Milton CAT 770 User Manual

Engine

Engine Model Cat®C15 ACERT™
Gross Power – SAE J1995 381 kW 511 hp
Net Power – SAE J1349 355 kW 476 hp

Weights – Approximate

Target Gross Machine 71 214 kg 157,000 lb
Operating Weight

Operating Specifications

Nominal Payload Class 36.3 tonnes 40 tons
Body Capacity – SAE 2:1 25.1 m

3

32.9 yd

3

• Refer to the Caterpillar®10/10/20 Overload Policy
for maximum gross machine weight limitations.

• Capacity with flat floor body.

770

Off-Highway Truck

®

®

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770 Off-Highway Truck

Engineered for performance, designed for comfort, built to last.

Top Performance.
Developed specifically for construction,
mining, and quarry applications, the 770
optimizes demands for lower cost per ton,
challenges of finding skilled labor, and
overall health and safety.

Reliable, Durable, Dependable.
Rugged construction and easy maintenance
procedures ensure long life with low
operating costs.

Truck Body Systems

The 770 offers two body types with six
different body liner system selections
to accommodate almost any type of
application. These body liner systems
are designed to maximize strength and
durability while providing the lowest
cost per ton. pg. 16

✔

Serviceability

The 770 offers 500-hour engine service
intervals – 250 hours more than the 769D.
Simplified service and maintenance
features combined with improved
service access are designed to
reduce downtime. pg. 14

✔

Structures

The 770 features a mild-steel, box-section
type frame to deliver durability and long
life with low operating costs. Castings and
forgings are strategically placed in high­stress areas to evenly distribute stresses
and provide long fatigue life. pg. 8

✔

Power Train – Transmission

The Cat®seven-speed power shift
transmission matched with the Cat C15
engine with ACERT Technology provides
constant power and efficiency over a
wide operating speed range for optimal
power train performance. pg. 6

✔

Power Train – Engine

The Cat®C15 engine with ACERT™
Technology uses advanced engine
technology to reduce emissions
without after-treatment. The turbocharged,
aftercooled 6-cylinder engine has faster
response for superior performance in
demanding applications. pg. 4

✔

Information and Monitoring Systems

Standard on the 770, the Cat Messenger
system provides real-time engine
performance and operating data. pg. 18

✔

✔ New Feature

3

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. 20

✔

Operator’s Station

The 770 features an all new operator
station with enhanced visibility,
increased operator space and
ergonomically designed controls that
set new industry standards for operator
comfort. All controls and gauges are
positioned for optimum efficiency
and total machine control. pg. 9

✔

Brake System

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. pg. 12

✔

Engine – Power Train Integration

The Cat Data Link electronically
combines engine, transmission,
brake and operational information
to optimize overall truck performance.
Stored diagnostic data can be accessed via
the Cat Electronic Technician (Cat ET)
service tool to improve troubleshooting
and reduce downtime. pg. 10

✔

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.

pg. 21

✔

Cat®C15 Engine with ACERT™
Technology. Caterpillar optimizes engine

performance while meeting U.S. EPA
Tier 3 and European Union Stage IIIa
engine emission regulations. ACERT
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 gases.

Block. The C15 block incorporates a one­piece, grey iron block, featuring generous
ribbing for stiffness and heavy bearing
bulkheads for rigidity and strength.

Caterpillar also has moved away from
pipe thread ports to straight-thread, o-ring
connection points, reducing the potential
for leaks. This new design supports the
engine’s higher compression ratios and
increased power density.

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

Overhead Cam. A single overhead cam
is driven by gears on the front of the
engine, which significantly reduce noise
and vibration. Caterpillar also has added
two pendulum absorbers, mounted at
the front of the camshafts to further
reduce noise and vibration.

Pistons, Connecting Rods, Cylinder Liners.

New design and material improvements
to the pistons, rods and liners have been
made to support the higher cylinder
pressures and the 18:1 compression
ratios associated with ACERT
Technology, while still providing
durability to engine overhaul.

A single-piece steel piston, pulsator-tested
to 25 560 kPa (4,000 psi), is matched to
a robust connecting rod to ensure long
component life. The piston’s steel skirt
increases its durability and results in
reduced thermal expansion, allowing
a tighter piston fit and reduced liner
vibration. The overall piston surface
area reduces friction and enhances
fuel economy.

The newly designed connecting rod
allows better lubrication and cooling and
is more securely fastened to the crankshaft
using two additional bolts. The new
improved rod bearings are made of steel­backed copper alloy with lead tin overlay.
This new metallurgy reduces flaking
and offers better fatigue strength.

Cylinder liners are wet liners made of
compacted graphite and iron for excellent
wear and strength characteristics. Also, the
tolerances between the pistons and the
wet cylinder liners have been tightened
to unprecedented levels for reduced
blow-by and higher efficiency.

4

The Cat®C15 engine with ACERT™ Technology is built for power, reliability and efficiency
for superior performance in the toughest applications.

Power Train – Engine

Turbochargers. The single, waste-gated

turbocharger found on the C15 engine is
water-cooled to accommodate sudden hot
machine shutdowns. Water cools the
bearings during this event, preventing
bearing seizure. The C15 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.

The turbocharger uses an aluminum
compression wheel. Changes enable
the C15 to deliver longer life and lower
maintenance costs and contribute to good
fuel economy. The design also provides
high horsepower with improved response
time while keeping exhaust temperatures
low for long hours of continuous
operation. The waste-gate turbocharger
design improves engine response and
peak torque, while providing higher
boost over a wider range.

MEUI Fuel System. The Cat MEUI
fuel system combines the technical
advancement of electronic control with
the simplicity of direct mechanically
controlled unit fuel injection. This system
electronically controls injection pressure
by sensing the engine speed and load
conditions over the entire engine
operating speed range.

A low-pressure fuel transfer pump
provides fuel to the injectors, which
then increases the pressure to deliver
very fine, atomized fuel particles into
the combustion chamber with precise
timing and duration. The result is a
more complete fuel burn with lower
emissions and better engine response.

Oil Coolers. The 770 is equipped with
three oil coolers: an engine-mounted
engine oil cooler, an engine-mounted
transmission/torque converter oil cooler,
and a remote-mounted, brake, hoist and
hydraulic fan oil cooler. These coolers
allow major components to expel heat,
maintaining optimal operating
temperatures.

Fuel Filters. The C15 engine is equipped
with two fuel filters. The primary filter is
engine-mounted and features oil/water
separation and an electric priming pump.
The electric pump provides easier priming
and better contamination control than a
manual unit. The secondary fuel filter is
also engine-mounted, and has a switch
that monitors pressure changes and
provides pressure drop warnings to
the operator.

Advanced Diesel Engine Management
A4 Engine Controller. The ADEM™ A4

electronic control module provides
flexible fuel mapping, allowing the
engine to respond quickly to varying
application needs.

Next Generation Modular Radiator
(NGMR). The new modular cooling

system with a 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 enables coolant to enter one end
of the core and flow out the opposite end
for more efficient ambient cooling
capability and greater durability.

Hydraulic Demand Fan and Accessory
Drive. The 770 includes a standard,

variable-speed, on-demand fan. This fan
provides cooling airflow only when
necessary, resulting in reduced parasitic
losses, a reduction of fuel consumption
and fan-generated noise.

The C15 engine includes a Poly-V
accessory drive belt with an auto­tensioner, which is self adjusting.

5

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 C15 diesel engine
with ACERT Technology delivers
constant power over a wide range
of operating speeds.

• Transmission Chassis Control (TCC).

Transmission shifting is based on
Transmission Output Speed for optimum
performance efficiency and clutch life.
The TCC provides integrated functionality
to controlled throttle shifting, directional
shift management, neutral coast inhibitor,
body-up shift limiter and body-up
reverse neutralizer.

Throttle Lock. The operator can now
electronically lock the throttle pedal
at full throttle, to reduce fatigue on long
uphill hauls. The throttle can be locked
on by momentarily depressing the throttle
lock switch located on the operator
console, while depressing the pedal
fully. The throttle is released whenever
braking is applied or the throttle is again
depressed.

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, as
well as a new torque converter adapter
that provides extra length to house the
additional clutch plate and enables the
converter components to be changed
without having to change the housing.
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.

New Differential and Proven Final Drives.

The new Cat differential works with
the proven final drives as a system to
deliver maximum power to the ground.
For improved serviceability, the pinion
gear is cantilever mounted, which allows
inspection of the differential without
pulling the rear-end. Visual inspection
of the pinion gear and bearings can be
performed in 1-2 hours versus 8 hours
on the previous models. In addition,
the differential bevel pinion gear set
is designed for improved adjustability,
which results in improved contact patterns
and life. The differential gear set also
provides enhanced bending life for
steeper grade applications.

New Differential Center Housing. A new,
ductile iron center housing improves
quality and reliability. The improved
stiffness allows for better main support
bearing life. The new housing also uses
bolts, reducing maintenance time.
This change also improves wheel
station bolted-joint life.

6

Cat power train delivers more to the ground for greater productivity and lower operating costs.

Power Train – Transmission

New A-Frame. The new A-frame mounts

directly to the spindles. The new A-frame
eliminates the “king” bolt and includes
a pin and bushing style mounting,
consistent with the 777 and 793.
This new design is simpler to
maintain and service.

New Ductile Iron Spindles. A stress­optimized, ductile iron spindle is
splined to the rear brakes, reducing
brake pack rebuild time by up to two
hours. In addition, the spindles are longer
and wider with fewer seals for increased
strength and durability.

Brake Packs. A single-piece brake anchor
eliminates more than 200 fasteners and
a row of bolted joints. Rebuild time is
reduced by up to two hours. In addition,
the brake pack is removable without
taking the spindle off the truck.

Each of the two oil-cooled disc brakes on
the 770 rear axle features 24 brake discs.
The brake discs have increased in diameter
from 495.3 to 540.0 mm (19.5 to 21.3 in).
By increasing the diameter, Caterpillar
has improved the overall reliability and
durability of the brake packs and has also
designed the brake packs to improve the
OD/ID ratio. The new 770 brake pack
design, moves the braking forces to the
outer edge of the disc, thereby using
greater surface area for improved
braking forces and longer life,
improving reliability and lowering
maintenance cost.

Wheel Stations. The wheel stations now
integrate both the wheel and the hub.
The single-piece design reduces removal
and installation time, and the risk of
brake cooling oil leakage. The inner
Duo-Cone™ seal has been changed
from a formed type to a cast design.
Brake cooling flow and the Duo-Cone
seal has also been reversed for better
sealing performance and improved
seal life.

Wheel stations are now interchangeable,
reducing the number of replacement
parts: left and right wheel stations are
symmetric and can be interchanged.
In addition, the new design eliminates one
o-ring seal, which improves reliability
and simplifies the system and the wheel
bearings have been enhanced for longer
bearing life.

Tires. The 770 uses 18.00R33 tires
as the standard tire configuration.

• 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

supplemental steering system uses
pressure accumulators and allows
up to three 90 degree turns in case
of engine failure.

• Wheels and Rims. Cast rear wheels and
Cat center-mount rims are mounted using
studs and nuts to minimize maintenance
and maximize durability.

7

Box-Section Design. The 770 frame uses
a box-section design, incorporating two
forgings and 13 castings in high-stress
areas with deep penetrating and
continuous wrap-around welds to resist
damage from twisting loads without
adding extra weight.

• Steel Structures. Mild steel used
throughout the frame provides 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.

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 of the truck
frame. The ROPS/FOPS structure
provides “five-sided protection”
for the operator.

Forgings and Castings.

• The 770 features a drop tube/casting
design and two forged steel mountings
for hoist cylinders, similar to the
design as found on the 773.

• A volcano casting that holds the center
tube is enhanced with thicker wall
dimensions for increased durability.

• New strut-mount castings have been
moved 254 mm (10 in) forward and

25.4 mm (1 in) outward on each side.
These thicker strut-mount castings
and their location improve ride
characteristics as well as durability.

• New steering casting (same as 773)
accommodates larger steering
cylinders and ball studs.

• New tail casting accommodates new
angled rail design.

Superior Weld Quality. Structural frame
welds are J-groove type, ensuring full
weld penetration for strength and
longevity. During fabrication, weld
integrity is further enhanced by rotating
the frames 360 degrees to provide
optimal, flat welding surfaces.

Technology Enhanced.

Caterpillar structures are tested using
System Structural Analysis (SSA) to
dynamically simulate operations in 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 Machine (CMM) is used to
inspect truck frames for consistency in
the manufacturing process. In addition,
all critical welds receive testing to verify
weld penetration, which results in frame
durability.

8

Rugged Cat structures are the backbone of the 770 off-highway truck’s durability.

Structures

9

All New Center-Mounted Cab. Center cab
positioning provides additional room and
creates a walk-in-style cab. The new
configuration allows the operator to
easily enter and exit the cab. The cab
environment offers a spacious
surrounding, giving the operator the
ability to stretch out and providing
superior comfort for an entire operating
shift. The operator seat is located on the
right hand side of the cab with the
trainer to the immediate left.

Ergonomic Layout. The 770 operator’s
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 52 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 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.

Secondary Brake Pedal. Conveniently
located on the floor for easy operator
control.

Steering Column. Comfortable steering
wheel with tilt and telescoping function
provides a comfortable driving position
for all operators.

Transmission Console. Ergonomic gear
shift lever with backlit gear indicators
provides easy operation. The parking
brake function is integrated into the
gear selector.

Trainer Seat. By moving the trainer seat
to the left of the operator, the trainer may
enter/exit the vehicle using the same
stairway door as the operator. When not
in use, the fold-down trainer seat creates
a working surface with cup holder.

Under seat storage is convenient
for stowing a lunch box.

Operator Controls. Easy to reach turn
signal, high beam, intermittent windshield
wiper and windshield washer controls are
located on the left side of the steering
column, and are designed for optimum
efficiency and comfort.

Radio Ready. Cab is prewired with power
converter, speakers, wiring harness,
antenna and necessities for add-on
communication systems.

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

Truck Production Management System
(TPMS) (Optional). TPMS provides

valuable payload and cycle time data,
which is viewed through Messenger.
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.

Ergonomically designed for operator comfort, superior control and high productivity.

Operator’s Station

Cat Data Link. Electronically integrates

machine computer systems to optimize
overall power train performance, increase
reliability and component life, and reduce
operating costs. All the information from
these controls can be accessed through
a laptop computer with Cat ET.

Transmission Chassis Control (TCC).

TCC uses electronically transferred
engine rpm data to execute shifts at
preset points for optimum performance,
efficiency and clutch life.

Electronic Technician (Cat ET). Cat ET
service 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.

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.

Directional Shift Management.

Regulates engine speed during directional
shifts to prevent damage caused by high­speed directional changes.

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

10

This system electronically combines critical power train components to work together more
intelligently to optimize overall truck performance.

Engine – Power Train Integration

1 Engine Control Module (ECM)
2 Sensors
3 Mechanical Electronic Unit Injector (MEUI)
4 Automatic Retarder Control (ARC)
Traction Control System (TCS)
Transmission/Chassis Control (TCC)
5 Transmission
6 Wheel Sensor
7 Brakes
8 CAT Data Link
9

Cat Messenger

6

9

4

ET

8

3

7

5

2

1