt, dependable include radio data communications,
support you get from your Cat dealer parts availability and expertise through machine monitoring and diagnostics,
makes the difference that counts. our global dealer network, ready to fleet management, and haul road
meet your needs 24/7. maintenance software – all designed
Dealer Capability. Cat dealers provide
to improve fleet efficiency, increase
the level of support you need, on a Service Support. Every piece of Cat
productivity, and lower costs.
global scale. Dealer expert technicians equipment is designed and built to
have the knowledge, experience, provide maximum productivity and www.cat.com. For more complete
training and tooling necessary to handle operating economy throughout its information on Cat products, dealer
your repair and maintenance needs, working life. Cat dealers offer a services, and industry solutions,
when and where you need them. wide range of service plans that will visit us on the web at www.cat.com.
maximize uptime and return on your
investment, including:
• Preventive Maintenance Programs
• Diagnostic Programs, such as
Scheduled Oil Sampling and
Technical Analysis
• Rebuild and Reman Options
• Customer Support Agreements

16
Safety
Caterpillar machines and systems are designed with safety as the first priority.

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.
WAVS Camera (optional). An optional rear
vision 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.
Steering System. A twin, double- A stairway lamp illuminates the cab
High Intensity Discharge (HID) Lights
acting cylinder steering system is access stairs and can be activated at
(optional). Thirty-five Watt HID lights can
designed to deliver precise control ground level during entry and shut
replace the standard high beam 65 Watt
under all loading and underfoot off with a switch in the cab.
Halogen lights. The powerful HID lights are
conditions. The steering hydraulic
almost two times brighter and 50 percent Standard Safety Features.
system is separate from the main
more efficient, improving night time • Slip resistant surfaces
hydraulic system to prevent cross-
visibility. • 75 mm wide orange three-point
contamination and overheating.
operator restraint
Brake Systems. Cat hydraulically controlled
Engine Shutoff Switch. A secondary • Heated, wide-angle mirrors
dry front and rear oil-cooled multiple disc
engine shutoff switch is located at • Body raised indicator
brakes provide exceptional, fade-resistant
ground level. • Guard rails
braking and retarding for maximum
• Reverse neutralizer when dumping
performance and productivity in all haul-road Electrical System Disconnect.
• Low interior sound level
conditions. The service brakes and retarding A battery disconnect switch, located
• Service platform level
system are actuated by modulated hydraulic directly above the front bumper,
transmission, hoist and steering
pressure, while secondary and parking brake provides ground-level lockout of the
disable switch
functions are spring applied and hydraulic electrical system.
• Service platform level starter
released. This reliable and durable system
Ladder/Secondary Egress. A wide, disable switch
ensures braking in the event of complete
stationary stairway allows easy
hydraulic failure.
access to and from the machine. The
ladder on the left side of the machine
permits secondary egress.

17
Engine Transmission Body Hoists

Cat C27 ACERT Forward km/h Pump flow – high idle 560 L/min
Rated Engine Speed 2000 rpm 1 10.8 Relief valve setting
Gross Power 587 kW/798 hp 2 15 raise 190 bar
Net Power 3 20.3 lower 35 bar
ISO 9249 552 kW/751 hp 4 27.3 Body raise time
EEC 80/1269 552 kW/751 hp 5 37 at high idle 9.5 Seconds
Number of Cylinders 12 6 49.9 Body lower time float 12.5 Seconds
Peak Torque 3501 Nm 7 67.5 Body power down
Bore 137 mm Reverse 14.2 at high idle 12.5 Seconds
Stroke 152 mm • Maximum travel speeds
Displacement 27 Liters with standard 24.00 R 35 (E4) tires.
• All engine horsepower (hp) are metric Steering
including front page.
• Compliant with European Union Steering Standards ISO 5010:1992
Stage II emissions standards. Brakes Steer Angle 31°
Turning Diameter – Front 23.5 m
Brake surface
Turning Circle Clearance
front 1395 cm2 Diameter 26.1 m
rear 61 269 cm2 • Target Gross Machine Operating
• Meets ISO 3450:1996 standards. Weight is 109 770 kg.

Approximate Weight Distribution Capacity Service Refill Capacities

Front axle Dual-slope 100% fill factor Liters

empty 49% Struck 33.1 m 3
Fuel tank 700
loaded 33% Heaped 2:1 (SAE) 42.5 m3 Cooling system 175
Rear axle Flat Floor 100% fill factor Crankcase 95
empty 51% Struck 32 m3 Differentials and final drives 155
loaded 67% Heaped 2:1 (SAE) 41.9 m3 Steering tank 34
Steering system (includes tank) 60
Brake/hoist system
Suspension (includes tank) 307
Final Drive Torque converter/
Effective cylinder stroke transmission sump 53
Differential ratio 3.64:1
front 235 mm Torque converter/transmission
Planetary ratio 4.80:1 system (includes sump) 72
rear 149 mm
Total reduction ratio 17.49:1 Brake/hoist hydraulic system 133
Rear axle oscillation 8°

Operator Sound ROPS/FOPS Tires

The operator sound pressure level • ROPS (Rollover Protective Structure) Standard 24.00 R 35 (E4)
measured according to the procedures for cab offered by Caterpillar meets • Productive capabilities of the 775F
specified in ISO 6394:1998 is 78 dB(A) ISO 3471:1994 ROPS criteria. truck are such that, under certain job
for the cab offered by Caterpillar when • FOPS (Falling Objects Protective conditions, TKPH capabilities of
properly installed, maintained and Structure) meets ISO 3449:1992 standard or optional tires could be
tested with doors and windows closed. Level II FOPS criteria. exceeded and, therefore, limit
production.
• Caterpillar recommends the customer
evaluate all job conditions and
consult the tire manufacturer for
proper tire selection.
18 775F Off-Highway Truck specifications
Dimensions
All dimensions are approximate. (Shown with dual slope body)

15

16

2 12 17
11
3

10

18
1 9

7 8 14 19

5 6 13 20

4 21

Dual Slope Flat Floor Dual Slope Flat Floor

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

Weight/Payload Calculation
(Example) All weights are in kg

Flat Floor Body Dual Slope Body

Steel Body System Rubber Body System Steel Liner System Rubber Liner System
Medium High Heavy Duty High Heavy Medium High Heavy Duty High Heavy
(16 mm) (20 mm) (25 mm) (102 mm) Duty (16 mm) (20 mm) (25 mm) (102 mm) Duty

Target Gross Machine Weight* 109 769 109 769 109 769 109 769 109 769 109 769 109 769 109 769 109 769 109 769
Empty Chassis Weight* 31 633 31 633 31 633 31 633 31 633 31 633 31 633 31 633 31 633 31 633
Body System Weight 13 456 14 178 15 840 14 436 15 293 13 552 14 175 15 987 14 327 15 188
Empty Machine Weight 45 089 45 811 47 473 46 069 46 926 45 185 45 808 47 620 45 960 46 821

Attachments
Empty Operating Weight** 45 620 46 342 48 044 46 600 47 457 45 716 46 339 48 151 46 491 47 352
Target Payload* 64 149 63 427 61 765 63 169 62 312 64 053 63 430 61 618 63 278 62 417
* Refer to Caterpillar 10/10/20 overload policy.
** Includes weight of all attachments.

775F Off-Highway Truck specifications 19

Retarding Performance

To determine retarding performance: Add lengths of all Select the proper gear to maintain engine rpm at the highest
downhill segments and, using this total, refer to proper possible level, without overspeeding the engine. If cooling oil
retarding chart. Read from gross weight down to the percent overheats, reduce ground speed to allow transmission to shift
effective grade. Effective grade equals actual % grade minus to the next lower speed range.
1% for each 10 kg/t 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 °C ambient temperature, at sea level, with 24.00 R 35 tires.

With ARC Only

ARC and Engine Brake
E Typical Field Empty Weight
L Target Gross Machine Operating Weight – 109 770 kg

Gross Weight

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

1 – 1st Gear
2 – 2nd Gear 30%
25%
3 – 3rd Gear
4 – 4th Gear
5 – 5th Gear
E L
6 – 6th Gear 20%
7 – 7th Gear

(Grade Minus Rolling Resistance)

1
15%

Effective Grade
2

3 10%
4

5
6 5%
7

0 10 20 30 40 50 60 70 8 0 km/h

Speed

Continuous Grade Length

20 775F Off-Highway Truck specifications

 Gross Weight Gross Weight

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

30% 25% 30%
25%
E L E L

(Grade Minus Rolling Resistance)

(Grade Minus Rolling Resistance)

20% 20%
1
1
2

Effective Grade

Effective Grade
2
3 15% 15%
3
4
4
5
10% 5 10%
6 6
7 7
5% 5%

0 10 20 30 40 50 60 70 8 0 km/h 0 10 20 30 40 50 60 70 8 0 km/h
Speed Speed

Grade Distance – 450 m Grade Distance – 600 m

Gross Weight Gross Weight

0 15 30 45 60 75 90 105 120 kg x 1000 0 15 30 45 60 75 90 105 120 kg x 1000
30% 30%
25% 25%
E L E L
(Grade Minus Rolling Resistance)

(Grade Minus Rolling Resistance)

20% 20%
1
1
Effective Grade

Effective Grade
2
2
3 15% 15%
3
4
4
5 10% 10%
5
6
7 6
5% 7 5%

0 10 20 30 40 50 60 70 8 0 km/h 0 10 20 30 40 50 60 70 8 0 km/h
Speed Speed

Grade Distance – 900 m Grade Distance – 1500 m

775F Off-Highway Truck specifications 21

Gradeability/Speed/Rimpull

To determine gradeability performance: Gross Weight

Read from gross weight down to the
0 15 30 45 60 75 90 105 120 kg x 1000
percent of total resistance. Total resistance kg x
equals actual percent grade plus 1% 1000
for each 10 kg/t of rolling resistance. 50
From this weight-resistance point, E L
read horizontally to the curve with the 45
highest obtainable gear, then down to
maximum speed. Usable rimpull will
depend upon traction available and weight 40
on drive wheels. 1
35
Torque Converter Drive
30%

(Grade plus Rolling)

30

Total Resistance
With ARC Only
Rimpull

ARC and Engine Brake 25%

25
E Typical Field Empty Weight
L Target Gross Machine 20 1 20%
Operating Weight – 109 770 kg Direct Drive

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

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

22 775F Off-Highway Truck specifications

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

Operator Environment Power Train Electrical

Air conditioning Cat C27 engine with ACERT Technology Alarm, backup
Ashtray and cigarette lighter 12–cylinder diesel Alternator, 50-amp
Coat hook Air-to-Air Aftercooler (ATAAC) Auxiliary jump start receptacle
Cup holders (4) Air cleaner with precleaner (2) Batteries, maintenance-free, 12V (4),
Diagnostic connection port, 24V Automatic cold mode idle control 190 amp-hour
Entertainment Radio Ready Electric priming pump Electrical system, 25-amp, 24V to 12V
5 amp converter Ether starting aid converter
Speakers Exhaust, body heat Lighting system:
Antenna Fuel filter/water separator Backup light (halogen)
Wiring harness QuickEvac™ System with engine Directional signals/hazard warning,
Gauges/indicators: prelube (front/rear LED)
Air cleaner service indicator Turbocharger (2) Headlights, halogen with dimmer
Brake oil temperature gauge Braking system: Operator access courtesy lights
Coolant temperature gauge Automatic Retarder Control (ARC) Side profile lights
Engine overspeed indicator (utilizes rear oil-cooled brakes) Stop/tail lights LED
Fuel level Brake release motor (towing) MineStar™ Ready
Hour meter Manual retarder (utilizes rear oil- Product Link Ready (Level 1)
Speedometer/odometer cooled brakes)
Guards
Tachometer Oil-cooled, multiple disc (rear)
Engine crankcase
Transmission gear indicator Front dry disc brakes
Driveline
Heater/defroster, (11 070 kCal) Transmission:
Fan and Air Conditioning
Hoist lever 7–speed automatic powershift
Horn with electronic Suspension System
Light, dome/courtesy Clutch Pressure Control (ECPC) Suspension, rear (European Union
Load counter, automatic Body up shift inhibitor compliant)
Messenger display unit Controlled throttle shifting
Other Standard Equipment
Mirrors, heated (left/right) Directional shift management
Body mounting group
Power port, 24V and 12V (2) Downshift inhibitor
Body safety pin (secures body in up
ROPS cab, insulated/sound suppressed Neutral start switch
position)
Seat, Caterpillar Comfort Neutral coast inhibitor
Body down indicator
Full air suspension Reverse shift inhibitor
CD-ROM parts book
Retractable, 3-point seat belt with Reverse neutralizer during dumping
Center mounted rims
shoulder harness Programmable top gear selection
Direct drive fan
Seat, training with lap belt
Antifreeze Fuel tank, 700 L
Steering wheel, padded, tilt and
Extended Life Coolant to –35° C Ground level battery disconnect
telescopic
Ground level engine shutdown
Storage compartment
Ground level grease fittings
Sun visor, tinted glass
Rims
Throttle lock
Rock ejectors
Windshield wiper (intermittent) and
Service platform level engine
washer
start/disable switch
Service platform level transmission,
hoist and steering disable switch
Supplemental steering (automatic)
Tow hooks, front
Tow pin, rear
Vandalism protection locks

775F Off-Highway Truck specifications 23

775F Off-Highway Truck

For more complete information on Cat products, dealer services, and industry solutions, visit us on the web at
www.cat.com
Materials and specifications are subject to change without notice. Featured machines in photos
may include additional equipment. See your Caterpillar dealer for available options.
© 2006 Caterpillar
All rights reserved
CAT, CATERPILLAR, their respective logos, “Caterpillar Yellow” and the POWER EDGE™ trade dress as well as
HEHQ5748 (09/2006) hr corporate and product identity used herein, are trademarks of Caterpillar and may not be used without permission.